WO2011090563A2

WO2011090563A2 - Ion-exchange filter cartridge

Info

Publication number: WO2011090563A2
Application number: PCT/US2010/059066
Authority: WO
Inventors: Roberto Fernandes
Original assignee: 3M Innovative Properties Company
Priority date: 2010-01-21
Filing date: 2010-12-06
Publication date: 2011-07-28
Also published as: WO2011090563A3

Abstract

A filter cartridge (100) comprises a filter media chamber (170), first (180) and second (185) conduits and ion-exchange filter media (190) disposed within the filter media chamber. The filter media chamber has a longitudinal axis (175), a closed end (120), a sidewall, and a connective end (140) opposite the closed end. The connective end comprises and inlet port (150) and an outlet port (160). The first conduit is in fluid communication with the outlet port and the filter media chamber. The second conduit (185) is in fluid communication with the inlet port (150) and the filter media chamber (170). A portion of the second conduit (185) is disposed adjacent to the ion-exchange filter media (190), and it has a terminus proximate the closed (120). Openings (155) in the second conduit (185) are disposed at a plurality of depths within the filter media chamber, and some of the second conduit (185) is disposed between the sidewall (130) and the longitudinal axis (175). The second conduit (185) may comprise hollow branches (186, 187) in fluid communication with a hollow core member (157) or may have a portion in the shape of a coil (5891).

Description

ION-EXCHANGE FILTER CARTRIDGE

TECHNICAL FIELD

The present disclosure relates broadly to ion-exchange filter cartridges.

BACKGROUND

Ion-exchange media cartridges are widely used in the treatment of water; for example, water from municipal water systems or wells.

Ion-exchange is widely used in separation, purification, and decontamination processes. Industries where ion-exchange purification is used include the food & beverage, hydrometallurgical, metals finishing, chemical & petrochemical, pharmaceutical, sugar & sweeteners, ground & potable water, nuclear, softening & industrial water, semiconductor, power, and a host of other industries. In many cases ion-exchange resins were introduced in such processes as a more flexible alternative to the use of natural or artificial zeolites.

However, in cases of hard water, complete ion exchange (with replacement of calcium, magnesium, etc. with sodium) can result in salty tasting water that is aesthetically displeasing to the palate.

An ion-exchange resin or ion-exchange polymer is an insoluble matrix (or support structure) normally in the form of small (1-2 mm diameter) beads fabricated from an organic polymer substrate. The material has highly developed structure of pores on the surface of which are sites with easily trapped and released ions. The trapping of ions takes place only with simultaneous releasing of other ions; thus the process is called ion- exchange. There are multiple different types of ion-exchange resin which are fabricated to selectively prefer one or several different types of ions.

Depending on water hardness and ion-exchange media design, mineral deposits may occur in the ion-exchange filter media, resulting in some cases in a degree of blockage of the ion-exchange media.

SUMMARY

In one aspect, the present disclosure provides a filter cartridge comprising: a filter media chamber having a longitudinal axis, a closed end, a sidewall, and a connective end opposite the closed end, wherein the connective end comprises an inlet port and an outlet port;

a first conduit in fluid communication with the outlet port and the filter media chamber;

ion-exchange filter media disposed within the filter media chamber;

a second conduit in fluid communication with the inlet port and the filter media chamber, wherein a major portion of the second conduit is disposed adjacent to the ion- exchange filter media, wherein the second conduit has a terminus proximate the closed end within the filter media chamber, wherein openings in the second conduit are disposed within the filter media chamber at a plurality of depths relative to the connective end, and wherein at least a length of the second conduit is disposed between the sidewall and the longitudinal axis.

In some embodiments, the terminus of the second conduit is closed. In some embodiments, the terminus of the second conduit comprises one of the openings. In some embodiments, the openings increase in size as the depth relative to the connective end increases. In some embodiments, the openings decrease in size as the depth relative to the connective end increases. In some embodiments, at least a portion of the second conduit comprises a coil.

In some embodiments, the second conduit comprises hollow branches in fluid communication with a hollow core member, wherein the hollow branches extend away from the hollow core member, and wherein at least some of the openings are disposed on the hollow branches.

