US20060261000A1 - Filter cartridge and method of construction thereof - Google Patents
Filter cartridge and method of construction thereof Download PDFInfo
- Publication number
- US20060261000A1 US20060261000A1 US11/429,711 US42971106A US2006261000A1 US 20060261000 A1 US20060261000 A1 US 20060261000A1 US 42971106 A US42971106 A US 42971106A US 2006261000 A1 US2006261000 A1 US 2006261000A1
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- US
- United States
- Prior art keywords
- housing
- filtration element
- filter cartridge
- granular material
- port
- 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.)
- Abandoned
Links
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Images
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D35/00—Filtering devices having features not specifically covered by groups B01D24/00 - B01D33/00, or for applications not specifically covered by groups B01D24/00 - B01D33/00; Auxiliary devices for filtration; Filter housing constructions
- B01D35/28—Strainers not provided for elsewhere
-
- 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
- B01D39/20—Other self-supporting filtering material ; Other filtering material of inorganic material, e.g. asbestos paper, metallic filtering material of non-woven wires
- B01D39/2068—Other inorganic materials, e.g. ceramics
- B01D39/2072—Other inorganic materials, e.g. ceramics the material being particulate or granular
- B01D39/2079—Other inorganic materials, e.g. ceramics the material being particulate or granular otherwise bonded, e.g. by resins
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D35/00—Filtering devices having features not specifically covered by groups B01D24/00 - B01D33/00, or for applications not specifically covered by groups B01D24/00 - B01D33/00; Auxiliary devices for filtration; Filter housing constructions
- B01D35/30—Filter housing constructions
-
- 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
-
- 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
- B01D39/1638—Other self-supporting filtering material ; Other filtering material of organic material, e.g. synthetic fibres the material being particulate
- B01D39/1653—Other self-supporting filtering material ; Other filtering material of organic material, e.g. synthetic fibres the material being particulate of synthetic origin
- B01D39/1661—Other self-supporting filtering material ; Other filtering material of organic material, e.g. synthetic fibres the material being particulate of synthetic origin sintered or bonded
-
- 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
- B01D39/20—Other self-supporting filtering material ; Other filtering material of inorganic material, e.g. asbestos paper, metallic filtering material of non-woven wires
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D2201/00—Details relating to filtering apparatus
- B01D2201/02—Filtering elements having a conical form
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D2201/00—Details relating to filtering apparatus
- B01D2201/30—Filter housing constructions
- B01D2201/301—Details of removable closures, lids, caps, filter heads
- B01D2201/302—Details of removable closures, lids, caps, filter heads having inlet or outlet ports
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D2201/00—Details relating to filtering apparatus
- B01D2201/40—Special measures for connecting different parts of the filter
- B01D2201/4015—Bayonet connecting means
-
- 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
-
- 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
- C02F2201/00—Apparatus for treatment of water, waste water or sewage
- C02F2201/002—Construction details of the apparatus
- C02F2201/006—Cartridges
Definitions
- This invention relates generally to filter cartridges and more particularly to filter cartridges having integrated filtration elements.
- Filter cartridges typically comprise a porous filtration element disposed within a structural housing. In such filters, unfiltered fluid enters the housing through an inlet port and passes through the filtration element, which removes contaminants or other impurities from the fluid. The filtered fluid is discharged through an outlet port.
- Filter cartridges include so-called “quick change” cartridges that typically have the inlet and outlet combined in a single port at one end of the housing and in-line cartridges in which the inlet and outlet ports are located at opposite ends of the housing. Because the fluid flow is often pressurized, these ports are typically sealed, such as with an O-ring or the like. It is therefore desirable to provide small ports because larger openings are more difficult to seal (the larger the seal, the larger the force it is subjected to for a given pressure). Accordingly, the ports are typically smaller in cross dimension than the interior of the housing that contains the filtration element.
- a bed of granular filtration media such as powdered activated carbon, activated alumina, silica, zeolites and the like, as the filtration element.
- granular is intended to encompass any material in a divided state; that is, material comprising separate particles that easily move and change their relative position without a separation of the mass and that are generally capable of flowing.
- particle refers to any relatively small, discrete portion or piece of something and includes grains, granules, particles, pellets, fibers and the like.
- a granular filtration media can be poured into the housing interior through the small port.
- filter cartridges provide excellent performance
- the two-piece design can add to the material, fabrication and assembly costs. Accordingly, it would be desirable to have a filter cartridge that is easier and more cost effective to manufacture than current filter cartridges. Additionally, it is desirable to eliminate the metal molds for forming the filter blocks and instead, form the blocks directly by using the one-piece filter housing itself.
- a filter cartridge that includes a one-piece housing having a port and a filtration element disposed in the housing.
- the filtration element is a coherent filter block that can be, but is not necessarily, larger in cross dimension than the port.
- the present invention includes a method of constructing a filter cartridge comprising providing a housing having a hollow interior and at least one port, introducing a granular material into the hollow interior via the port, and transforming the granular material in the hollow material into a coherent filter block.
