FILTRATION SYSTEM

Abstract

A sediment filter system includes a series of segment layers each having a fibrous layer sandwiched between outer layers, wherein each of the series of segment layers includes different ratios of the material comprising the fibrous layer as compared to the material comprising the outer layers. The fibrous layer comprises a low-density material relative to the outer layers. The segment layers with higher compositions of outer layers include additional sheets of outer layers thereby decreasing the range of pore sizes.

Claims

1. A filter system, comprising: a first filter that includes a fibrous layer having a first and second filter surface, and a pair of surface layers sandwiching the first and second filter surface of the fibrous layer, wherein the surface layers comprise a higher density than the fibrous layer, the surface layers each include a first range of pore sizes, and the first filter comprises a composition of 75% fibrous layer and 25% surface layers; a second filter that includes a fibrous layer having a first and second filter surface, and a pair of surface layers sandwiching the first and second filter surface of the fibrous layer, wherein the surface layers comprise a higher density than the fibrous layer, the surface layers each include a second range of pore sizes, and the second range of pore sizes is smaller than but overlaps with the first range of pore sizes; and wherein the second filter comprises a composition of 55% fibrous layer and 45% surface layers; and a third filter that includes a fibrous layer having a first and second filter surface, and a pair of surface layers sandwiching the first and second filter surface of the fibrous layer, wherein the surface layers comprise a higher density than the fibrous layer, the surface layers each include a third range of pore sizes, and the third range of pore sizes is smaller than but overlaps with the second range of pore sizes, and wherein the third filter comprises a composition of 25% fibrous layer and 75% surface layers.

2. The filter of claim 1, wherein the fibrous layer and the surface layers of the first, second and third filter include edges that are bonded together.

3. The filter of claim 1, wherein surfaces of the fibrous layer and the surface layers of the first, second and third filter are bonded together.

4. The filter of claim 1, wherein the fibrous layer of the first, second and third filter comprises a web of entangled fibers that comprise a three-dimensional layer.

5. The filter of claim 1, wherein the fibrous layer of at least one of the first, second and third filter comprises a depth that is substantially greater than a depth of the pair of surface layers.

6. The filter of claim 1, wherein at least one of the fibrous layer of the first, second and third filter comprises polyethylene terephthalate.

7. The filter of claim 1, wherein the surface layers of at least one of the first, second and third filter comprise polypropylene.

8. (canceled)

9. The filter of claim 1, wherein the fibrous layer of at least one of the first, second and third filter comprises a highly entangled fiber structure.

10. The filter of claim 1, wherein the fibrous of at least one of the first, second and third filter comprises a crystalline structure.

11. The filter of claim 1, wherein the fibrous layer of at least one of the first, second and third filter comprises pseudoboehmite.

12. The filter of claim 1, wherein the range of pore sizes of the second filter is smaller than the range of pores sizes of the first filter by adding additional surface layers to the second filter and the range of pore sizes of the third filter is smaller than the range of pores sizes of the second filter by adding additional surface layers to the third filter.

13. A sediment filter system, comprising: a series of first, second and third segment layers each having a fibrous layer sandwiched between outer layers, wherein each of the series of segment layers includes different ratios of the material comprising the fibrous layer as compared to the material comprising the outer layers; wherein the fibrous layer comprises a low-density material relative to the outer layers; and wherein the segment layers with higher compositions of outer layers include additional sheets of outer layers thereby decreasing the range of pore sizes; and wherein the first segment layer comprises a composition of 75% fibrous layer and 25% outer layers; the second segment layer comprises a composition of 55% fibrous layer and 45% outer layers, and the third segment layer comprises a composition of 25% fibrous layer and 75% outer layers.

14. (canceled)

15. The sediment filter system of claim 13, wherein the outer layers comprise polypropylene (PP) and the fibrous layer comprises polyethylene terephthalate (PET).

16. (canceled)

17. The sediment filter of claim 13 wherein the low-density fibrous layers are configured as three-dimensional structures that allow dust particles to move through the fibrous layers in a circuitous direction.