In some embodiments, the second conduit comprises hollow branches in fluid communication with a hollow core member, wherein the hollow branches extend away from the hollow core member, wherein at least some of the openings are disposed on the hollow branches, and wherein the hollow core member is disposed along the longitudinal axis. In some embodiments, the hollow branches are arranged in a rotationally symmetric pattern about the longitudinal axis. In some embodiments, the hollow branches are arranged in a plane. In some embodiments, some of the openings are disposed at ends of the hollow branches. In some embodiments, the hollow branches extend from the hollow core member toward the closed end. In some embodiments, each of the hollow branches has an effective diameter, and the effective diameter increases with decreasing distance from the closed end. In some embodiments, each of the hollow branches has a substantially equal effective diameter. In some embodiments, the connective end further comprises a bypass conduit in fluid communication with the inlet port and outlet port, wherein the bypass conduit is substantially free of ion-exchange media.

Advantageously, ion-exchange filter cartridges according to the present disclosure typically partially or entirely eliminate one or more problems inherent in typical prior filter designs. Such problems may include: clogging or blocking of the ion-exchange media by- deposits that limit flow throughout the bulk of the ion-exchange media.

The features and advantages of the present disclosure will be understood upon consideration of the detailed description as well as the appended claims. These and other features and advantages of the disclosure may be described below in connection with various illustrative embodiments of the disclosure. The above summary is not intended to describe each disclosed embodiment or every implementation of the present disclosure. The Figures and the detailed description which follow more particularly exemplify illustrative embodiments.

BRIEF DESCRIPTION OF THE DRAWINGS

Fig. 1 is a schematic perspective view of a water purifier apparatus including an exemplary ion-exchange filter cartridge according to the present disclosure.

Fig. 2 is a schematic perspective view of an exemplary ion-exchange filter cartridge according to the present disclosure.

Fig. 3 is a schematic partial cross-sectional view of the ion-exchange filter cartridge shown in Fig. 2 taken along line 3-3.

Fig. 4 is a schematic perspective view of an exemplary porous plate suitable for use as upper and/or lower porous plates 172, 174, respectively.

Figs. 5A-5L are side views of various exemplary embodiments of the second conduit.

While the above-identified drawing figures set forth several embodiments of the present disclosure, other embodiments are also contemplated, as noted in the discussion. In all cases, this disclosure presents the disclosure by way of representation and not limitation. It should be understood that numerous other modifications and embodiments can be devised by those skilled in the art, which fall within the scope and spirit of the principles of the disclosure. The figures may not be drawn to scale. Like reference numbers may have been used throughout the figures to denote like parts.

DETAILED DESCRIPTION

Ion-exchange filter cartridges according to the present disclosure are generally- adapted for use in water purification equipment. Referring now to Fig. 1 , exemplary ion- exchange filter cartridge 100 is installed in a water purifier apparatus 1 10. Optionally, additional filter cartridges may be installed in the water purifier apparatus 110; for example, a carbon block filter cartridge (not shown) for removal of chlorine, chloramine, and/or volatile organic solvents.

Exemplary ion-exchange cartridge 100 is shown in more detail in Fig. 2. Filter cartridge 100 comprises a closed end 120, a sidewall 130, and a connective end 140 opposite the closed end 120. The connective end 140 comprises an inlet port 150 and an outlet port 160. Closed end 120, a sidewall 130, and a connective end 140 collectively enclose a filter media chamber 170; for example, as in one embodiment shown in Fig. 3.

Referring now to Fig. 3, filter media chamber 170 has a longitudinal axis 175 and a depth d relative to the connective end 140. A first conduit 180 is in fluid communication with the outlet port 160 and the filter media chamber 170. Ion-exchange filter media 190 is disposed within the filter media chamber 170. A second conduit 185 is in fluid communication with the inlet port 150 and the filter media chamber 170. A major portion of the second conduit 185 is disposed adjacent to the ion-exchange filter media 190. The second conduit 185 has a terminus 187 proximate the closed end 120. Openings 155 in the second conduit 185 are disposed at a plurality of depths within the filter media chamber 170. At least a length 183 of the second conduit 185 is disposed between the sidewall 130 and the longitudinal axis 175.