- the present invention includes a method of constructing a filter cartridge comprising providing a filtration element in the form of a coherent filter block, and overmolding a housing around the filtration element.
- the invention provides a filter cartridge comprising a filtration element in the form of a coherent filter block and an overmolded housing around the filtration element.
- a filter cartridge that includes a one-piece housing having an inner surface defining a hollow interior and a filtration element disposed in the housing.
- the filtration element is a coherent filter block that generally conforms to the shape of the hollow interior, but is slightly smaller than the hollow interior so as to define a gap between the filtration element and the inner surface.
- FIG. 1 is a perspective view of a filter cartridge in accordance with one embodiment of the present invention.
- FIG. 2 is a side view of the filter cartridge of FIG. 1 .
- FIG. 3 is a cross-sectional view of the filter cartridge taken along line A-A of FIG. 2 .
- FIG. 4 is an exploded view of the filter cartridge of FIG. 1 .
- FIG. 5 is a perspective view of a filter cartridge in accordance with another embodiment of the present invention.
- FIG. 6 is a longitudinal cross-sectional view of the filter cartridge of FIG. 5 .
- FIG. 7 is a perspective view of a filtration element wrapped in netting.
- FIG. 8 is a side section view of an injection molding tool for producing the filter cartridge of FIG. 5 .
- FIG. 10 is a longitudinal cross-sectional view of the filter cartridge of FIG. 9 .
- FIG. 11 is an exploded view of an injection molding tool for producing the filter cartridge of FIG. 9 .
- FIG. 15 is a longitudinal cross-sectional view of a filter cartridge having another alternative filtration element configuration.
- FIG. 16 is a longitudinal cross-sectional view of a filter cartridge having yet another alternative filtration element configuration.
- FIG. 17 is a perspective view of a filter cartridge in accordance with one embodiment of the present invention.
- FIG. 18 is a side view of the filter cartridge of FIG. 17 .
- FIG. 19 is a cross-sectional view of the filter cartridge taken along line 3 - 3 of FIG. 18 .
- FIG. 20 is an exploded view of a flow distribution tube for use in an embodiment filter cartridge of the invention.
- the granular material that becomes the filter block can comprise one or more of a variety of materials including polyethylene (particularly ultra-high molecular weight polyethylene and cross-linked polyethylene) polyester, epoxy, carbons, ceramics, fibers, oxides, etc.
- the granular material can preferably, but not necessarily, comprise a mixture of a filtration media and a binder.
- the filtration media can be one of several types of adsorbent material that will function as a porous matrix, including but not limited to, powered or granular activated carbon, diatomaceous earth, perlite, activated alumina, silica, ion exchange resins, ryholites, and zeolites.
- FIGS. 1-4 show a filter cartridge 10 constructed in accordance with one embodiment of the present invention.
- the filter cartridge 10 includes a housing 12 , a filtration element 14 disposed in the housing 12 , and a flow distribution tube 16 extending in part through the filtration element 14 .
- the housing 12 is a bottle-like, one-piece construction comprising a substantially cylindrical, elongated body 18 having a hollow interior and a central, longitudinal axis.
- the body 18 is closed at one end and has an open neck 20 formed on the other end.
- the neck 20 defines a port 22 for providing fluid communication to the hollow interior.
- a number of holes 42 are formed in the flange 40 to allow fluid communication between the “head space” (i.e., the portion of the port 22 located above the flange 40 ) and the interior of the housing 12 .
- the holes 42 are preferably numerous in number and small in size so as to function as “capillary holes” and thereby reduce spillage from the filter cartridge 10 when removed from an installation.
- a pair of diametrically opposed shoulders 44 are formed on the flange 40 , closely adjacent to the cup section 38 .
- the shoulders 44 are designed to connect the filter cartridge 10 with mating outlet tubing in a filtering system.
- the shoulders 44 may be configured to have internal or external threads, lugs, ears, or bayonets as required to fit any manifold or connector.
- a process for constructing the filter cartridge 10 begins with producing the housing 12 .
- the housing 12 can be fabricated with a variety of techniques such as blow molding, stretch blow molding (see, for example, the process described in U.S. Pat. No. 5,735,420 issued Apr. 7, 1998 to Nakamaki et al.), or injection molding with gas or water assist if the housing 12 is made of a plastic material and casting or spin forming if the housing 12 is made of a metallic or similar material.
- yet another granular material comprising a mixture of a granular filtration media such as cellulose, cotton and wood fiber and an appropriate binder is introduced into the housing 12 on top of the second- introduced granular material to make up the open first section 26 .
- the granular materials collectively fill the housing 12 to a level at or close to the neck 20 .
- the flow distribution tube 16 is inserted into the housing 12 via the port 22 so as to be positioned coaxially within the housing 12 . This is accomplished by pushing the flow distribution tube 16 tip first through the granular material until the tip 34 is in the desired location of being very close to, or in contact with, the closed bottom of the housing 12 .
