Patent Abstract:
A filter element for a pool or spa including a sintered plastic outer cylinder of a first diameter, a sintered plastic inner cylinder of a second diameter less than said first diameter; the inner cylinder being position coaxially with respect to the outer cylinder to define an annular interior chamber; and a selected granulated filter medium or combination of media residing in the annular interior chamber.

Full Description:
RELATED APPLICATIONS 
       [0001]    This application is a continuation-in-part of U.S. patent application Ser. No. 12/762,632 filed Apr. 19, 2010, which claims priority to U.S. Provisional Patent application No. 61/242,749 filed Sep. 15, 2009, the contents of which are each hereby incorporated herein by reference in their entirety. 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    1. Field of Invention 
         [0003]    The subject disclosure relates to pools and spas and more particularly to improved methods and apparatus for filtering contaminants from pools and spas. 
         [0004]    2. Description of Related Art 
         [0005]    Portable spas have become quite popular as a result of their ease of use and multiplicity of features such as varied jet and seating configurations. One area where the inventor has recognized that ease of use could be enhanced is the area of maintaining proper water chemistry and sanitation. 
       SUMMARY 
       [0006]    The following is a summary description of illustrative embodiments of the invention. It is provided as a preface to assist those skilled in the art to more rapidly assimilate the detailed design discussion which ensues and is not intended in any way to limit the scope of the claims which are appended hereto in order to particularly point tout the invention. 
         [0007]    In an illustrative embodiment, water chemistry and sanitation are improved by installing a novel filter element in a filter compartment of a portable spa or tub In one embodiment, the filter element comprises a sintered plastic outer cylinder of a first diameter and a sintered plastic inner cylinder of a second diameter less than the first diameter. The inner cylinder is positioned coaxially with respect to the outer cylinder to define an annular interior chamber. A selected granular filter medium or media may then be placed in the annular chamber to combat one or more particular contaminants in the spa water. 
         [0008]    In an alternative embodiment, a donut shaped bag containing selected filter media is placed in the annular chamber. In such an embodiment, the inner cylinder may be a suitable plastic mesh material and the bag may be adapted to hook over the inner cylinder. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0009]      FIG. 1  is a schematic side sectional view of a portable spa; 
           [0010]      FIG. 2  is a perspective view of an exchangeable media filter according to an illustrative embodiment; 
           [0011]      FIG. 3  is a side sectional view of the filter of  FIG. 2  taken at  3 - 3  of  FIG. 2 ; 
           [0012]      FIG. 4  is a side sectional view of an alternate embodiment. 
           [0013]      FIG. 5  is a side sectional view of an alternate embodiment; 
           [0014]      FIG. 6  is a side sectional view of an embodiment employing a resin filled bag; 
           [0015]      FIG. 7  is a perspective view illustrating a mesh structure forming an inner cylinder in one embodiment; 
           [0016]      FIG. 8  is a top view of a resin filled bag with a top hook feature; 
           [0017]      FIG. 9  is a side sectional view of the bag of  FIG. 8 ; 
           [0018]      FIG. 10  is a side sectional view of a media filter embodiment employing the bag of  FIGS. 8 and 9 ; 
           [0019]      FIG. 11  is an exploded perspective view of another media filter embodiment; 
           [0020]      FIG. 12  is a perspective view of the filter of  FIG. 11  in an assembled state without media present between the mesh cylinders of the filter; 
           [0021]      FIG. 13  is a perspective view of an end cap of the embodiment of  FIG. 11 ; 
           [0022]      FIG. 14  is a perspective view of the filter of  FIG. 1  in an assembled state; 
           [0023]      FIG. 15  is a perspective view of a baffled filter media bag embodiment; 
           [0024]      FIG. 16  is a top view of the bag of  FIG. 15 ; 
           [0025]      FIG. 17  is a side view of an inner panel of the bag of  FIG. 15 ; and 
           [0026]      FIG. 18  is a side view of an outer panel of the bag of  FIG. 15 . 
