Patent ID: 12251665

DETAILED DESCRIPTION OF THE INVENTION

Certain terminology is used in the following description for convenience only and is not limiting. The words “right,” “left,” “lower,” and “upper” designate directions in the drawings to which reference is made. The words “inwardly” or “distally” and “outwardly” or “proximally” refer to directions toward and away from, respectively, the geometric center or orientation of the device and instruments and related parts thereof. The terminology includes the above-listed words, derivatives thereof and words of similar import.

Referring to the drawings in detail, wherein like numerals indicate like elements throughout the several views,FIGS.1-3show a liquid treatment system, generally designated10. The liquid treatment system10comprises one or more filtration modules12, and more preferably an array of a plurality of filtration modules12, arranged in any desired configuration and supported on a frame60. The filtration modules12preferably form a filtration or other treatment apparatus for liquid, such as water. Piping, pumps, vessels, valves and/or other components (not shown) are preferably built around and/or operatively connected to the filtration modules12to form a complete liquid treatment system.

It will be understood by those skilled in the art that the filtration modules12may be any known form of a filtration module. In a preferred embodiment, each filtration module12includes an outer shell16having a first or lower end18and an opposing second or upper end20. A longitudinal axis A of the outer shell16extends from the first end18to the second end20. The outer shell16has a generally cylindrical outer peripheral sidewall14. The outer shell16may be formed of, for example, a polymeric material, a metal (e.g., stainless steel), fiber reinforced plastic, and the like. However, each filtration module12is not limited to such a shape and/or material, as the filtration module12may be formed in any shape or from any material that allows for the functionality described herein. Each filtration module12preferably has a height, as measured along the longitudinal axis A, of several feet, but the module12may have any height that is desirable and allows for the functionality described herein. Each filtration module12may be a nanofiltration, microfiltration or ultrafiltration module, so as to filter relatively small particulate matter, such as colloidal matter.

Referring toFIGS.1-3and14, the outer shell16of each filtration module12at least partially surrounds a plurality of filtration membranes13therein. In one embodiment, each filtration membrane13is generally tubular in shape and is preferably formed of a polymeric material. In one embodiment, each filtration membrane13is formed of a fibrous material, such that each filtration membrane13may be a hollow fiber. Each filtration membrane13preferably extends generally parallel to the longitudinal axis A. Opposing ends of each filtration membrane13are preferably fixed in place within the respective filtration module12, for example by a potting section or adhesive (not shown) proximate at least one, and more preferably both, of the ends18,20of the filtration module12. Each filtration membrane13is preferably at least partially hollow such that at least some liquid can flow within each filtration membrane13either generally parallel or perpendicular to the longitudinal axis A. It will be understood by those skilled in the art that the structure and configuration of the filtration membranes13is not limited to a hollow fiber membrane13, but rather the filtration membranes13may have any known structure and configuration as long as they are suitable for filtration of a liquid flowing through the filtration module12.

The plurality of filtration modules12are connected to a common first or upper manifold assembly22and to a common second or lower manifold assembly24. More particularly, the lower end18of each filtration module12is in fluid communication with a lower manifold assembly24, and the upper end20of each filtration module12is in fluid communication with an upper manifold assembly22. The upper manifold assembly22is comprised of a plurality of interconnected headers26, and the lower manifold assembly24is comprised of a plurality of interconnected headers26. The headers26of the upper and lower manifold assemblies22,24are identical to each other.

Referring toFIGS.2and4, each header26comprises a main body28and at least three passageways30,32,34which extend through the main body28in a direction generally perpendicular to the longitudinal axis A. More particularly, the first, second and third passageways30,32,34are in the form of tubular conduits extending through the main body28in a direction generally perpendicular to the longitudinal axis A. The main body28of each header26is preferably formed of one or more rigid polymeric materials, such as polyvinyl chloride (PVC), acrylonitrile butadiene styrene (ABS) copolymer, polypropylene (PP) and polycarbonate (PC). Most preferably, the main body28is formed of PP or PVC. The polymeric material of the main body28may also include filler materials, and more preferably inorganic filler materials, such as silica, graphite and glass fiber.