- the flow distribution tube 16 is situated so that the tube section 32 is coaxially positioned in the housing interior and the flange 40 is coaxially positioned in the port 22 .
- Another optional step would be to pneumatically pressurize the housing interior. Although this would have little affect as far as compacting the granular filtration media, it would tend to cause the housing 12 to expand and would be useful in constructing filter cartridges intended for pressurized applications.
- applying an appropriate pressure during the material loading and sintering steps would simulate the expansion the housing 12 would undergo during use in a pressurized application.
- the granular material would conform to the size of the expanded housing so that after sintering the filtration element 14 would also correspond to the size of the expanded housing.
- the housing 12 would essentially be “pre-pressurized.” This would avoid expansion of the housing 12 under pressure during use and undesirable gaps between the inner wall of the housing and the filtration element 14 that could develop due to such expansion.
- the next step is to sinter the granular material so as to produce the finished filtration element 14 in the form of a coherent filter block.
- the housing 12 functions as a mold for forming the filtration element 14 .
- Sintering is brought about by heating the granular material to a temperature (referred to as the “sintering temperature”) at which molecules at the surface of the binder particles become mobile enough to intermingle with the molecules at the surface of adjoining particles, thus forming a bond between adjoining particles.
- the sintering temperature will typically be the Vicat softening temperature (VST) of the polymer.
- VST Vicat softening temperature
- the materials used for the housing 12 and the binder should be thermally compatible.
- the housing 12 should be selected from a material that will not lose structural integrity when subjected to the sintering temperature of the binder material.
- the granular material is maintained at the sintering temperature until the desired degree of bonding has occurred, after which the entire assemblage is cooled.
- the heating duration will depend on a number of variables including the materials selected and the size of the filtration element.
- the filtration element 54 is a coherent filter block made of any suitable material or combination of materials, such as the filtration materials described above. Unlike the previously described embodiment, the filtration element 54 is not formed and thermally set within the housing interior. Instead, the filtration element 54 is first formed separately by any known of later developed technique. The housing 52 is then formed around the filtration element 54 as an overmolded shell in a manner described in more detail below. This results in a filter cartridge 50 having an one-piece housing 52 that contains a coherent block filtration element 54 that is larger in cross-dimension than the port 60 .
- the filtration element 54 is a cylindrical carbon block having a center bore 62 formed therethrough.
- a first end cap 64 is disposed over the end of the filtration element 54 that is closest to the neck 58
- a second end cap 65 is disposed over the other end of the filtration element 54 .
- the first end cap 64 includes a round annular base 66 and an upstanding tube section 68 extending outward from a first (upper) side of the base 66 .
- the base 66 has an outer rim 70 around its perimeter that extends outward from the second side thereof (i.e., in the direction opposite of the tube section 68 ).
- the outer rim 70 is slightly larger in diameter than the cylindrical filtration element 54 so as to fit over the filtration element 54 and position the first end cap 64 relative to the filtration element 54 .
- Ridges 72 formed on the second side of the base 66 space the base 66 from the end of the filtration element 54 so as to provide room for filtrate to freely pass.
- the tube section 68 is located inside of the neck 58 and is aligned axially with the center bore 62 .
- At least one inlet hole 74 (two shown in FIG. 6 ) is formed in the sidewall of the tube section 68 and is aligned with a corresponding inlet hole 76 formed in the neck 58 .
- the filter cartridge 50 can optionally include netting 80 wrapped around the circumference of the filtration element 54 (see FIG. 7 ) so as to be located between the filtration element 54 and the housing 52 .
- the space created by the netting 80 defines outer flow channels that allow filtrate to flow over the outer surface of the filtration element 54 .
- a protective sheet 82 is wrapped around the netting 80 to prevent molten plastic from flowing into the channels defined by the netting 80 during the overmolding of the housing 52 .
- the netting 80 can be omitted.
- filtrate enters the filter cartridge 50 through the inlet holes 74 and 76 and flows through the annular inlet flow channel defined between the tube section 68 and the center tube 78 to the space between the end cap base 66 and the end of the filtration element 54 . From there, filtrate flows axially into the filtration element 54 and through the outer channels defined by the netting 80 and then into the filtration element 54 as depicted by the arrows in FIG. 6 . The filtrate passes through the filtration element 54 into the center bore 62 .
- a process for constructing the filter cartridge 50 includes separately forming the coherent block filtration element 54 .
- the filtration element 54 can be formed using any suitable technique, including now known or later developed processes.
- the first end cap 64 and center tube 78 are positioned over one end of the filtration element 54 , with an end of the center tube 78 extending into the center bore 62 .
- the second end cap 65 is positioned over the other end of the filtration element 54 .
- the netting 80 and the protective sheet 82 are wrapped around the outer surface of the filtration element 54 .
- This assembly is then placed into an injection molding tool 83 , as shown in FIG. 8 .