       
    
    
     DETAILED DESCRIPTION 
       [0027]      FIG. 1  shows a first embodiment of a portable spa  11  containing an exchangeable media filter element  15 . The spa  11  includes a water circulation, purification and heating system, which includes a filter compartment or “filter bucket”  13 . In the system of  FIG. 1 , spa water  29  passes through a circulation pipe  16  to a circulation pump  19 . A “T” junction  21  may be provided to supply water to a water feature such as a waterfall. 
         [0028]    The circulation pump  19  further pumps the spa water through a “no fault” heater  22 , with which are associated a regulating sensor  23  and a hi-limit sensor  25 . An ozone generator and associated injector or other water purification apparatus  27  is also positioned in the return flow path to the spa  11 , which may comprise an 8 to 10 foot contact chamber  29  and a spa inlet  31  where a circulation return jet is created. A secondary drain  33  may also be provided. An electronic control unit  17  controls the pump  19  and ozone generator  27 , as well as other accessories which may be provided as part of the spa  11 . In one embodiment, the filter bucket  13  may be a conventional filter bucket traditionally manufactured as part of the original spa equipment. 
         [0029]    An exchangeable media filter  15  according to an illustrative embodiment is shown in  FIGS. 2 and 3 . The filter  15  includes inner and outer co-axially mounted annular filter cylinders  43 ,  44  with a top cap  50  and a bottom cap  52 . The cylinders  43 ,  44  are formed of sintered plastic, such as, for example, polypropylene or polyethylene. Other materials for the cylinders  43 ,  44  may include, for example, and without limitation, PTFE (poly tetrafluoroethylene), PVDF (poly vinylidene fluoride), EVA (ethyl vinyl acetate) Nylon, thermoplastic polyurethane. The top and bottom caps  50 ,  52  may be formed, for example, of plastisol, polyurethane, PVC, ABS, or Noryl, polypro, polyethylene, or chemically/thermally set plastic resin elastomer. 
         [0030]    Presently preferred thicknesses W 1 , W 2  for each of the cylinders range from 1/16″ to ½″ with an exemplary thickness of ⅛″ for both W 1  and W 2 . Porosity of the cylinders may range from 25 to 150 microns, with 100 microns being a typical porosity. While the filter  15  is cylindrical, other geometrical shapes, such as square or star-shaped could be employed. Various heights and outer diameters may also be employed, including diameters of conventional filter elements such as, for example, 8 to 20 inches tall and 5 to 12 inches in outer diameter. 
         [0031]    The respective filter elements  43 ,  44  define an annular hollow inner chamber  47 . The annular chamber  47  constitutes a space which is filled with a selected granulated or beaded medium or combination of granulated or beaded media. Such media may include, for example, and without limitation:
       Ion exchange resin   De-ionization resin   Zeolite   Activated carbon   Silver based media   Ceramic   Solid sanitizer (chlorine/bromine)       
 
         [0039]    After filling the chamber  47 , the top cap  50  is fixed in place to close the unit. In operation, water flows radially from the outside larger diameter cylinder  43  to the inner cylinder  44 , at a flow rate of e.g. 1-10 gallons per minute, thus bringing the water in contact with the active media. An advantage of the illustrative embodiment is that cylinders containing different filter media can be added or exchanged after the spa has been filled with water in response to occurrence of a problem with a particular type of contaminant. 
         [0040]    In use, when a spa is filled with water, there is an amount of contamination already in the water. Through usage, chemical addition, evaporation, and water addition; waste and other toxic elements can build up in the water. Traditionally, it is recommended to change the water when the total dissolved solids (TDS) exceed 1500 ppm, or based on a days of use measure; for example, according to the formula [(Spa size in gallons)/3] (times) (number of bathers per day)=the number of days before water change is needed. 