18. The sediment filter of claim 17, wherein the circuitous path of dust particles through the fibrous layers increases the dust particle storage capacity of the fibrous layers.

19-20. (canceled)

21. The filter system of claim 1, wherein the surface layers comprise polypropylene (PP) and the fibrous layer comprises polyethylene terephthalate (PET).

22. (canceled)

23. The filter system of claim 21, wherein the surface layers comprise polypropylene (PP) and further comprising a fourth filter comprising a composition of 100% PP.

24. The filter system of claim 1, wherein each fibrous layer of the first, second and third filter comprises a low-density fibrous layer configured as a three-dimensional structure that allows sediment particles to move laterally and in a circuitous direction relative to direction of water flow through the surface layers.

25. The filter system of claim 1, wherein each fibrous layer of the first, second and third filter comprises a three-dimensional structure that stores a high volume of sediment particles relative to a sediment particle storage capacity of the surface layers.

26. A filter system, comprising: a first filter that includes a first fibrous layer and a first pair of outer layers, wherein the outer layers comprise a higher density than the fibrous layer, wherein the outer layers include a first range of pore sizes, and wherein the first filter comprises a depth of 75% fibrous layer and 25% outer layers; and a second filter that includes a second fibrous layer and a second pair of outer layers, wherein the second outer layers comprise a higher density than the second fibrous layer, the second outer layers include a second range of pore sizes wherein the second range of pore sizes is smaller than but overlaps with the first range of pore sizes, and wherein the second filter comprises a depth of 55% fibrous layer and 45% outer layers; and a third filter that includes a third fibrous layer and a third pair of outer layers, wherein the third outer layers comprise a higher density than the third fibrous layer, the third outer layers include a third range of pore sizes that is smaller than but overlaps with the second range of pore sizes, and wherein the third filter comprises a depth of 25% fibrous layer and 75% outer layers; wherein the first, second and third fibrous layers each are configured with randomly varying ranges of pore sizes that filter sediment particles while allowing the sediment particles to move laterally and in a circuitous direction relative to a direction of water flow through surfaces of the first second and third outer layers thereby increasing a sediment particle storage capacity of the first, second and third fibrous layers.

27. The filter system of claim 1, wherein the first, second and third pairs of surface layers are bonded to the first, second and third fibrous layers, respectively.

28. The filter system of claim 1, further comprising: a first filter segment that comprises a plurality of first filters; a second filter segment that includes a plurality of second filters; and a third filter segment that includes a plurality of third filters.

29. The filter system of claim 1, wherein the surface layers of the first, second and third filters comprise sediment particle filters and the fibrous layers of the first, second and third filter comprise sediment particle storage media between the sediment particle filters.

Description

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

[0026] FIGS. 1-6 illustrate a portable water filtration system according to an embodiment of the present invention.

[0027] FIG. 7 shows a protective filter cage of the portable water filtration system.

[0028] FIGS. 8 and 9 illustrate partial cross-sectional views of the portable water filtration system.

[0029] FIG. 10 shows an exploded view of a water filter assembly according to an embodiment of the present invention.

[0030] FIG. 11 shows a cross-sectional view of the water filter assembly.

[0031] FIG. 12 is an exploded view of concentric filters of the water filter assembly.

[0032] FIG. 13 is a perspective view of the water filter assembly.

[0033] FIGS. 14 and 15 illustrate perspective and cross-sectional views of a protective filter cage of the water filter assembly.

[0034] FIG. 16 illustrates a cross-sectional view of a conventional filter.

[0035] FIGS. 17 and 18 show surface views of a conventional filter.

[0036] FIGS. 19 and 20 illustrate surface views of a sediment filter according to an embodiment of the present invention.

[0037] FIGS. 21-23 show segment layers of the sediment filter.

[0038] FIGS. 24 and 25 show surface and cross-sectional views of the sediment filter.