- the molding tool 83 includes side action pins 86 and 87 that support the assembly in the tool cavity 84 so as to provide a gap 85 between the assembly and the tool cavity 84 .
- the first side action pin 86 moves into engagement with the first end cap 64 and center tube 78
- the second side action pin 87 moves into engagement with a pocket formed in the center of the second end cap 65 .
- the two halves of the injection molding tool 83 then close and the injection cycle begins.
- the tool 83 includes raised surfaces in the cavity 84 that abut the faces of the inlet ports 74 , insuring that plastic does not plug these ports 74 .
- the housing 52 can be made from any suitable material; one material that is particularly suitable for many applications is polypropylene.
- the end caps 64 , 65 and protective sheet 82 are preferably made of a material that is thermally compatible with the housing material. That is, these elements should be made of a material that will withstand the molding temperature of the molten plastic material during the overmolding step. Suitable materials include acrylontitrile-butadiene styrene and polycarbonate, which are thermally compatible with polypropylene.
- the filter cartridge 400 includes a housing 402 having a hollow interior and a filtration element 404 disposed within the hollow interior.
- the housing 402 is a bottle-like, one-piece construction comprising a substantially cylindrical, elongated body 406 defining the hollow interior.
- the body 406 is closed at one end and has an open neck 408 formed on the other end.
- the neck 408 defines a port 410 for providing fluid communication to the hollow interior.
- the port 410 is smaller in cross dimension than the hollow interior and the filtration element 404 , although the port 410 and the filtration element 404 could alternatively be equal in cross dimension.
- the filtration element 404 is a coherent filter block made of any suitable material or combination of materials, such as the filtration materials described above. Like the embodiment described above, the filtration element 404 is first formed separately by any known of later developed technique. The housing 402 is then formed around the filtration element 404 as an overmolded shell in a manner described in more detail below. This results in a filter cartridge 400 having an one-piece housing 402 that contains a coherent block filtration element 404 that is larger in cross-dimension than the port 410 .
- the filtration element 404 is a cylindrical carbon block having a center bore 412 and inlet bores 414 formed within a partial length of the carbon block.
- An end cap 416 is disposed over the end of the filtration element 404 that is closest to the neck 408 .
- the end cap 416 includes a round annular base 418 and an upstanding tube section 420 extending outward from a first (upper) side of the base 418 .
- the base 418 has an outer rim 422 around its perimeter that extends outward from the second side thereof (i.e., in the direction opposite of the tube section 420 ).
- the outer rim 422 is slightly larger in diameter than the cylindrical filtration element 404 so as to fit over the filtration element 404 and position the end cap 416 relative to the filtration element 404 .
- Ridges 424 formed on the second side of the base 418 space the base 418 from the end of the filtration element 404 so as to provide room for filtrate to freely pass.
- Inlet bores 414 extend from the second side of the base 418 .
- the tube section 420 is located inside of the neck 408 and is aligned axially with the center bore 412 .
- At least one inlet hole 426 (two shown in FIG. 22 ) is formed in the sidewall of the tube section 420 and is aligned with a corresponding inlet hole 428 formed in the neck 408 .
- a center tube 430 is disposed coaxially in the tube section 420 and includes a lower section that extends a short distance into the center bore 412 .
- the diameter of the center tube 430 is smaller than the inside diameter of the tube section 420 so as to define an annular inlet flow channel therebetween.
- the inner passage of the center tube 430 defines an outlet flow channel.
- the filter cartridge 400 can optionally include netting (not shown) wrapped around the circumference of the filtration element 404 (see FIGS. 6 & 7 ) so as to be located between the filtration element 404 and the housing 402 .
- filtrate enters the filter cartridge 400 through the inlet holes 426 and 428 and flows through the annular inlet flow channel defined between the tube section 420 and the center tube 430 to the space between the end cap base 418 and the end of the filtration element 404 . From there, filtrate flows into the inlet bores 414 of filtration element 404 and through the outer channels defined by the netting 432 and then into the filtration element 404 as depicted by the arrows in FIG. 22 . The fluid flow may be described as going from axial flow to radial flow. The filtrate passes through the filtration element 404 into the center bore 412 .
- a process for constructing the filter cartridge 400 includes separately forming the coherent block filtration element 404 .
- the filtration element 404 can be formed using any suitable technique, including now known or later developed processes.
- the inlet bores 414 may be formed into the filtration element by any method known in the art.
- the inlet bores 414 may be formed in the block via the insertion of pins during the block forming process, and then removing the pins to form the inlet bores 414 .
- the bores 414 may also be machined into the block using any boring technique such as drilling or milling.
- the first end cap 416 and center tube 430 are positioned over one end of the filtration element 404 , with an end of the center tube 430 extending into the center bore 412 .
- the molding tool 83 includes side action pins 86 and 87 that support the assembly in the tool cavity 84 so as to provide a gap 85 between the assembly and the tool cavity 84 .