The main body28has opposing first and second base surfaces36,38which extend in planes that are parallel to each other; opposing first and second side surfaces40,42which extend in planes that are parallel to each other and perpendicular to the first and second base surfaces36,38; and opposing third and fourth side surfaces70,72which extend in planes that are parallel to each other and perpendicular to the first and second base surfaces36,38. A longitudinal axis of the main body28extends from the first base surface36toward the second base surface38parallel to the longitudinal axis A of the module12. Each of the three passageways30,32,34has a first open end30a,32a,34aat the first side surface40of the main body28, and an opposing second open end30b,32b,34bformed at the second side surface42of the main body28. Adjacent headers26are connected to each other at each of the first, second and third passageways30,32,34, so as to form contiguous first, second and third passageways30,32,34through the entirety of each of the upper and lower manifold assemblies22,24.

In one embodiment, the first open end30aof the first passageway30is preferably configured as a female port and the second open end30bis preferably configured as a male port, although it will be understood that the opposite configuration could be implemented in the alternative. The male port30bpreferably includes a protruding annular lip or rim39and the female port30bpreferably includes an annular groove or recess41sized and shaped to correspond to the annular lip39. As such, when two or more headers26are connected, the annular lip39of a first header26is received within the corresponding annular recess41of the adjacent second header26, the annular lip39of the second header26is received within the corresponding annular recess41of the adjacent third header26, and so forth, such that the headers26are well aligned with each other and a contiguous first passageway30is formed through the entirety of the upper and lower manifold assemblies22,24. A clamp, gasket, O-ring, etc. may be provided at the interface of each connected female and male port30a,30bof the headers26so as to ensure a fluid tight seal at the interfaces. More particularly, at the interface of each connected annular lip39and annular recess41, a peripheral groove is formed, and a gasket and a clamp63are received within the groove.

In one embodiment, the first open end32aof the second passageway32is preferably also configured as a female port and the second open end32bis preferably also configured as a male port, although it will be understood that the opposite configuration could be implemented in the alternative. The male port32bpreferably includes a protruding annular lip or rim43and the female port32apreferably includes an annular groove or recess45sized and shaped to correspond to the annular lip43. As such, when two or more headers26are connected, the annular lip43of a first header26is received within the corresponding annular recess45of the adjacent second header26, the annular lip43of the second header26is received within the corresponding annular recess45of the adjacent third header26, and so forth, such that the headers26are well aligned with each other and a contiguous second passageway32is formed through the entirety of the upper and lower manifold assemblies22,24. A clamp, gasket, O-ring, etc. may be provided at the interface of each connected female and male port32a,32bof the headers26so as to ensure a fluid tight seal at the interfaces. More particularly, at the interface of each connected annular lip43and annular recess45, a peripheral groove is formed, and a gasket and a clamp65are received within the groove.

In one embodiment, the first end34aof the third passageway34and the second end34bof the third passageway34each includes an auxiliary adapter52attached thereto. The adapter52has a main body53circumscribing a generally cylindrical opening55and an externally threaded conduit61extending from a first surface of the main body53and configured to be received within the first and second open ends34a,34bof the third passageway34. The main body53is preferably of a hexagonal shape, but it will be understood that the main body could have any known shape, such as a circle, square, rectangle, and the like. The main body53of each adapter52is preferably formed of one or more rigid polymeric materials, such as PVC, ABS copolymer, PP and PC. Most preferably, the main body53of the adapter52is formed of PP or PVC. The polymeric material of the main body53of the adapter52may also include filler materials, and more preferably inorganic filler materials, such as silica, graphite and glass fiber.

A plurality of dowels57are also provided which extend from the first surface of the main body53and which are configured to be received within openings59formed in the main body28of each header26. One or more screws54may be used to secure the adapter52to the main body28of each header26. A generally tubular connector portion56extends from a second surface of the main body53of the adapter52. The connector portion56of the adapter52of a first header26is configured to be secured to the connector portion56of the adapter52of an adjacent second header26, and so forth, such that a contiguous third passageway34is formed through the entirety of the upper and lower manifold assemblies22,24. A clamp, gasket, O-ring, etc. may be provided at the interface of each connected adapter52of the headers26so as to ensure a fluid tight seal at the interfaces. More particularly, at the interface of connected adapters52, a gasket and a clamp67are provided to ensure a tight seal, with the interface being designed to maintain the sealing component (e.g., gasket or clamp) in place to ensure correct functionality.