[0039] FIGS. 26-28 illustrate surface, cut-away and full stack profile views of segment layers AA, A, B, C and D of the sediment filter.

[0040] FIGS. 29-33 show cross-section, layered surface, single layer surface, profile and stack profile views of segment layer AAA of the sediment filter.

[0041] FIGS. 34-36 show surface, profile and stack profile views of segment layer D.

[0042] FIGS. 37-39 show surface, profile and stack profile views of segment layer E.

[0043] FIGS. 40-42 show surface, profile and stack profile views of segment layer F.

[0044] FIGS. 43 and 44 show full stack profiles of segment layers AAA, AA, A, B, C, D, E and F with one bottom exit and two bottom exits, respectively.

[0045] FIG. 45 shows a single layer profile view of one of segment layers AA, A, B, C or D.

[0046] FIGS. 46-48 show another embodiment of a filter of the present invention as a cylindrical filter.

[0047] FIG. 49 is another embodiment of a filter of the present invention as a bag filter.

DETAILED DESCRIPTION OF THE INVENTION

[0048] Referring to FIGS. 1-6, a portable water filtration system 100 can be used in areas where potable water systems are not available. The system 100 includes a handle 105, a filter assembly 110 and a container vessel 115 that holds a volume of water. A pump 120 can be used to pressurize the vessel 115 to facilitate water flow through the filter assembly 110.

[0049] Referring to FIG. 3, the vessel 115 has a fill port that is covered by a cap 125. A retainer ring 130 is used to retain the cap 125. A sediment drain covered by a drain cap 135 is positioned at the bottom of the vessel 115. An outlet hose 140 is installed in an outlet of the filter assembly 110.

[0050] Referring to FIG. 4, the pump 120 includes a squeezable bulb 145, a pressure hose 150 and a valve actuated by a butterfly handle 155. The valve can seal the vessel 115 to maintain pressure.

[0051] Referring to FIGS. 7, 14 and 15, a protective cage 158 surrounds the filter assembly (not shown). The cage 158 includes a series of ribs that encircle the filter assembly. This protects the filter assembly against impact, such as, for example, if the container 100 is dropped.

[0052] Referring to FIG. 8, the filter assembly 110 include a carbon ring 160 and a series of corrugated filters 165 in a concentric ring. As will be described in more detail below, water flows from the outside to the inside of the concentric ring of filters to an exit port.

[0053] Referring to FIG. 9, the filter assembly 110 is positioned in a threaded collar 165 attached to the container 110. A threaded cap 170 is screwed into the threaded collar 165 to secure the filter assembly 110 in the container 110. A sealing ring 175 or gasket is positioned between the threaded cap and a lip 180 of the filter assembly 110 so that the filter assembly is clamped between the threaded collar 165 and the threaded cap 170 for a watertight seal.

[0054] Referring to FIGS. 10 and 11, the filter assembly 110 includes a circular intake cover 185, a sediment filter 190, a generally cylindrical wall 195, an inner circular wall 200 and a cover wall 205 over the concentric filters. The circular intake cover 185 has a series of ribs and openings that allow water to flow from the vessel 115 into the filter assembly 110. The inner circular wall 200 separates the filter assembly into a sediment filter chamber 210 and a concentric ring filter chamber 215. The inner circular wall 200 has a series of ports to allow water to flow from the sediment filter chamber 210 to the concentric ring filter chamber 215.

[0055] The generally cylindrical wall 195 may have straight or parallel sides and a circular or oval cross-section in the shape or form of a cylinder. However, it may have other rectangular shafts or notches.

[0056] The sediment filter 190 is positioned in a vertical orientation with respect to the height of the vessel 115. Thus, heavy sediment bypasses the sediment filter 190 and falls directly to the sediment drain thereby extending the life of the sediment filter 190.