- the first side action pin 86 moves into engagement with the first end cap 416 and center tube 430
- the second side action pin 87 moves into engagement with a pocket formed in the center of the block.
- the two halves of the injection molding tool 83 then close and the injection cycle begins.
- the tool 83 includes raised surfaces in the cavity 84 that abut the faces of the inlet ports 426 , insuring that plastic does not plug these ports 426 . Molten plastic is then injected into the tool cavity 84 so as to fill the gap 85 .
- the second side action pin 87 is retracted and the void created by the retracted pin 87 is filled with plastic.
- the plastic encases the assembly, thereby forming the overmolded shell that becomes the housing 402 .
- the indent at the bottom of the housing 402 is where the pin 87 stops.
- the tool 83 is opened and the side action pins 86 and 87 are completely retracted, allowing the filter cartridge 400 to be removed.
- the housing 402 can be made from any suitable material; one material that is particularly suitable for many applications is polypropylene.
- the end cap 416 and protective sheet 434 are preferably made of a material that is thermally compatible with the housing material. That is, these elements should be made of a material that will withstand the molding temperature of the molten plastic material during the overmolding step. Suitable materials include acrylontitrile-butadiene styrene and polycarbonate, which are thermally compatible with polypropylene.
- FIGS. 9 and 10 show another embodiment of a filter cartridge 90 having an overmolded housing.
- the filter cartridge 90 is an in-line type cartridge having a housing 92 and a filtration element 94 disposed within the hollow interior of the housing 92 .
- the housing 92 is a one-piece construction comprising a substantially cylindrical body having a first opening 96 formed on one end and a second opening 98 formed on the opposite end.
- the filtration element 94 is a coherent filter block made of any suitable material or combination of materials.
- the filtration element 94 is a solid cylindrical carbon block.
- An end cap 100 is disposed over each end of the filtration element 94 .
- Both end caps 100 include a round annular base 102 and an upstanding tube section 104 extending outward from a first side of the base 102 .
- Each base 102 has an outer rim 106 around its perimeter that extends outward from the second side thereof (i.e., in the direction opposite of the tube section 104 ).
- Each outer rim 106 is slightly larger in diameter than the cylindrical filtration element 94 so as to fit over the respective end of the filtration element 94 .
- Each end cap 100 includes an annular shoulder 108 formed on the base 102 at the foot of the outer rim 106 .
- the shoulder 108 abuts the respective end of the filtration element 94 to space the base 102 from the end of the filtration element 94 and provide room for filtrate to freely pass.
- the filter cartridge can optionally include netting as described above, wrapped around the circumference of the filtration element so as to be located between the filtration element and the housing.
- Each tube section 104 extends through a corresponding one of the openings 96 and 98 formed in the housing 92 . That is, one of the tube sections 104 extends through the first opening 96 to define an inlet port, and the other one of the tube sections 104 extends through the second opening 98 to define an outlet port. These inlet and outlet ports are preferably, but not necessarily, smaller in cross dimension than the housing interior and the filtration element 94 .
- a plurality of gussets 110 is provided around each tube section 104 .
- filtrate enters the filter cartridge 90 through the inlet port and flows into the space between the end cap base 102 and the end of the filtration element 94 . From there, filtrate flows axially through the filtration element 94 and into the space between the second end cap base 102 and the other end of the filtration element 94 . The now-filtered filtrate exits the filter cartridge 90 via the outlet port.
- a process for constructing the filter cartridge 90 includes separately forming the coherent block filtration element 94 .
- the filtration element 94 can be formed using any suitable technique, including now known or later developed processes.
- an end cap 100 is positioned over each end of the filtration element 94 .
- This assembly is then placed into the tool cavity 112 of an injection molding tool 114 , as shown in FIG. 11 .
- the distal ends of the end cap tube sections 104 are placed in appropriately shaped recesses 116 formed in the tool 114 adjacent to the tool cavity 112 .
- the distal ends of the end cap tube sections 104 are then clamped between the two halves of the injection molding tool 114 .
- the assembly is thus supported in the tool cavity 114 so as to provide a gap between the assembly and the tool cavity 114 .
- the housing 92 can be made from any suitable material such as polypropylene.
- the end caps 100 are preferably made of a material that is thermally compatible with the housing material. That is, these end caps 100 should be made of a material that will withstand the molding temperature of the molten plastic material during the overmolding step. Suitable materials include acrylontitrile-butadiene styrene and polycarbonate, which are thermally compatible with polypropylene.
- the filter cartridge 120 includes a housing 122 and a filtration element 124 disposed within the hollow interior of the housing 122 .
- the housing 122 is a one-piece construction comprising a substantially cylindrical body having an inlet port 126 formed on one end and an outlet port 128 formed on the opposite end.
- the ports 126 and 128 provide fluid communication to the interior of the housing 122 .
- the filtration element 124 is a coherent filter block made of any suitable material or combination of materials.
