Patent ID: 12227435

DETAILED DESCRIPTION OF THE INVENTION

Referring toFIGS.1-6, a portable water filtration system100can be used in areas where potable water systems are not available. The system100includes a handle105, a filter assembly110and a container vessel115that holds a volume of water. A pump120can be used to pressurize the vessel115to facilitate water flow through the filter assembly110.

Referring toFIG.3, the vessel115has a fill port that is covered by a cap125. A retainer ring130is used to retain the cap125. A sediment drain covered by a drain cap135is positioned at the bottom of the vessel115. An outlet hose140is installed in an outlet of the filter assembly110.

Referring toFIG.4, the pump120includes a squeezable bulb145, a pressure hose150and a valve actuated by a butterfly handle155. The valve can seal the vessel115to maintain pressure.

Referring toFIGS.7,14and15, a protective cage158surrounds the filter assembly (not shown). The cage158includes a series of ribs that encircle the filter assembly. This protects the filter assembly against impact, such as, for example, if the container100is dropped.

Referring toFIG.8, the filter assembly110include a carbon ring160and a series of corrugated filters165in 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.

Referring toFIG.9A, the filter assembly110is positioned in a threaded collar165attached to the container110. A threaded cap170is screwed into the threaded collar165to secure the filter assembly110in the container110. A sealing ring175or gasket is positioned between the threaded cap and a lip180of the filter assembly110so that the filter assembly is clamped between the threaded collar165and the threaded cap170for a watertight seal. Referring toFIG.9B, the threaded cap is integrated into the filter assembly110so that the entire filter assembly110screws into the collar by rotating the integrated cap.

Referring toFIGS.10and11, the filter assembly110includes a circular intake cover185, a sediment filter190, a generally cylindrical wall195, an inner circular wall200and a cover wall205over the concentric filters. The circular intake cover185has a series of ribs and openings that allow water to flow from the vessel115into the filter assembly110. The inner circular wall200separates the filter assembly into a sediment filter chamber210and a concentric ring filter chamber215. The inner circular wall200has a series of ports to allow water to flow from the sediment filter chamber210to the concentric ring filter chamber215.

The generally cylindrical wall195may 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.

The sediment filter190is positioned in a vertical orientation with respect to the height of the vessel115. Thus, heavy sediment bypasses the sediment filter190and falls directly to the sediment drain thereby extending the life of the sediment filter190.

Referring toFIG.11, water flows through the intake cover185from the vessel115into the sediment filter chamber210in the direction shown by Arrow A. Water then flows from the sediment filter chamber to the concentric ring filter chamber215. The cover wall205over 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 chamber215as shown by Arrow B. The water then flows downward between the cylindrical wall195and the outside surface of the carbon ring160in the direction of Arrow C. The carbon ring160includes 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.

Water flows through the carbon ring190from the outside to the inside in the direction of Arrow D. Water then flows through a perforated dividing wall218into the concentric ring of corrugated filters165.

The embodiment shown inFIG.11has a series of four corrugated filters220,225,230and235. The filters220,225,230and235are spaced apart by dividing walls240,245, and250.

As shown inFIG.12, each of the perforated dividing walls218,240,245, and250has ports or slots that allow the flow of water toward the center of the concentric rings. A circular outlet tube255is positioned at the center of the perforated dividing walls218,240,245, and250. In other embodiments, additional dividing walls may be added or dividing walls may not be used. One or more of the concentric filters220,225,230and235may be configured to remove suspended matter, microbiological matter and/or chemicals.

Referring again toFIG.11, a circular outlet tube255forces the water to change direction upward toward the sediment filter190and then down again through an outlet port260into an outlet chamber as shown by Arrow E. Water then flows down toward an exit port265in a direction to exit the container100as shown by Arrow F.

Referring toFIG.13, a spiral flow agitator component270is positioned in the circular outlet tube255. The agitator component270causes turbulence so that water has increased contact with a disinfectant media in the outlet tube255. In another embodiment, the agitator component may also include disinfection media.

Referring toFIGS.19and20, the filter material is designed with a larger range of pore sizes than that of a conventional filter. The range of pore sizes shown inFIG.19are generally larger than that shown inFIG.20, however, the range of pore sizes can overlap.

FIG.21shows 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.

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.

In the embodiment that is shown inFIG.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.

Referring toFIGS.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.

Referring toFIG.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 other process, a form of heat welding may be used to bond the segment edges together.

Referring toFIG.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.

Referring toFIGS.29-33the 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).

Referring toFIGS.26-28and45, 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.

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.

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.

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.

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.

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.

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.

Referring toFIGS.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.

Referring toFIGS.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 AlO. It consists of finely crystalline boehmite, but with a higher water content than in boehmite.

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.

Referring toFIGS.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.

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.

FIGS.43and44are photos of the full stack of segment layers AAA, AA, A, B, C, D and F shown inFIGS.21-23mentioned 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.

Referring toFIGS.46and47, a cylindrical sediment filter300is 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 toFIGS.21-23and43-44. In other embodiments, there may be more or less segment layers of different compositions.

FIG.48illustrates the cylindrical sediment filter300in use. The cylindrical sediment filter300is installed in a filter casing310. The filter casing has a water input line with water flowing into the filter casing shown by Arrow A.

The bottom of the filter300is 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 filter300and flows out of the casing case through output line330in the direction shown by Arrow C.

FIG.49illustrates another embodiment of a sediment filter configured as a bag filter350. The bag filter350includes multiple segment layers as that described above or may have another configuration of segment layers. The edges of the bag filter350may essentially be crimped or secured together by a round collar or may be heat bonded or glued together.