By providing the auxiliary adapter52at the open ends34a,34bof the gas passageway34, which typically has the smallest diameter, the header26may be manufactured (e.g., injection molded) without the need for any computer numeric controlled (CNC) machining. That is, while CNC machining might have been required to achieve the desired geometry at the open ends34a,34bof the small diameter gas passageway34, no such machining is required because the adapter52which provides the desired geometry is produced separately and secured to the header26(e.g., by threaded engagement and screws). The auxiliary adapters52also enable each header26to be truly modular.

The first passageway30, the second passageway32and the third passageway34are preferably fluidically separated from each other. In other words, the first passageway30, the second passageway32and the third passageway34are separate and distinct from each other. In one embodiment, the first passageway30is a fluid passageway through which a feed or retentate stream flows, the second passageway32is a fluid passageway through which a filtered or treated liquid (e.g., filtrate or permeate) flows, and the third passageway34is a fluid passageway through which a gas flows. As such, hereinafter, the first passageway30is sometimes referred to as the feed passageway, retentate passageway or feed/retentate passageway; the second passageway32is sometimes referred to as the filtrate passageway, permeate passageway or filtrate/permeate passageway; and the third passageway34is sometimes referred to as the gas passageway.

The inner diameter, of the first passageway30is preferably larger than the inner diameter of the second passageway32, and the inner diameter of the second passageway32is preferably larger than the inner diameter of third passageway34. In a preferred embodiment, the inner diameter of the feed/retentate passageway30is 6 inches, the inner diameter of the filtrate/permeate passageway32is 4 inches and the inner diameter of the gas passageway34is 3 inches. However, it will be understood by those skilled in the art that the diameters of the feed/retentate passageway30, the filtrate/permeate passageway32and the gas passageway34may be adjusted and selected as necessary or desired to suit an end application.

Referring toFIG.5, in one embodiment, at least a portion27of the main body28of each header26is equipped with a transparent material to enable viewing of the flow through the header26. More particularly, a portion27of the body28of the header26which corresponds to the first passageway30(i.e., the feed/retentate passageway30) is provided with a transparent material, such as a transparent resin (e.g., PC) or glass material, hereinafter referred to as sight glass, for bubble observation, because bubbles are a typical sign of development in the event of a membrane's failure due to exposure to mechanical and/or chemical stresses. In one embodiment, the sight glass27is in the shape of a keystone. However, it will be understood that the sight glass27could have any shape, size, dimensions, etc. A gasket (not shown) may be provided around the periphery of the sight glass27to ensure a tight and secure engagement with the main body28of the header26.

Referring toFIGS.4and10, the first base surface36of the main body28of each header26preferably includes a connection member or socket31configured to couple the header26to a respective filtration module12. The connection member31preferably has a generally concave body33surrounded by a peripheral rim35. The connection member31may be integrally and unitarily formed with the main body28or may be removably attached thereto. The connection member31of each header26of the lower manifold assembly24is connected to the lower end18of a respective filtration module12(e.g., at the peripheral rim35) such that the lower manifold assembly24and the filtration modules12are in fluid communication with each other, and the connection member31of each header26of the upper manifold assembly22is connected to the upper end20of a respective filtration module12(e.g., at the peripheral rim35) such that the upper manifold assembly22and the filtration modules12are in fluid communication with each other. A clamp69, gasket, O-ring, etc. may be provided at the interface of each connection member31and filtration module12so as to ensure a fluid tight seal.

The connection member31preferably includes a liquid exit port44, for example formed in the concave body33, and more particularly formed in a base of the concave body33at a position offset from a geometric center of the concave body33. The liquid exit port44is in fluid communication with the filtrate/permeate passageway32(seeFIG.10). Filtered or otherwise treated liquid, hereinafter referred to as filtrate/permeate, exits each filtration module12through the lower and/or upper ends18,20after the liquid has passed through or otherwise circulated within the module12, and then passes into the filtrate/permeate passageways32of the respective headers26of the upper and lower manifold assemblies22,24via the respective liquid exit port44. The size, shape and/or configuration of the liquid exit port44is not limited in any particular manner.