- the filtration element 124 is a solid cylindrical carbon block.
- An end cap 130 is disposed over each end of the filtration element 124 .
- Both end caps 130 include a round annular base 132 having a central opening and an outer rim 134 around its perimeter that extends outward from one side thereof. The central openings are aligned with a corresponding one of the inlet and outlet ports 126 and 128 .
- Each outer rim 134 is slightly larger in diameter than the cylindrical filtration element 124 so as to fit over the respective end of the filtration element 124 .
- An annular notch 136 is formed in the outer edge of each end of the filtration element 124 .
- filtrate enters the filter cartridge 120 through the inlet port 126 and flows into the space between the end cap base 132 and the first end of the filtration element 124 . From there, filtrate flows axially through the filtration element 124 and into the space between the second end cap base 132 and the other end of the filtration element 124 . The now-filtered filtrate exits the filter cartridge 120 via the outlet port 128 .
- FIG. 14 shows an in-line filter cartridge 150 having an overmolded housing 152 and a filtration element 154 disposed within the hollow interior of the housing 152 .
- the housing 152 includes an inlet port 156 and an outlet port 158 .
- An end cap 159 is disposed over each end of the filtration element 154 .
- the filtration element 154 is a two-part element comprising a first block 160 and a second block 162 .
- the first block 160 has a substantially cylindrical outer surface and a tapered bore formed in one end and extending most of the way through the block 160 .
- filtrate enters the filter cartridge 150 through the inlet port 156 .
- the filtrate flows axially through the filtration element 154 , passing first through the first block 160 into the second block 162 and then to the bore 164 . From there, the now-filtered filtrate exits the filter cartridge 150 via the outlet port 158 .
- FIGS. 17-19 show a filter cartridge 300 constructed in accordance with another embodiment of the present invention.
- the filter cartridge 300 includes a housing 302 , a filtration element 304 disposed in the housing 302 , and a flow distribution tube 306 that supports the filtration element 304 within the housing 302 .
- the housing 302 is a bottle-like, one-piece construction comprising a substantially cylindrical, elongated body 308 having an inner surface defining a hollow interior and a central, longitudinal axis.
- the body 308 is closed at one end and has an open neck 310 formed on the other end.
- the neck 310 defines a port 312 for providing fluid communication to the hollow interior.
- the port 312 is shown as being smaller in cross dimension than the body 308 to facilitate sealing thereof. However, it should be noted that the port 312 could alternatively be equal in cross dimension to the body 308 .
- Two diametrically opposed shoulders 314 are formed on the outer surface of the neck 310 . The shoulders 314 are designed to interface with corresponding structure for connecting the filter cartridge into a filtering system.
- the housing 302 can be made from any suitable material; one material that is particularly suitable for many applications is polyethylene terephthalate (PET).
- the filtration element 304 is a coherent filter block (e.g., a matrix of granular filtration media and a binder) that is formed and set within the interior of the housing 302 .
- the filtration element 304 generally conforms to the substantially cylindrical shape of the housing interior, but is slightly smaller than the housing interior so as to define a substantially annular gap or space 316 between the filtration element 304 and the inner surface of the housing 302 .
- the filtration element 304 substantially fills the housing interior from the bottom of the housing 302 to a point just below the neck 310 and is larger in cross dimension than the port 312 .
- the filtration element described herein is just one example of a filtration element that can be used in this embodiment; many other configurations are possible.
- the open second end of the stem 318 is positioned adjacent to the port 312 , beyond the filtration element 304 .
- the cylindrical cup section 320 is formed concentrically on the second end so as to be disposed within the port 312 .
- the cup section 320 has a larger diameter than the stem 318 and is positioned inside the port 312 .
- An annular flange 324 is formed on the upper edge of the cup section 320 .
- the flange 324 has a circular outer edge defining an outside diameter that is substantially equal to the diameter to the port 312 so that the outer edge snugly abuts the inner surface of the neck 310 .
- Interior cup section 320 serves to provide a sealing surface with the mating manifold elastomeric seal. Cup section 320 acts much like a straw to channel the filtered fluid without leakage to the manifold. Both of the port 312 and cup section 320 have O-ring seals with the mating manifold where the cup section O-ring seals between the inlet and outlet and the port O-ring seals the housing to the inlet.
- the flow distribution tube 306 includes a porous sleeve 330 positioned over the stem 318 .
- the sleeve 330 is made of a screen material or a permeable membrane formed into a cylinder that is sized to fit snugly over the stem 318 and cover the slots 322 .
- the sleeve 330 thus prevents granular material from entering the stem 318 prior to transformation into a coherent filter block, while providing a fluid flow path for filtrate to pass from the filtration element 304 into the stem 318 .
- filtrate enters the filter cartridge 300 through the port 312 and flows through the flange holes 326 (as best seen in FIG. 19 ) into the interior of the housing 302 .
