Abstract:
A water filtration system for the removal of bacteria and protozoa as well as certain chemical contaminants which includes a bottle having a top, a bottom and an interior, where the bottle is oriented in an upright attitude when the top is above the bottom. A first filter is disposed in the bottle interior, and a second filter is disposed in the bottle interior downstream from and in series with the first filter. The second filter is formed of a sub-micron hollow fiber membrane filter and includes a filtered water outlet. The first and second filters are configured such that filtered water exits the filtered water outlet with the bottle in the upright attitude.

Description:
CROSS-REFERENCES TO RELATED APPLICATIONS  
       [0001]     This application is a continuation-in-part (CIP) of U.S. patent application Ser. No. 11/056,387, filed Feb. 14, 2005, pending, which claims the benefit of U.S. Provisional Patent Application Ser. No. 60/543,574, filed Feb. 12, 2004, the entire contents of which are herein incorporated by reference. U.S. patent application Ser. No. 11/056,387 is also a CIP of U.S. patent application Ser. No. 10/486,346, filed Oct. 21, 2004, pending, which is a CIP of U.S. patent application Ser. No. 09/566,384, filed May 8, 2000, now U.S. Pat. No. 6,569,329, which claims the benefit of U.S. Provisional Patent Application Ser. Nos. 60/132,808 filed May 6, 1999, 60/133,855 filed May 12, 1999, and 60/182,911 filed Feb. 16, 2000. U.S. patent application Ser. No. 10/486,346 also is the U.S. national phase of International PCT Application No. PCT/US02/25188, filed Aug. 12, 2002, which designated the United States. International PCT Application No. PCT/US02/25188 claims priority of U.S. Provisional Patent Application Ser. No. 60/311,098, filed Aug. 10, 2001. The entire contents of these applications are incorporated herein by reference. 
     
    
     STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT  
       [0002]     (Not Applicable)  
       BACKGROUND AND SUMMARY OF THE INVENTION  
       [0003]     The present invention relates to a water filtration bottle and, more particularly, to a water filtration bottle including a dual filter system enabling filtered water to exit the bottle when the bottle is in an upright attitude.  
         [0004]     It has been recognized for years that a real necessity existed to treat water for biological contamination as well as chemical contamination. Those that could are typically bulky and require the use of a hand pump capable of forcing the water through a sub-micron ceramic filter or a membrane such as used for reverse osmosis. Thus, a product, which could be configured as a Water Sport Bottle, or hydration unit, was needed. This product would need to remove by filtration both bacteria and protozoa, and have an absolute functional pore size in the 0.2 micron range. While there have been products introduced to the market which could potentially remove protozoa such as Crytosporidium and Giardia, few if any could remove bacteria when the user consumes the water directly from the bottle without post filtration chemical treatment, and remove virtually all the water from the bottle.  
         [0005]     There is also the question of virus, which cannot be filtered but, when a concern, may be chemically treated with either iodine or chlorine compounds. When so treated it is highly desirable to be able to remove the disinfecting chemical, and if not the complete chemical, certainly the taste thereof, which users find highly objectionable.  
         [0006]     In a previous design, dual filter elements were used, arranged in tandem, or in a nested configuration, and enclosed within a shroud, which functioned as a straw annulus. The straw annulus with water entry ports near the top enabled the user to force water to the upper filter when the bottle is inverted for drinking, and less water is in the bottle than would otherwise reach or cover the inlet ports of the primary carbon composite filter positioned in tandem with the secondary filter. The shroud precludes the secondary hollow fiber membrane (HFM) filter from normally being drained of water, which enhances ease of use, eliminating the necessity to expel the energy required to refill the filter element with water in order to drink. The primary filter is manufactured of carbon composite materials and pre-treats the water before delivering the water into the sub-micron hollow fiber membrane filter from which the treated water is delivered directly to the user. In this configuration, however, it is difficult to filter the last ounce or two from the bottle.  