Referring toFIG.4, an adapter66is preferably inserted through a central opening31aof the connection member31of each header26. The adapter66is preferably formed of one or more rigid polymeric materials, such as PVC, ABS copolymer, PP and PC. Most preferably, the adapter66is formed of PP, PVC or ABS copolymer. The polymeric material of the adapter66may also include filler materials, and more preferably inorganic filler materials, such as silica, graphite and glass fiber.

The adapter66has a generally cylindrical body, with one end attached to and/or in communication with the connection member31and the opposing end attached to and/or in communication with the respective filtration module12. The adapter66preferably includes two fluid passageways46,48which are fluidically separated from each other. In one embodiment, the first passageway46is delimited by a first tubular conduit47and the second passageway48is delimited by a second tubular conduit49which surrounds the first tubular conduit47. The first passageway46is preferably a gas passageway that is in communication with the filtration membrane13of each filtration module12and the gas passageway34of each header26. The second passageway48is preferably a liquid passageway that is in communication with the filtration membrane13of each filtration module12and the feed/retentate passageway30of each header26.

The first passageway30of each of the upper and lower manifold assemblies22,24is preferably in communication with a feed liquid vessel or source (not shown) and/or a retentate storage vessel (not shown). For example, in one embodiment, the exposed port30aor30bof the first or upstream header26of the first passageway30of the lower manifold assembly24is preferably in communication with a feed liquid vessel or source, the exposed port30aor30bof the last or downstream header26of the first passageway30of the lower manifold assembly24is closed off by a plug, the exposed port30aor30bof the first header26of the first passageway30of the upper manifold assembly22is in communication with a retentate storage vessel, and the exposed port30aor30bof the last header26of the first passageway30of the upper manifold assembly22is closed off by a plug. It will be understood that the reverse configuration may be implemented, depending on the desired filtration configuration.

The second passageway32of each of the upper and lower manifold assemblies22,24is preferably in communication with a filtrate/permeate storage vessel (not shown). More particularly, at least one of the exposed ports32aor32bof the first and/or last header26of the upper manifold assembly22or lower manifold assembly24is connected to a filtrate/permeate storage vessel, while the other exposed ports32a,32bare closed off by a plug. The third passageway34of the lower manifold assembly24is preferably in communication with a gas (e.g., air) source. More particularly, at least one of the exposed ports34aor34bof the first and/or last header26of the lower manifold assembly24is connected to a gas source, while the other exposed ports34a,34bare closed off by a plug.

The liquid treatment system10preferably has and/or is operable in a first configuration which is for treating a feed liquid and a second configuration which is for cleaning of the filtration membranes13of the filtration modules10. In the first and second configurations, liquid and gas are preferably injected into the upper and/or lower manifold assemblies22,24and are permitted to exit the upper and/or lower manifold assemblies22,24by operation of one or more valves.

In operation in the first configuration (i.e., the treatment configuration), feed liquid to be treated is introduced into the feed passageway30of the upper manifold assembly22and/or the lower manifold assembly24, preferably by opening a feed valve (not shown) connected to or associated with the feed passageway30of each of the upper and/or lower manifold assemblies22,24. In each header26of the upper or lower manifold assemblies22,24, the feed liquid flows through the feed passageway30of the header26toward the adapter66, to the second passageway48of each adapter66, and then flows through the second passageway48of each adapter66into the respective filtration module12to be filtered by the respective filtration membrane13. In the treatment configuration, a gas valve (not shown), a drain valve (not shown) and a gas vent valve (not shown) are all preferably at least initially closed. However, a filtrate/permeate valve (not shown), which is operatively connected to the filtrate/permeate passageway32of the upper manifold assembly22and/or lower manifold assembly24is preferably at least initially opened. The feed liquid to be filtered penetrates the filtration membranes13of the plurality of filtration modules12, and the filtrate/permeate flows upwardly and/or downwardly therein. Because two liquid exit ports44are provided (i.e., at the headers26of the upper manifold assembly22and also at the headers26of the lower manifold assembly24), filtrate or permeate can exit the filtration modules12at both the upper and lower ends20,18thereof, flow into the filtrate/permeate passageway32of the upper manifold assembly22and/or lower manifold assembly24, and ultimately out of the system10, as shown inFIG.11, for collection. Introduction of the feed liquid and removal of the filtrate/permeate can be conducted in series or in parallel.