- the filtrate completely floods the gap 316 between the filtration element 304 and the inner surface of the housing 302 and then penetrates the full exterior of the filtration element 304 .
- Filtrate flows through the porous filtration element 304 inward toward the stem 318 (i.e., substantially radially), passes through the sleeve 330 and the slots 322 , and is collected in the stem 318 .
- the now-filtered filtrate flows upward through the stem 318 into the cup section 320 and exits the filter cartridge 300 via the port 312 .
- a process for constructing the filter cartridge 300 begins with producing the housing 302 .
- the housing 302 can be fabricated from a plastic material with a variety of techniques such as blow molding, stretch blow molding (see, for example, the process described in U.S. Pat. No. 5,735,420 issued Apr. 7, 1998 to Nakamaki et al.), or injection molding with gas or water assist.
- the housing 302 can be made from a metallic or similar material using techniques such as casting, spin forming, stamping, drawing, or the like.
- the granular material which will be transformed into a coherent filter block, can preferably, but not necessarily comprise a mixture of a granular filtration media and a binder.
- the binder will typically be a polymer or polymer-based substance in granular form that can be dry mixed with granular filtration media.
- the granular material could alternatively be comprised entirely of a polymer material.
- the granular material is formulated so that it will shrink during subsequent processing.
- the granular material will shrink so as to produce a completed filtration element 304 having the desired size and shape.
- suitable ingredients such as polyethylene (particularly ultra-high molecular weight polyethylene)
- the granular material will shrink so as to produce a completed filtration element 304 having the desired size and shape.
- a size and shape that generally conforms to the substantially cylindrical shape of the housing interior, but is slightly smaller than the housing interior so as to define the gap 316 .
- the shrinkage factor will preferably be in the range of about 1-10%, depending on materials, processing, and temperature.
- a shrinkage factor of 5% with a housing 302 having an inside diameter of 2.00 inches (5.1 cm) will yield a filtration element diameter of 1.90 inches (4.8 cm) with radial gap of 0.050 inches (0.13 cm) an each side.
- the flow distribution tube 306 is inserted into the housing 302 via the port 312 so as to be positioned coaxially within the housing 302 . This is accomplished by pushing the flow distribution tube 306 tip first through the granular material until the tapered end of the stem 318 is in the desired location of being near the closed bottom of the housing 302 .
- the flow distribution tube 306 is situated so that the stem 318 is coaxially positioned in the housing interior and the flange 34 is coaxially positioned in the port 312 .
- the granular material can optionally be compressed or “packed” to assure that the desired porosity is achieved upon transformation of the granular material into a coherent filter block.
- Possible techniques for compressing the granular material include vibrating the filled housing 302 or spinning the filled housing 302 in a centrifuge.
- an expanding bladder can be inserted into the housing 302 to compress the material.
- the granular material could be compressed with a ram although this would be difficult due to the narrowness of the port 312 and the presence of the flow distribution tube 306 .
- the next step is to process the granular material so as to produce the finished filtration element 304 in the form of a coherent filter block.
- the housing 302 functions as a mold for forming the filtration element 304 .
- sintering is one approach to processing the granular material. In this case, sintering is brought about by heating the granular material to a temperature (referred to as the “sintering temperature”) at which molecules at the surface of the binder particles become mobile enough to intermingle with the molecules at the surface of adjoining particles, thus forming a bond between adjoining particles.
- the sintering temperature is at least, but can exceed the Vicat softening temperature (VST) of the polymer.
- VST Vicat softening temperature
- the materials used for the housing 302 and the binder should be thermally compatible. That is, the housing 302 should be selected from a material that will not lose structural integrity when subjected to the sintering temperature of the binder material.
- the granular material is maintained at the sintering temperature until the desired degree of bonding has occurred, after which the entire assemblage is cooled.
- the heating duration will depend on a number of variables including the materials selected and the size of the filtration element. During the heating and cooling process, the filtration element 304 shrinks and bonds itself to the stem 318 .
- the stem 318 can be textured (such as with a roughened surface or small protrusions) so as to enhance the bonding of the filtration element 304 thereto.
- the stem can be made from a material that is suitable for chemical bonding with the binder.