The second conduit 185 has a hollow core member 157 with respective upper and lower hollow branches (186, 187) extending downwardly therefrom. Hence, at least a length (e.g., 183) of the second conduit 185 is disposed between the sidewall 130 and the longitudinal axis 175. The hollow branches extending from the hollow core will typically have a smaller effective diameter than the hollow core, although this is not a requirement. For example, upper hollow branches may have an effective diameter that is from 5 to 15 percent (e.g., 10 percent) of the effective diameter of the hollow core member, and lower hollow branches may have an effective diameter that is from 10 to 30 percent (e.g., 20 percent) of the effective diameter of the hollow core member 157.

Suitable ion-exchange filter media include, for example, crosslinked organic sulfonated polymers (e.g., cross-linked sulfonated polystyrene). Ion-exchange filter media are widely available from commercial sources; for example, under the trade designation "AMBERLYST" and "AMBERLITE" from Rohm & Haas Co. of Philadelphia, PA, and under the trade designation "DOWEX" from Dow Chemical of Midland, MI.

During use, the ion exchange filter media lose their potency and should be regenerated or replaced before further use. In typical cases, this problem is solved by installation of a fresh ion-exchange filter cartridge

In the embodiment shown in Fig. 3, filter media chamber 170 has upper and lower porous plates 172, 174 that collectively contain the ion-exchange resin within the filter media chamber. In the embodiment shown in Fig. 3, the second conduit 185 extends through the upper and lower porous plates 172, 174 (e.g., see Fig. 4). One embodiment of upper porous plate 172 (and optionally lower porous plate 174) is shown in Fig. 4, wherein a porous nonwoven material 411 is supported on porous frame 413.

The ion-exchange filter cartridge 100 may have an optional bypass conduit 135, as shown in phantom in Fig. 3, that fluidly connects the inlet and outlet ports 150, 160 without contacting the ion-exchange filter media 190. In some embodiments, a flow control device such as, for example, a valve may be used to control fluid flow through the bypass conduit. Typically, the flow of water through the bypass conduit will depend on the water to be treated and the end use.

Depending on the desired flow characteristics through the ion-exchange filter media, the second conduit may have a variety of shapes such as, for example, a branched structure or a coil. In general, the second conduit has openings that serve to dispense water into the ion-exchange filter media at predetermined intervals and at predetermined flow rates such that the clogging of the ion-exchange filter media is substantially minimized and life of the filter cartridge is substantially maximized. Accordingly, the water passing through the second conduit is distributed at points in the ion-exchange filter resin that have different contact times between the water and the resin before leaving the filer cartridge.

The second conduit may comprise hollow branches in fluid communication with a hollow core member, wherein the hollow branches extend away from the hollow core member, and wherein at least some openings are disposed on the hollow branches. The second conduit may end at a terminus that may be open or closed. In some embodiments, (for example, that shown in Fig. 3) the hollow core member is disposed along the longitudinal axis.

Referring now to Fig. 5A, the terminus 587a of the second conduit 585a is closed. Second conduit 585a has hollow core member 557a and downward extending hollow branches 588a, each terminating at an opening 555a.

Alternatively, as shown in Fig. 5B the terminus 587b of the second conduit 585b may be open. Second conduit 585b has hollow core member 557b and downward extending hollow branches 588b, each terminating at an opening 555b.

Various other arrangements of the second conduit are shown in Figs. 5C -5K, wherein elements are identified as in Figs. 5A and 5B, using respective index lettering. As can be seen from Figs. 5C-5K, the hollow branches 588c, 588k of the second conduit 585c, 585k extend from hollow core member 557c, 557k and terminate at openings 555c, 555k. The hollow branches may expand and/or taper. The hollow branches may be upwardly, horizontally, and/or downwardly directed; and, as shown in Fig. 5G, they may have hollow branches on hollow branches. Openings 555c, 555k distribute water throughout the ion exchange filter media.

Fig. 5L shows a configuration of the second conduit 5851 that includes a hollow core member 5571 shaped as a coil 5891 with openings 5551. Although not shown, it is envisaged that hollow branches could extend from hollow core member 5571 .