During operation in the treatment configuration, particulate matter tends to accumulate on and/or within the filtration membranes13and the interiors of the filtration modules12. To continue to effectively and efficiently filter liquid, the particulate matter should be removed from the filtration membranes13and the interiors of the filtration modules12. To do so, the introduction of liquid into the feed passageway30of the upper and/or lower manifold assemblies22,24is preferably at least temporarily stopped, for example, by closing the feed valve. In addition, filtrate/permeate is also preferably at least temporarily stopped from exiting the upper and/or lower manifold assemblies22,24, which can be accomplished by simply allowing all of the filtrate/permeate to drain from the filtration modules10through the liquid exit ports44and the filtrate/permeate passageway32, or by closing the filtrate/permeate valve.

Next, the system10is operated in the second configuration (i.e., the cleaning configuration). In the cleaning configuration, gas, such as air, is preferably injected into the gas passageway34of the headers26of the lower manifold assembly24. This can be accomplished by opening the gas valve, such that gas preferably travels through the gas passageway34of the headers26of the lower manifold assembly24, into the first passageway46of each adapter40, and then into each of the filtration modules12to contact the filtration membranes13within the modules12to scour the filtration membranes13. Gas is also preferably at least temporarily permitted to exit the filtration modules12via the feed/retentate passageway30by opening the gas vent valve, as shown inFIG.11A. The gas essentially helps to clean the filtration membranes13and the interiors of the filtration modules12by loosening the particulate matter from their surfaces.

Gas is then preferably at least temporarily prevented from exiting the filtration modules12which can be done, for example, by closing the gas vent valve. Next, at least some particulate matter scoured from the filtration membranes13as a result of the injection of gas into the modules12is preferably at least temporarily permitted to drain from or otherwise exit the modules12, for example, by opening the drain valve. The scouring and draining steps are preferably carried out in parallel. Meanwhile, gas is preferably continuously injected into the filtration module12, as described above, which promotes draining of the particulate matter. The draining of the particulate matter is then preferably at least temporarily stopped. This can be accomplished by simply allowing all of the particulate matter to drain from the filtration module12or by closing the drain valve. Gas in the filtration modules12is preferably permitted to exit the modules12which can be done, for example, by opening the gas vent valve.

In a preferred embodiment, the lower manifold assembly24is secured to a frame60which provides stability to the overall treatment system10. More particularly, each header26is detachably or permanently secured to the frame60. The frame60is made of a metal material, preferably stainless steel. In one embodiment, referring toFIG.13, the second base surface38of the main body28of each header26includes at least one pocket, slot or recess58, and preferably a plurality of pockets, slots or recesses58. More particularly, the pockets58are formed between the second base surface38and the fourth side surface72. Upstanding walls74extend upwardly from the second base surface38to form the distinct pockets58. The frame60includes a plurality of tongues or beams76, and more particularly cantilevered tongues or beams76, in positions corresponding to the pockets58of each header26. To assemble the lower manifold assembly24with the frame60, the cantilevered tongues76of the frame60are positioned or inserted within respective pockets58of each header26in a secure fit. In one embodiment, the tongues76may be bolted, nailed, welded, adhered, snap-fit, etc. to the respective pockets58of each header26.

Since all liquid and gas passageways are formed in each modular header, a modular manifold assembly is provided. For example, in the event of the failure of one header and/or filtration module12, the failed header and/or filtration module12may be easily disconnected and separated from the manifold assembly, while the modular headers which remain in place continue to function and operate as needed.

It will be appreciated by those skilled in the art that changes could be made to the embodiments described above without departing from the broad inventive concept thereof. It is understood, therefore, that this invention is not limited to the particular embodiments disclosed, but it is intended to cover modifications within the spirit and scope of the present invention as defined by the appended claims.