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Priority Applications (2)
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US11/429,711 US20060261000A1 (en) | 2005-05-08 | 2006-05-08 | Filter cartridge and method of construction thereof |
US12/135,915 US8246883B2 (en) | 2005-05-08 | 2008-06-09 | Filter cartridge and method of construction thereof |
Applications Claiming Priority (2)
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US67927305P | 2005-05-08 | 2005-05-08 | |
US11/429,711 US20060261000A1 (en) | 2005-05-08 | 2006-05-08 | Filter cartridge and method of construction thereof |
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US12/135,915 Continuation US8246883B2 (en) | 2005-05-08 | 2008-06-09 | Filter cartridge and method of construction thereof |
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US20060261000A1 true US20060261000A1 (en) | 2006-11-23 |
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US12/135,915 Expired - Fee Related US8246883B2 (en) | 2005-05-08 | 2008-06-09 | Filter cartridge and method of construction thereof |
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US12/135,915 Expired - Fee Related US8246883B2 (en) | 2005-05-08 | 2008-06-09 | Filter cartridge and method of construction thereof |
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US (2) | US20060261000A1 (ja) |
EP (1) | EP1888200A1 (ja) |
JP (1) | JP2008542001A (ja) |
KR (1) | KR20080006591A (ja) |
CN (1) | CN101218009A (ja) |
WO (1) | WO2006121932A1 (ja) |
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2006
- 2006-05-08 JP JP2008511207A patent/JP2008542001A/ja active Pending
- 2006-05-08 WO PCT/US2006/017544 patent/WO2006121932A1/en active Application Filing
- 2006-05-08 KR KR1020077025942A patent/KR20080006591A/ko not_active Application Discontinuation
- 2006-05-08 US US11/429,711 patent/US20060261000A1/en not_active Abandoned
- 2006-05-08 CN CNA2006800250015A patent/CN101218009A/zh active Pending
- 2006-05-08 EP EP06759214A patent/EP1888200A1/en not_active Withdrawn
-
2008
- 2008-06-09 US US12/135,915 patent/US8246883B2/en not_active Expired - Fee Related
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Cited By (21)
Publication number | Priority date | Publication date | Assignee | Title |
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WO2009010728A3 (en) * | 2007-07-13 | 2009-03-12 | John Courtney | Improved water filter apparatus |
WO2009010728A2 (en) * | 2007-07-13 | 2009-01-22 | John Courtney | Improved water filter apparatus |
US8940163B2 (en) | 2008-07-21 | 2015-01-27 | 3M Innovative Properties Company | Apparatus for dispersing additive into a fluid stream |
US9833731B2 (en) | 2010-02-12 | 2017-12-05 | O2C Raleigh, Llc | Squeezable beverage bottle and filter system |
US20130292323A1 (en) * | 2010-09-30 | 2013-11-07 | Indian Institute Of Technology | Axial flow filter block for water purification |
US20130299429A1 (en) * | 2010-11-19 | 2013-11-14 | Phosbox Technologies Limited | Wastewater treatment process |
US11504646B2 (en) * | 2011-07-08 | 2022-11-22 | Emd Millipore Corporation | Depth filters for disposable biotechnological processes |
US20140158608A1 (en) * | 2011-07-22 | 2014-06-12 | Illinois Tool Works Inc. | Filter assembly for fluid system |
US10035131B2 (en) | 2011-11-24 | 2018-07-31 | Indian Institute Of Technology | Multilayer organic-templated-boehmite-nanoarchitecture for water purification |
US20130220910A1 (en) * | 2012-02-24 | 2013-08-29 | Ningbo Hidrotek Co., Ltd. | Hot Detachable and Replaceable Water Filter Assembly |
US9056269B2 (en) * | 2012-02-24 | 2015-06-16 | Ningbo Hidrotek Co., Ltd. | Hot detachable and replaceable water filter assembly |
US10041925B2 (en) | 2012-04-17 | 2018-08-07 | Indian Institute Of Technology | Detection of quantity of water flow using quantum clusters |
US10023475B2 (en) * | 2012-10-19 | 2018-07-17 | Kuraray Co., Ltd. | Water processing filter and manufacturing method therefor |
US20150266751A1 (en) * | 2012-10-19 | 2015-09-24 | Kuraray Chemical Co., Ltd. | Water processing filter and manufacturing method therefor |
US10398059B2 (en) * | 2016-12-07 | 2019-08-27 | The Boeing Company | System and method for cryogenic cooling of electromagnetic induction filter |
CN113039031A (zh) * | 2018-09-10 | 2021-06-25 | 瑞尼斯豪公司 | 粉末床熔融设备和方法 |
USD862795S1 (en) | 2019-01-22 | 2019-10-08 | Lerman Container Corporation | Cartridge tube |
US11155402B2 (en) | 2019-01-22 | 2021-10-26 | Lerman Container Corporation | Cartridge tube |
USD967331S1 (en) * | 2020-05-12 | 2022-10-18 | Kohler (China) Investment Co., Ltd. | Filter |
USD958933S1 (en) * | 2020-09-18 | 2022-07-26 | Tianjin Bright Sight Commerce Co., Ltd | Filter |
WO2023025906A1 (en) * | 2021-08-27 | 2023-03-02 | Merck Patent Gmbh | Depth filter media |
Also Published As
Publication number | Publication date |
---|---|
US20080237924A1 (en) | 2008-10-02 |
US8246883B2 (en) | 2012-08-21 |
CN101218009A (zh) | 2008-07-09 |
KR20080006591A (ko) | 2008-01-16 |
JP2008542001A (ja) | 2008-11-27 |
WO2006121932A1 (en) | 2006-11-16 |
EP1888200A1 (en) | 2008-02-20 |
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