[0057] Referring to FIG. 11, water flows through the intake cover 185 from the vessel 115 into the sediment filter chamber 210 in the direction shown by Arrow A. Water then flows from the sediment filter chamber to the concentric ring filter chamber 215. The cover wall 205 over the concentric filters is a solid circular wall that diverts the flow of water from a downward to a lateral direction toward the outside of the concentric ring filter chamber 215 as shown by Arrow B. The water then flows downward between the cylindrical wall 195 and the outside surface of the carbon ring 160 in the direction of Arrow C. The carbon ring 160 includes activated carbon and may be a composition of materials, such as, for example, carbon with embedded silver. Other types of filter media may be used instead of or in addition to carbon, such as, for example, an ion-exchange resin or ion-exchange polymer.

[0058] Water flows through the carbon ring 190 from the outside to the inside in the direction of Arrow D. Water then flows through a dividing wall 218 into the concentric ring of corrugated filters 165.

[0059] The embodiment shown in FIG. 11 has a series of four corrugated filters 220, 225, 230 and 235. The filters 220, 225, 230 and 235 are spaced apart by dividing walls 240, 245, and 250.

[0060] As shown in FIG. 12, each of the dividing walls 218, 240, 245, and 250 has ports or slots that allow the flow of water toward the center of the concentric rings. A circular outlet tube 255 is positioned at the center of the dividing walls 218, 240, 245, and 250. In other embodiments, additional dividing walls may be added or dividing walls may not be used. One or more of the concentric filters 220, 225, 230 and 235 may be configured to remove suspended matter, microbiological matter and/or chemicals.

[0061] Referring again to FIG. 11, a circular outlet tube 255 forces the water to change direction upward toward the sediment filter 190 and then down again through an outlet port 260 into an outlet chamber as shown by Arrow E. Water then flows down toward an exit port 265 in a direction to exit the container 100 as shown by Arrow F.

[0062] Referring to FIG. 13, a spiral flow agitator component 270 is positioned in the circular outlet tube 255. The agitator component 270 causes turbulence so that water has increased contact with a disinfectant media in the outlet tube 255. In another embodiment, the agitator component may also include disinfection media.

[0063] Referring to FIGS. 19 and 20, the filter material is designed with a larger range of pore sizes than that of a conventional filter. The range of pore sizes shown in FIG. 19 are generally larger than that shown in FIG. 20, however, the range of pore sizes can overlap.

[0064] FIGS. 21 shows various filter media segment layers that make up the sediment filter. Generally, the range of pore sizes of the surface material making up each filter segment layer AAA, AA, A, B, C, D, E and F generally get smaller. In one embodiment, some of the segment layers AA, A, B, C, E and F are made up of varying amounts of a first surface material sandwiching a second filter material.

[0065] The range of pore sizes of the first surface material can be adjusted by adding or subtracting various layers of a filter media together, such as, for example, layers of a melt blown polypropylene (PP) web. The degree of fiber-entanglement, fiber diameter and density of the melt blown web can also be used to vary effective pore sizes of the PP. In another embodiment, spunbond fabric may be used in addition to or to replace the PP when, for example, additional strength is needed.

[0066] In the embodiment that is shown in FIG. 21, segment layers AAA, AA, A, B, C and D include four individual layers that make up each of the segment layers. In different embodiments the four individual layers may have surfaces that are bonded to each other to make up the segment layer or they may be stacked on each other so that they contact adjacent individual layers without being bonded together. In another embodiment, the surfaces of the individual layers are tacked to adjacent individual layers in discrete locations such as in the center of each layer and at the edges.

[0067] Referring to FIGS. 22-23, the filter media segment layers AAA, AA, A, B, C, D, E and F are stacked together. Each segment AAA, AA, A, B, C, D, E and F is in contact with adjacent segment layers, but the surfaces of the segment layers are not bonded together.

[0068] Referring to FIG. 24, the filter media segment layers are stacked and cut together in a desired shape. For example, the segment layers may be stacked, and an ultrasonic cutter may be used. A seal or bond at the edges of the segment layers may be formed during the cutting process. In another process, heat welding may be used to bond the segment edges together and/or a round collar may be used to clamp the edges together.