Referring toFIGS.50-54, in another embodiment the carbon ring160is replaced by an annular ring filter510that includes adsorption particles, such as, activated carbon granules or ion exchange resin media, in a casing or enclosure. The filter510includes a first circular wall515and a second circular wall520mounted between a first annulas wall525and a second annulas wall530. The internal volume of the annular ring filter510is filled with activated carbon granules and/or ion exchange resin. The first and second circular walls515,520are permeable to water but retain the granules or beads. Mesh or screen may also be used to confine the filter media to various portions of the filter.

A first dividing wall535and a second dividing wall540is mounted between the first and second circular wall515,520to divide the internal volume into first, second and third channels545,550,555. A bisecting or termination wall560is attached between the first and second circular walls to the dividing walls to change the direct of water flow from a first direction in the first channel to a second direction in the second channel and to a third direction in a third channel.

Protrusion walls (turbulators)565are mounted in the second channel with the turbulators partially obstructing the second channel thereby increasing turbulent water flow in the second channel. The turbulators include mating pairs of curling walls configured to cause a z-shaped or s-shaped water flow within the second channel Each protrusion wall565is mounted to the dividing walls535,540. Alternatively, the turbulators565can be mounted to the annulas walls at a position in the second channel555.

Water flows from the outside to the inside of the annular ring filter510. The water enters the filter through the outer circular wall515. The water flows in a first channel550until it reaches the end of the dividing wall535where it enters the second channel555. The second channel555is filled with the protruding walls565that partially obstruct or change direction of water flow in the second channel555. The resulting circuitous path results in more contact with the activated carbon granules.

The water flows through the second channel555until it reaches the end of second dividing wall540. The water is then in contact with the permeable inside filter wall520. As such, the water flows the permeable filter wall520to exits the annular filter ring510into the center of the ring. Some of the water also flows into the third channel545until it also exits through the permeable inside filter wall520. The water may then enter other filters that are part of a concentric ring inside the annular ring filter510.

Referring toFIGS.55,56aand56b, another embodiment of the annular ring filter610includes adsorption particles, such as, activated carbon granules, ion exchange resin or other filter material, in the casing or enclosure. In this embodiment of the annular ring filter610, some of the outer components have been omitted for ease of reference to internal details. The omitted components include first and second circular wall515,520mounted between first and second annulas walls525,530shown above with respect toFIGS.51-53above.

First, second and third dividing walls635,640,643are mounted between the first and second circular walls515,520(not shown) to divide the internal volume into first, second, third and fourth channels645,650,655,657. Bisecting or termination walls660intersect the dividing walls635,640,643to change the direct of water flow from a first, to a second, to a third and then a fourth direction on the outside of or between the dividing walls635,640,643. An opening663in the second dividing wall640fluidly connects the second and third channels640,655.

Referring toFIG.56b, a screen or mesh667may be positioned in the opening663. The screen667holds filter particulate matter in the channel.

Protrusion walls (also referred to as turbulators)665are mounted in the inner channels, which are the second and third channels650,655. The turbulators partially obstruct the channel650,655thereby increasing turbulent water flow in the second channel. The turbulators include mating pairs of curling walls configured to cause a z-shaped or s-shaped water flow within the second channel Each protrusion wall or turbulator665may be mounted to the dividing walls635,640,643. Alternatively, the turbulators665can be mounted to the annulas walls (not shown) at a position in the inner channels650,655. The turbulators665cause a turbulent fluid flow through the second and third channels to mitigate “tunneling” of fluid through the granular filter media.

The inner channels650,655are filled with the various filter media. For example, the second channel650may be filled with carbon granules (seeFIG.62) and the third channel655may be filled with ion exchange resin (seeFIG.63) that are contained by mesh screens (seeFIG.64). Other types of filter media may be used.

FIG.57is another embodiment of the filter assembly710that can be installed in an inline filter system. A water inlet715allows water to enter the sediment filter chamber210. The water then travels through the filter assembly710to the exit port265as shown above with respect toFIG.11.

FIG.58show a perspective view of the filter assembly710ofFIG.57andFIGS.58and59show exploded views of portions of the filter assembly710. The filter assembly710includes a housing720and a threaded cover725that is received within a threaded portion of the housing720.

An upper ring730is positioned in the cover725above the sediment filter (not shown) along with an upper spacer735. The upper spacer735has lift bars and wedge-shaped cut-outs to allow water to flow through the spacer735with a more efficient flow into the sediment filter. A lower spacer740has protrusions that can thread into the housing720and include circular cut-outs for fluid flow from the sediment filter chamber to the next stage of the filter.

FIG.60shows the filter assembly positioned on a stand745that could be positioned on a countertop.

FIG.61shows another embodiment of the filter assembly810. The filter assembly810has an input tube815that shuttles water into the sediment filter chamber. An output tube820receives water from the inner most portion of the cylindrical filter to direct the filtered water out of the filter assembly.

FIGS.62-63illustrate various types of filter media andFIG.64shows a mesh screen used to confine the filter media to portions of the filter. Different types of filter media may be used. For example, the filter media may be granular particles of activated carbon or activated alumina.

FIG.65illustrates a partially raised wall825that prevents channeling or tunneling of the filter media. As shown inFIG.66, the partial raised wall825may have a height of about 2.5 cm while the channel height may be about 8 cm. The partial raised walls825may be positioned around the filter at periodic intervals. The raised walls may be mounted to the top and bottom of each channel while the turbulator walls can be mounted to the left and right side of each channel.

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 water system. The filter assembly may also be used for filtering air other types of fluids, including liquids and gases. As another example, the sediment filter may have another shape, such as, a rectangle, globe or bag. All such modifications are intended to be within the scope of the claims provided below.