In some embodiments, the openings increase in size as the depth increases; see, for example, Figs. 5E-5H. In some embodiments, the openings decrease in size as the depth increases; see, for example. Figs. 5C-5D. In some cases, the size of the openings is constant or mixed; see Figs. 5G, 51, and 5L. In some embodiments, the hollow branches are arranged in a rotationally symmetric pattern about the longitudinal axis; for example, see Fig. 51. In some embodiments, the hollow branches are arranged in a plane; for example, see Fig. 5A-5F. In some embodiments, some or all of the openings are disposed at ends of the hollow branches although at least some of the hollow branches may have closed ends; for example, see Figs. 5A-5K. In some embodiments, the hollow branches extend from the hollow core member toward the closed end of the ion-exchange filter cartridge; for example, see Figs. 5A-5E. In some embodiments, each of the hollow branches has an effective diameter that increases with decreasing distance from the closed end; for example, see Fig. 5K. In some embodiments, each of the hollow branches has an effective diameter that is substantially equal; for example, see Figs. 5A and 5B.

The various component parts of the filter cartridge may be made of any suitable material including, for example, metal or plastic. Examples of suitable plastics include polyamides, polycarbonates, polyolefins, and acrylics (e.g., ABS acrylic polymers).

In some embodiments, the connective end provides fluid communication between the filter media chamber and a filter head, and wherein the filter head comprises an inlet conduit, an outlet conduit, and a receiving member adapted to engage the connective end.

Various modifications and alterations of this disclosure may be made by those skilled in the art without departing from the scope and spirit of this disclosure, and it should be understood that this disclosure is not to be unduly limited to the illustrative embodiments set forth herein.

Claims

What is claimed is:

1. A filter cartridge comprising:

a filter media chamber having a longitudinal axis, a closed end, a sidewall, and a connective end opposite the closed end, wherein the connective end comprises an inlet port and an outlet port;

a first conduit in fluid communication with the outlet port and the filter media chamber:

ion-exchange filter media disposed within the filter media chamber;

2. The filter cartridge of claim 1, wherein the terminus of the second conduit is closed.

3. The filter cartridge of claim 1 , wherein the terminus of the second conduit comprises one of the openings.

4. The filter cartridge of claim 1, wherein the openings increase in size as the depth relative to the connective end increases.

5. The filter cartridge of claim 1, wherein the openings decrease in size as the depth relative to the connective end increases.

6. The filter cartridge of claim 1, wherein at least a portion of the second conduit comprises a coil.

7. The filter cartridge of claim 1 , wherein the second conduit comprises hollow branches in fluid communication with a hollow core member, wherein the hollow branches extend away from the hollow core member, and wherein at least some of the openings are disposed on the hollow branches.

8. The filter cartridge of claim 7, wherein some of the openings are disposed at ends of the hollow branches.

9. The filter cartridge of claim 7, wherein the hollow branches extend from the hollow core member toward the closed end.

10. The filter cartridge of claim 7, wherein each of the hollow branches has an effective diameter, and wherein the effective diameter increases with decreasing distance from the closed end.

11. The filter cartridge of claim 7, wherein each of the hollow branches has a substantially equal effective diameter.

12. The filter cartridge of claim 1 , wherein the second conduit comprises hollow branches in fluid communication with a hollow core member, wherein the hollow branches extend away from the hollow core member, wherein at least some of the openings are disposed on the hollow branches, and wherein the hollow core member is disposed along the longitudinal axis.

13. The filter cartridge of claim 12, wherein the hollow branches are arranged in a rotationally symmetric pattern about the longitudinal axis.

14. The filter cartridge of claim 12, wherein the hollow branches are arranged in a plane.

15. The filter cartridge of claim 12, wherein some of the openings are disposed at ends of the hollow branches.

16. The filter cartridge of claim 12, wherein the hollow branches extend from the hollow core member toward the closed end.

17. The filter cartridge of claim 12, wherein each of the hollow branches has an effective diameter, and wherein the effective diameter increases with decreasing distance from the closed end.

18. The filter cartridge of claim 12, wherein each of the hollow branches has a substantially equal effective diameter.

19. The filter cartridge of claim 1, wherein the connective end further comprises a bypass conduit in fluid communication with the inlet port and the outlet port, wherein the bypass conduit is substantially free of ion-exchange media.