[0069] Referring to FIG. 25, the edges of the segment layers can be clamped or bonded together with a plastic ring or silicone over molding to form the sediment filter. As shown, the sediment filter can be much denser at the edges while the center bulges outward at the top, bottom or both the top and bottom.

[0070] Referring to FIGS. 29-33 the media filter segment layer AAA is shown in more detail with a multiple layer surface view, single layer surface view and a profile view. Each profile view is a from the side with the filter media sandwiched between glass slides for illustration purposes only. Segment layer AAA is formed from multiple layers of PP that are bonded together. In one embodiment, four individual layers make up one segment layer AAA which is 100% PP with a density of 20-70 grams per square meter (GSM).

[0071] Referring to FIGS. 26-28 and 45, the segment layers AA, A, B and C are illustrated by surface, cut-away, full stack profile and single layer profile views. The term full stack profile refers to the combinational of individual layers that make up the segment layer and single layer profile refers to an individual layer of the segment layer. The outer layers of each individual layer are formed from PP bonded to an inner layer formed from polyethylene terephthalate (PET) fibers. The outer PP layers dictate the range of pore sizes while the PET fibers provide a three-dimensional matrix of filter media with much less resistance to particle flow than the PP surface or outer layers. The PET fiber matrix allows sediment particles to travel in varying directions through the filter media as well as laterally. This provides a higher volume of particle loading in comparison to a filter with a more single directional flow through the filter media. The PET and PP fibers are bonded together to form each layer.

[0072] The segment layers have different compositions with decreasing pore sizes and sediment particle storage capacity. For example, in one embodiment segment layer AA includes a composition of 75% PET/25% PP, segment layer A includes a composition of 55% PET/45% PP, segment layer B includes a composition of 45% PET/55% PP, and segment layer C includes a composition of 25% PET/75% PP. Each segment layer AA, A, B and C may have a density of about 70 GSM.

[0073] Each of the segment layers AA, A, B and C can be composed of three or more layers of individual sandwich structures of PP layers on each side of PET fibers. The outer PP layers exhibit randomly distributed pore size structure across the surface of a sheet which also is a micro three-dimensional structure. This helps maintain flow rate and prevent pressure drop. The inner PET layer is composed of fibers which create a further three-dimensional structure to allow better dust loading capacity whilst maintaining randomly distributed pore sizes which again helps prevent pressure drop and premature clogging. The PET layer generally has a lower density and has much more porosity than the PP layer.

[0074] Multiple layers of the sandwich are stacked one on top of another to create a segment with more depth and hence more voids and more of a three-dimensional structure. These randomly distributed voids help to capture a range of particle sizes to prevent subsequent segment layers from clogging prematurely. Stacking of these layers helps create a more three-dimensional structure with multidirectional flow.

[0075] Segment layer AA is made from PET fibers sandwiched between layers of PP. This “sandwich” is more open than subsequent segment layers and exhibits a larger pore size structure in general than subsequent segment layers but has a smaller pore size than previous segment layers.

[0076] In one embodiment, segment layer AA can be composed of three or more individual sandwich structures. The outer layers of each sandwich are composed of melt blown polypropylene which exhibits randomly distributed pore size structure across the surface of a sheet which is which also a micro three-dimensional structure. This helps maintain flow rate and prevent pressure drop. The inner layer is composed of polyethylene terephthalate fibers which create a further three-dimensional structure to allow better dust loading capacity whilst maintaining randomly distributed pore sizes which again helps prevent pressure drop and premature clogging.

[0077] Multiple layers of the sandwich are stacked one on top of another to create a segment with more depth and hence more voids and more of a three-dimensional structure. These randomly distributed voids help to capture particle sizes to prevent subsequent segment layers from clogging prematurely. Stacking of these layers helps create a more three-dimensional structure with multidirectional flow.