         [0041]    A filter constructed according to the illustrative embodiments serves to extend the life of the water, reduce the number of water changes and save water by removing the accumulated TDS from the water. Such TDS include: toxic metals such as lead, iron, copper, manganese, minerals, calcium, magnesium, sodium, chloride, soaps, detergents, foaming agents, oils, suntan lotions, cyanuric acid, ammonia, pesticides, pharmaceuticals, organic acids, beer/wine, components of human sweat and waste, chlorinated by-products, humic acid, urine, body fluids, and tannins. 
         [0042]    In an alternative embodiment, a screw-on cap is provided on a filter like that of  FIG. 1 , enabling a user to change the media. In such case, the filter is removed from the spa, the top is unscrewed, and the media is replaced. In some embodiments the media may be limited to consumer friendly media like carbon, resin beads, and zeolites. As illustrated in  FIG. 4 , such an embodiment may comprise two cylinders  143 ,  144  with a potted bottom cap  152 . A ring  155  with internal threads  157  is provided, which is seated and bonded to the top of the outer cylinder  143 . The top cap  150  has external threads  159 , which permits the top cap  150  to be screwed onto the top of the filter  140  until an internal sealing surface  161  on an inner ring  163  of the top cap  150  contacts and seals with the inner cylinder  144 . 
         [0043]    In an alternative embodiment, a press-fit or friction fit, rather than screw-on, cap is provided on a filter like that of  FIG. 2 . As illustrated in  FIG. 5 , such an embodiment may comprise two cylinders  243 ,  244  with a potted bottom cap  252 . The top cap  250  has a grooved surface  259 , defining a groove  246 , which is dimensioned to press fittingly engage surface  243 . The internal sealing surface  261  on an inner ring  263  of the top cap  250  may also contact and press-fittingly seal with the inner cylinder  244 . 
         [0044]      FIG. 6  illustrates an embodiment wherein the filter media  260  is contained within a donut-shaped or annular cross-sectioned bag  261  formed of a suitable water permeable, porous material. Such material may comprise, for example, polypropylene, polyester, cotton, rayon, polyethylene, nylon, PTFE (Teflon), polyacrylonitrile, or acrylic. In various embodiments, the fabric type may be woven, nonwoven, felt, or mesh of a thickness of, for example, 0.01″-0.25″. Illustrative porosities range from 10 microns to 500 microns. 
         [0045]    In an embodiment such as  FIG. 6 , the inner cylinder  144  may comprise a plastic net/mesh material  263  as shown in  FIG. 7 , such as, for example, part No. 2370 as manufactured by Industrial Netting, Minneapolis, Minn. Additionally, in one embodiment, shown in  FIGS. 8 and 9 , the donut bag  261  may have a fabric flange, flap, or hook  267  formed as a part thereof or attached thereto for purposes of slipping over the top rim or edge of an inner filter core. Thereafter, a top cap can be installed to hold the bag  260  in place, as illustrated in  FIG. 10 . In one embodiment, an inner core or cylinder  244  of reduced height may be employed to accommodate the thickness of the fabric hook  267 . 
         [0046]    In another embodiment of a filter  310  illustrated in  FIGS. 11-14 , both an inner cylinder  311  and an outer cylinder  313  may comprise a plastic net or mesh material such as Part No. 2370 as manufactured by Industrial Netting, Minneapolis, Minn. In general the plastic mesh or net may comprise expanded or extruded plastic heated or ultra welded to form a rigid to semi-rigid mesh network. In various embodiments, the mesh network comprises openings of a uniform shape and size, for example, square, diamond, or rectangular. In one specific embodiment, the openings are square and 0.150 inches on a side. 
         [0047]    Exemplary diameters for the inner and outer cylinders  311 ,  312  may be 1½ to 3 inches and 5 to 10 inches respectively with 2½ inches and 6 inches being the dimensions of an exemplary embodiment. Such dimensions of course may vary in various embodiments. In one embodiment, the inner cylinder  311  may be extruded as a single seamless tube, whereas the outer cylinder  312  is extruded as a flat sheet and is then rolled and sealed along a vertical edge. 