         [0007]     As a means to simplify the design as well as to permit the product to be used upright with a drinking “straw,” a modification of the preceding design is required. There is also a group of users, both men and women, that prefer to drink from a “straw” rather than a “pull-push” valve, which requires inverting the bottle to obtain water. Two means are used to maintain the water within the hollow fiber membrane filter, precluding the water from draining out by gravity when not in use in the normal, or vertical up-right plane of this new design.  
         [0008]     It is recognized that for the product to be used in the up-right or vertical attitude that the water must be picked up from the bottom of the container. This is accomplished by encapsulating the primary carbon composite filter in a shroud forming an annulus about the filter. Thus, while delivering water to the entire circumferential surface area of the filter, water entry ports are limited to the base of the shroud housing. Without the use of the shroud design, air would intrude with several inches of water remaining within the bottle making removal of the water below the air access point more difficult. The use of such a shroud is disclosed in U.S. Pat. No. 6,153,096. The shroud may be used to directly support the carbon composite element, or a housing otherwise containing the filter element.  
         [0009]     In use, the water is either, or both, sucked and pressurized by squeezing the bottle by hand drawing / forcing the water into and through the carbon composite filter and then directly into the hollow fiber membrane filter for delivery to the user. It has been recognized that to enhance usage as well as to reduce the distance of water flow, it is desirable to retain the water within the hollow fiber membrane filter housing to preclude the necessity of purging air that may have reentered the filters as a result of the water draining back through the filter elements. The mechanics to do this are relatively simple when using tubing as a delivery “straw”. The tubing is crimped shut by a top closure causing a vacuum within the tube holding the residual water in place. This mechanism is coupled with the use of the carbon filter shroud, which only has water access ports at its base, and forms a narrow water chamber, in the form of an annulus, surrounding the radial flow carbon composite filter. Using a small annulus with a space approximating 0.01-0.035 inches, the surface tension from both the filter element and shroud preclude all but very slow drainage back into the bottle. This feature in conjunction with the filter water entry ports positioned at the bottom of the shroud at the base of the bottle combines with the water remaining within the bottle to provide a head pressure, thereby restraining the flow of water back from the radial flow carbon composite filter, as well as from the hollow fiber membrane filter, and back into the bottle.  
         [0010]     With the subject invention the user may now choose between a “pull-push” valve and a bottle that flows water to the user when inverted, or using the described means to access the water directly from the bottom of the bottle, the bottle is used up-right with the water delivered through tubing (“straw”) that may be clamped shut to retain the residual water within the tubing.  
         [0011]     The use of the sub-micron hollow fiber membrane with a nominal pore diameter of 0.2 microns and an absolute pore size within 0.1-0.3 microns, but of such a configuration based upon wall and pore geometry that all protozoa and bacteria through 0.2 microns in size are precluded from passage, is a unique feature of the Innova products. Another advantage is the large surface area achieved by the use of the sub-micron hollow fiber membrane bundled within a filter housing. This system is superior to carbon block or ceramic type filters as the smaller pore size of the HFM assures the effective filtration of bacteria, whereas the carbon and ceramic filters must employ significantly larger pore size, relying upon what is termed a torturous path and van der Waals forces to restrain the bacteria. In a portable bottle type unit, the backpressure is too great with a thick-walled ceramic or carbon filter element to use with pore sizes below 10-20 micron, and if employed would be suspect in their ability to effectively remove bacteria over a reasonable and usable time. Further, due to the nature of the media and manufacturing process, the ability to closely regulate pore size is absent, and pores significantly larger than claimed, possibly by a factor of two to three times, would occur. With the sub-micron hollow fiber membrane used by Innova, approximately 7.3 cm in length and 3 cm in diameter, a flow rate of 12 ml per second is achieved with an applied pressure of 1.5 to 10 psig, which is well within the comfortable limit of the normal user. The functional 0.2 micron absolute pore size assures the desired performance.  
         [0012]     The other option that is considered is the use of thin film membranes with an absolute pore size no larger than 0.2 microns. The problem encountered is the inability to configure such a membrane into a effective surface area by accordian pleating or rolling in a manner providing channels between layers. As importantly, no method has been found by which both hydraphillic and hydrophobic properties could be created allowing the film membrane to effectively pass gases (air) as well as liquid (water) within the available pressure range.  