[0078] Referring to FIGS. 34-36, segment layer D is illustrated by in profile, stack profile and surface views. In one embodiment, segment layer D has all PP individual sheets with a density of about 40 GSM that are bonded together into segment layer D. The PP sheet may have a depth of 0.5-2 mm Multiple individual sheets are stacked to create a segment with depth and voids. These randomly distributed voids help to capture larger particle sizes above 3 microns to prevent the subsequent layers from clogging prematurely and causing a drop in pressure. This stacking helps creates a more three-dimensional filter segment with greater dust holding capacity and with multidirectional flow.

[0079] Referring to FIGS. 37-39, segment layer E is shown in surface, cut away and profile views. Segment layer E includes PP on outer surfaces with pseudoboehmite sandwiched in-between. Pseudoboehmite is an aluminum compound with the chemical composition AIO. It consists of finely crystalline boehmite, but with a higher water content than in boehmite

[0080] Segment layer E can be composed of one or more layers of individual sandwich structures with a 6.25 mean micron pore size. The pseudoboehmite creates a further three-dimensional structure to allow better dust loading capacity whilst maintaining randomly distributed micro pore sizes which again helps prevent pressure drop and premature clogging. This helps maintain flow rate and prevent pressure drop with multidirectional flow. Powder activated carbon may also be incorporated in the inside of the sandwich for taste, odor contaminant reduction.

[0081] Referring to FIGS. 40-42, segment layer F is shown in surface, cut away and profile views. Similar to segment layer E, segment layer F can be composed of includes PP on outer surfaces with pseudoboehmite sandwiched in-between, however, the individual sandwich structures have a much finer 1.25 micron mean pore size.

[0082] Other filter media may be used instead of pseudoboehmite, such as, for example, very fine (small diameter), highly entangled and/or dense layers of PET fibers.

[0083] FIGS. 43 and 44 are photos of the full stack of segment layers AAA, AA, A, B, C, D and F shown in FIGS. 21-23 mentioned above. All the segment layers are in contact with adjacent layers. The resulting sediment filter has can have a finer pore size and/or higher dust load capacity relative to conventional filters before the sediment filter gets clogged and loses its filtration capacity.

[0084] Referring to FIGS. 46 and 47, a cylindrical sediment filter 300 is illustrated with filter media segment layers AAA′, AA′, A′, B′, C′, D′, E′ and F′ are configured as a concentric ring. Each segment AAA′, AA′, A′, B′, C′, D′, E′ and F′ are in contact with adjacent segment layers but the surfaces of adjacent segment layers are not bonded together. The composition of the segment layer may be similar to that described above with respect to FIGS. 21-23 and 43-44. In other embodiments, there may be more or less segment layers of different compositions.

[0085] FIG. 48 illustrates the cylindrical sediment filter 300 in use. The cylindrical sediment filter 300 is installed in a filter casing 310. The filter casing has a water input line with water flowing into the filter casing shown by Arrow A.

[0086] The bottom of the filter 300 is sealed or pressure fitted against the bottom of the casing such that water flows through the filter as shown by Arrow B. The water flows into an open channel at the center of the filter 300 and flows out of the casing case through output line 330 in the direction shown by Arrow C.

[0087] FIG. 49 illustrates another embodiment of a sediment filter configured as a bag filter 350. The bag filter 350 includes multiple segment layers as that described above or may have another configuration of segment layers. The edges of the bag filter 350 may essentially be crimped or secured together by a round collar or may be heat bonded or glued together.

[0088] The description above has been described with reference to particular embodiments, however, those skilled in the art will understand that various changes may be made and equivalents may be substituted without departing from the spirit and scope of the invention. In addition, many modifications may be made to adapt to a particular situation, material, composition of matter, process, process step or steps, to the objective spirit and scope of the present disclosure. For example, the filter assembly may be incorporated into another type of water vessel, such as, a drum, barrel or a fixed system. The sediment filter may be configured as a particulate filter for liquid, gases or air. As another example, the sediment filter may have another shape, such as, a rectangle, globe, container or bag. All such modifications are intended to be within the scope of the claims.