         [0048]    The filter of  FIGS. 11-14  further includes a top cap  315  and a bottom cap  317 , which may be identical components in one embodiment. The caps  315 ,  317  each include an inner circular channel  319  of rectangular cross-section and an outer circular channel  321  of rectangular cross-section, each of a width of, for example, 0.1 to 0.2 inches. The cylinders  311 ,  313  are preferably potted into the bottom cap  317 , while the top cap  315  press-fits or friction-fits into place. In other embodiments, the cylinders  311 ,  313  could be glued or snap fitted or otherwise attached to the end caps. 
         [0049]    The inner circular channel  319  of the caps  315 ,  317  is formed of two concentric cylinders  323 ,  325  with the inner cylinder  323  having a height greater than the outer cylinder  325  in order to assist with alignment of parts during assembly. Similarly, the outer channel  321  is defined between concentric cylinders  327 ,  329  where the inner cylinder  329  has a greater height for same purpose. The end caps  315 ,  317  may be molded or otherwise fabricated of a suitable plastic such as, for example, ABS, PVC, acetyl, Delrin, polypropylene, polyethylene, polyurethane and/or plastisol. 
         [0050]    Various filter media may be placed within the annular cavity defined between the inner and outer cylinders  311 ,  313 . One such medium may be a spun bonded depth filter  316 . Such a filter may be formed, for example, of polyethylene, polypropylene, or nylon, and may be resin coated and sized to fit in between the inner and outer cylinder  311 ,  313 . In other embodiments, porous bags of various suitable media described above may be formed as illustrated generally in  FIGS. 6 ,  9  and  10  and inserted into the annular cavity. In some embodiments, a spun bonded element such as element  316  and a porous filter media bag may both be used at the same time to achieve advantageous results. In one embodiment, a cylindrical spun bonded filter element may be positioned concentrically with a porous bag  351 , as shown in  FIG. 19 . 
         [0051]    The alternative fabric bag  351  is illustrated in detail in  FIGS. 15-17 . The bag  351  includes inner and outer rectangular fabric components  353 ,  355 , which are suitably sewn together to form a baffled structure  361 , which includes a plurality of vertical compartments  363  arranged in a circle. The bottom of each compartment  363  is first sewn shut, and each compartment  363  is then filled with a suitable medium or combination of media and thereafter sewn shut. In one embodiment, vertical stitching along lines  362  ( FIG. 18 ) is used to form the baffled compartments  363 . In other embodiments, the bag may be formed by ultra sonic or heat welding. 
         [0052]    Suitable fabric materials for the bag may be the same as those for bag  261  of  FIG. 6 . Suitable media for the bag may comprise silver media beads of various compositions, as well as various other media listed or discussed above. 
         [0053]    Various embodiments of the filters according to  FIGS. 11-18  are designed such that the inner cylinder  311  fits down and around a conventional filter stand pipe having a threaded top end such that a threaded cap or plug may be attached to the end of the stand pipe to hold the filter element  310  and its top cap  315  in place. One such embodiment is shown in  FIG. 20  where the cylindrical or portion  366  of a cap  365  plugs through the central opening of top cap  315 . The interior of the cylinder  366  has threads which mate with those at the top end of a stand pipe  367  allowing the cap  365  to be screwed onto the stand pipe  367 . As the cap  365  is screwed down onto the stand pipe the circular flange portion  367  of the cap comes into flush abutment against the top cap  315  thereby further securing it in position. These and other mesh embodiments provide an easy-to-use filter wherein the filter elements can be easily removed for cleaning or replacement. 
         [0054]    Those skilled in the art will appreciate that various adaptations and modifications of the just described embodiments can be configured without departing from the scope and spirit of the invention. Therefore, it is to be understood that, within the scope of the appended claims, the invention may be practiced other than as specifically described herein.

Technology Classification (CPC): 2