         [0013]     For use where there is expected high levels of chemical contamination, such as with potential military applications, it would be desirable to replace the carbon composite primary filter element with Innova&#39;s Low Density media, which provides maximum contaminant removal over a wide range of contaminants including VOC&#39;s and is also advantageous due to its exceptionally long life and ability to reduce particulate matter and turbidity. The Low Density Media operates in a static as well as a dynamic mode, thus allowing the filtration process to continue as long as the water is statically retained within the media. By using the Low Density media, a second application and configuration of the “straw” and upright based biological sport bottle combines the unique low-density media covered in U.S. patent application Ser. No. 09/963,636, and U.S. Pat. No. 6,506,449 pertaining to the manufacture of the Low Density media with an independent hollow fiber membrane positioned at the base of the bottle and connected to the bottle top and valve by means of a tube or straw. The advantage of the positioning of the sub-micron hollow fiber membrane element at the base of the bottle takes advantage of gravity to retain water within the base of the adjacent low density filtration media, particularly when the water volume becomes low. If the HFM was attached to the top of the bottle, or bottle top with valve, and the bottle was inverted to drink, there would be some delay as the water drained back to the top of the bottle, when partially filled.  
         [0014]     A second advantage is the ability to have all the water treated to a maximum with the positioning of the HFM at the base of the bottle. The water when filled into the bottle will percolate down through the Low Density filtration media, removing or significantly reducing the non-biological contaminants, the biological contaminants being removed by the HFM. An alternative to the bottle being completely filled with the low-density media is to use a partial media fill, essentially surrounding the sub-micron hollow fiber membrane support and separator. The quantity of Low Density Media required is determined by the anticipated amount of water that will be withdrawn for drinking at any one time. The time period between water removal is calculated by the desirability of having a 2 to 3 minute residence time for the water within the media.  
         [0015]     In an exemplary embodiment of the invention, a water filtration system includes a bottle having a top, a bottom and an interior, and first and second filters. The bottle is considered in an upright attitude when the top is above the bottom. The first filter is disposed in the bottle interior, and the second filter is disposed in the bottle interior downstream from and in series with the first filter. The second filter is a hollow fiber membrane filter and includes a filtered water outlet. The first and second filters are configured such that filtered water exits the filtered water outlet with the bottle in the upright attitude. Preferably, at least the second filter includes a water inlet disposed in the bottle interior adjacent the bottle bottom.  
         [0016]     A one-way valve may be provided to permit re-inflation of the bottle. In this context, a bottle lid may be removably securable to the bottle top, where the one-way valve is a relief valve in the bottle lid.  
         [0017]     A water outlet tube may be affixed to the filtered water outlet of the second filter. The water outlet tube directs the filtered water out of the bottle. Additionally, the water outlet tube may serve as a straw enabling user withdrawal of the filtered water. The bottle top preferably includes structure for closing the bottle top from the atmosphere and for sealing off the water outlet tube such that when the closure means is closed, water residing in the first and second filters is prevented from being drained.  
         [0018]     The first filter and the second filter may be affixed together via a water tight friction fit, where the first filter includes a water inlet disposed in the bottle interior adjacent the bottle bottom. In a preferred arrangement, the first filter comprises a carbon composite filter. The first filter may include an outer shroud housing the carbon composite filter, which outer shroud is circumferentially spaced from the carbon composite filter to define an annular water reservoir. The first filter may be removable, where the water filtration system is functional with the first filter removed. The entire filter assembly is hence enclosed in an outer shroud, the purpose of which is to retain residual water encompassing the hollow fiber membrane and restrict air intrusion.  
         [0019]     The first filter may alternatively include a low density medium substantially filling the bottle interior. In this context, the first filter has an opening therethrough to receive the second filter. A flange plate may be disposed over the opening in the first filter. The flange plate is sized and shaped to prevent raw water from entering the opening.  
         [0020]     Preferably, at least the first filter is cleanable.  
         [0021]     In one arrangement, the first filter is attached to and at least partially surrounding the second filter. In this context, the first filter is circumferentially spaced from the second filter to define an annular water reservoir between the first filter and the second filter. The first filter may be formed of a polysulphone membrane.  
         [0022]     The water filtration system may additionally include a pre-filter disposed adjacent the bottle top. The pre-filter includes at least two levels of filter sheets having progressively finer pore size, where the filter sheets are separated by mesh screens. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0023]     These and other aspects and advantages of the present invention will be described in detail with reference to the accompanying drawings, in which:  
         [0024]      FIG. 1  illustrates an embodiment of the invention combining a sub-micron hollow fiber membrane element and an independent carbon composite filter; all contained within an outer shroud;  
         [0025]      FIG. 2  illustrates an alternative embodiment using low density filtration in conjunction with the sub-micron membrane;  
         [0026]      FIG. 3  illustrates yet another alternative embodiment using a partial low density filled bottle with HFM and removable base;  
         [0027]      FIG. 4  illustrates a hollow fiber membrane enclosed within a shroud housing for use with an optional external prefilter; and  
         [0028]      FIG. 5  illustrates assembly components for an optional multi-layered varying porosity bundled pre-filter. 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0029]      FIG. 1  illustrates a first embodiment of the invention. A bottle  6  includes a lid  5  which threads on the bottle top to form a water tight seal. A one way air relief vent is incorporated within the lid  5  as shown in  FIG. 1 . Bottle lid  5  supports a pivoting top cover  2 , which when opened allows a drinking tube  3  to extend to an upright drinking position. The drinking tube  3  is fastened by sliding over and being held by friction to a cylindrical extension molded as a component into the lid  5 . When the pivoting cover top  2  is pivoted 90 degrees, it forces the drinking tube  3  over a crimping shoe  4 , effectively sealing the bottle from leakage as well as forming a protective cover over the drinking tube  3 .  
         [0030]     The drinking tube  3  connects through the lid  5  via a tight slip fit hole molded into the lid  5 . A connecting housing  8  attaches by mating male and female friction fit parts. The connecting housing  8  supports an HFM filter housing  19  containing hollow fiber membrane filter materials  1 .  
         [0031]     The HFM housing  19  is retained within the connecting housing  8  by means of a threaded, or snap-in outer shroud housing  7 , which threads, or snap locks into connecting housing  8  and retains the compressed “O” ring seal  9  to preclude bacterial by-pass. The opposite end of the threaded sleeve  11  includes an internal ring defining a snap in connection  13  to form an assembly and locking means to secure the carbon filter  17  in a position to interface with the HFMs  1 .  
         [0032]     With the carbon filter  17  locked in position, a water reservoir  14  is formed between the carbon composite filter  17  and the HFMs  1  to feed and distribute water to the HFMs  1 . The carbon filter outer shroud housing  12 , containing the carbon filter elements, remains independent and may be slipped on or off connector  13  for replacement of the carbon filter, or limited use purposes of the HFM. The radial flow carbon composite filter  17  is contained within housing  12  and aligned by means of a controlled fit at the top of the shroud housing  12 . The space between the carbon filter  17  and the shroud housing  12  forms an annular water reservoir  16  providing access to the full circumference of the radial flow filter body  17 . As the water flows radially through the filter  17 , it accumulates in a central water reservoir  14  and is forced out of reservoir  14  by either or both hand force squeezing the bottle  6  and/or drawing a vacuum on the drinking tube  3 . Water entry ports  15  are at the base of the filter housing  12  adjacent a bottom part of the outer shroud  7 . An air evacuation port  11  allows entrapped air within the outer shroud  7 , should such occur, to evacuate. A small (0.0020 inch) air port  7   a , may be incorporated within the HFM housing  19  should air accumulate. The entrapped air may be ejected and redissolve within the residual water chamber  10 , formed between the filter element housings  19  and  12  and the outer shroud housing  7 . The outer shroud housing  7  is partially open at the base, and water entrance holes  18  are opened when pressure or suction is applied, to allow the intake of water to be filtered. Water entry holes  18  are closed by the one-way umbrella valve  20  which is affixed to the base of the carbon filter housing  12  when pressure is released.  
         [0033]     The embodiment in  FIG. 1  is a more direct approach combining a sub-micron hollow fiber membrane element with the means to both support the HFM to a water transfer tube and to integrate an independent primary carbon composite filter. The carbon composite radial flow filter removes better than 80-90% of chlorine and 97% of lead at a flow rate of 10 ml/sec as tested by NSF. Granular activated carbon GAC operating as an axial flow filter could also be used. Operating as the primary (first) filter, the carbon composite element reduces both chemical and metal contaminants while also acting as a particulate and turbidity filter.  
         [0034]     The HFM operates as a secondary (second) filter and eliminates protozoa cysts and bacteria above the level specified by the EPA under EPA testing protocol which for bacteria is 99.9999%, and the lower requirement of 99.99% for the larger protozoa cysts. The drinking tube extends from a fitting on the topside of the top which is opened by rotating back a hinged cover; similarly, the tube is squeezed shut and hidden (covered) as the cover is rotated back to the closed position. The HFM may be used independently simply for the removal of biological contamination.  
         [0035]     An alternative embodiment of the invention is illustrated in  FIG. 2 . Components of like construction in  FIG. 2  are labeled with the same reference numerals, and the description will not be repeated. With reference to  FIG. 2 , the connecting housing  8  attaches by mating male and female friction fit components and supports HFM filter housing  19  containing the HFMs  1 . The HFM housing  19  is retained within the connecting housing  8  by means of a threaded or mechanical connection  7 A, which threads or assembles into connecting housing  8  and retains the “O” ring seal  9  to preclude bacterial by-pass. The HFM housing  19  containing the HFM bundle  1  is open at the bottom  26  for water access.  
         [0036]     Internally, within the bottle  6 , a top pre filter  21  may be installed to pre-filter water entering the bottle. Each element of the pre-filter is slit at  24  to permit the removal and replacement of the pre-filter around the drinking tube  3 . A low-density static filtration media  28 , for chemical-metal removal, fills the remainder of the bottle with the exception of filter tube  25 . The filter tube  25  centers the HFM component assembly and provides a path by which the HFM assembly may be elevated in conjunction with the removal of the top allowing the bottle to be refilled. This is accomplished without interfering with the Low Density media  28 . The media  28  used is preferably low-density non-woven material coated with activated carbon and complementing medias. A cylindrical opening is formed by filter tube  25  in the media  28  and is closed with a flanged washer  22  containing a central pass through hole  27  providing a mechanism for partially removing the HFM filtration assembly  1 ,  8 ,  19 , when the lid  5  is removed for filling. The flanged washer  22  is mechanically fastened to the filter tube  25 , but may be removed to permit complete removal and disassembly of the HFM assembly. The base of the HFM housing  19  is open at  26  for the normal in-feed of water. Openings  23  are formed in the filter tube  25  near the bottom as well as slightly above the connecting housing  8  when positioned in the normally operating position (i.e., in an upright attitude with the top above the bottom). The openings  23  permit water to flow into and out of the media  28 , from and into the filter tube  25 . One additional function of the holes  23  at the base is to allow entrapped air to escape from the media  28  during filling, which function is also provided by the upper set of holes  23 . The holes  23  in the filter tube  25  also permit ready access of water and permit any water that may enter through the tube access connecting hole to migrate into the treatment media and treated water to occupy the filter tube  25 , increasing the total volume of water contained.  
         [0037]     The embodiment in  FIG. 2  is similarly a sport type bottle that functions in the same manner as the  FIG. 1  embodiment with the exception that the low density static filtration media is used as the primary (first) filtration media instead of the radial flow carbon composite filter. An advantage to this construction is the ability to remove a broader range of chemical and metal contaminants, with a longer life than the radial flow carbon composite block filter or a GAC axial flow filter. An additional advantage is the reduction in pressure required to force water through either of the alternative carbon filters, thus making the product easier to use with enhanced water flow and contaminent removal. Considerably less pressure drop is encountered. Using this media, the product may be housed in a solid, non-squeezable bottle due to the easy flow characteristics of the filter components.  
         [0038]     To permit the lid to be easily removed for refilling the bottle with water, the HFM assembly and connecting tube are positioned within the filter tube  25  allowing the HFM to be partially removed with the lid during the refilling operation. The flange  22  covering the top of the filter tube  25  contains a central hole through which the tubing  3  connecting the HFM through the lid while fastened to the filter tube  25  may slide.  
         [0039]     The flange is nested upon and retains a split non-woven particle pre filter  21 , which is replaceable as the need may arise. The pre-filter bundle (described in detail below) is unique as it pre filters the water on entry, removing sequentially various sizes of particulate matter. The characteristics when only a single piece filter is employed are dependent upon the requirements or aesthetic appearance desired.  
         [0040]      FIG. 4  illustrates still another embodiment of the invention. In this embodiment, the optional primary (first) filter  27  is attached to and at least partially surrounding the HFM housing  19  within retaining sleeve  7 . The optional first filter  27  is circumferentially spaced from the HFM housing  19  to define an annular pretreated water reservoir  29  between the first filter  27  and the HFM housing  19 , which also functions as a shroud.  
         [0041]     Preferably, the first filter  27  is formed of a polysulphone membrane with a pore size ranging from 8 to 0.5 microns, although a pore size as low as 0.2 microns could also be used. One suitable filter is the Versapor filter from Pall Corp. of East Hills, N.Y.  
         [0042]     An advantage of the polysulphone membrane when the silt is present is that it extends the life of the HFM filter  1  and may lower the pressure drop across the HFM filter media, making it easier for the user to extract the water. Additionally, the filter  27  is cleanable. The filter  27  is typically cylindrical but may also be formed into a pleated configuration to materially add to the filter surface area. The use of this first filter is optional.  
         [0043]     Similar to the embodiments described above, the HFM bundle  1  is retained within an impervious shroud  19 , which is the housing supporting the HFMs, permitting water entry from the base, thus allowing substantially all of the water to be extracted from the bottle, with the bottle in an upright configuration.  
         [0044]     With reference to  FIG. 3 , this design contains some of the embodiments found under  FIG. 2 . The primary difference is the reduced quantity of Low Density static filtration media  28 , a shortened separation tube  25 , to support and provide a nest for the HFM separating the low density media  28  from the HFM housing. There are holes  23  in the base of separation tube  25  to permit filtered water to enter the water reservoir chamber  22 . The HFM housing  19  is open at the base  26  for water entry. To facilitate changing the low density filter, a thread on base cap  25  has been incorporated. The flanged connection housing  8  is sized to locate the HFM housing  19  within the separation tube  25 . A short threaded sleeve  7 A is used to secure the HFM housing  19  to the connection housing  8 . The HFM is sealed against by pass by “O” ring seal  9 . A non-woven prefilter  21  is used to remove larger turbid particles and also to function as a cosmetic barrier shielding the appearance of the low-density media. The non-woven pre-filter may also be of one or more layers as shown by  FIG. 5  and may consist of several layer numbers  30 - 39 .  
         [0045]     With reference to  FIG. 5 , the filter bundle  21 , if employed, preferably includes four separate layers of progressively smaller pore size pads  31 ,  35 ,  37 ,  39  from approximately 25 microns down to 5 microns; each pad being separated by a screen  30 ,  32 ,  36 ,  38  of varying mesh sizes from approximately 10 mesh down to 60 mesh. The separating screens enhance flow and filter life by providing an area to accumulate particulate held back by the respective filter pad(s). The bundled pad is optional in use to a single non-woven pad of practically any reasonable thickness or porosity. Each pad and screen includes a slit  32 , which should be slightly staggered on assembly, and a tubing access hole  31 . By staggering the slits  32 , a path where water can flow without passing through and of the filter pads is avoided. The purpose of the screens between the progressively smaller pore size pads is to permit an area for particulate accumulation enhancing flow while extending the filter&#39;s life.  
         [0046]     While the invention has been described in connection with what is presently considered to be the most practical and preferred embodiments, it is to be understood that the invention is not to be limited to the disclosed embodiments, but on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims.