U.S. patent application number 17/098036 was filed with the patent office on 2021-03-04 for retrofitting and use of rectangular filters, assembly and method for filtration.
The applicant listed for this patent is FILTRATION TECHNOLOGY CORPORATION. Invention is credited to James D. HARRIS, Tyler J. JOHNSON, Christopher D. WALLACE.
Application Number | 20210060465 17/098036 |
Document ID | / |
Family ID | 1000005241315 |
Filed Date | 2021-03-04 |
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United States Patent
Application |
20210060465 |
Kind Code |
A1 |
WALLACE; Christopher D. ; et
al. |
March 4, 2021 |
RETROFITTING AND USE OF RECTANGULAR FILTERS, ASSEMBLY AND METHOD
FOR FILTRATION
Abstract
An adaptor device for retrofitting in a pool filter housing is
disclosed, where the pool filter housing has a conventional
cylindrical concentric filter. The adaptor device allows the pool
filter to be retrofitted with a plurality of filter elements,
thereby improving its filtering efficiency.
Inventors: |
WALLACE; Christopher D.;
(Houston, TX) ; HARRIS; James D.; (Houston,
TX) ; JOHNSON; Tyler J.; (Houston, TX) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
FILTRATION TECHNOLOGY CORPORATION |
Houston |
TX |
US |
|
|
Family ID: |
1000005241315 |
Appl. No.: |
17/098036 |
Filed: |
November 13, 2020 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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16112023 |
Aug 24, 2018 |
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17098036 |
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15901580 |
Feb 21, 2018 |
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16112023 |
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62550096 |
Aug 25, 2017 |
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62462327 |
Feb 22, 2017 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B01D 2201/296 20130101;
B01D 29/96 20130101; B01D 29/333 20130101; C02F 2103/42 20130101;
B01D 2201/12 20130101; C02F 1/001 20130101; B01D 29/52 20130101;
C02F 2201/006 20130101; B01D 35/306 20130101 |
International
Class: |
B01D 35/30 20060101
B01D035/30; B01D 29/96 20060101 B01D029/96; B01D 29/52 20060101
B01D029/52; B01D 29/33 20060101 B01D029/33; C02F 1/00 20060101
C02F001/00 |
Claims
1. A filter system for filtering pools and spa water, comprising:
a) a filter housing; b) a fluid inlet to the filter housing; c) a
clean fluid outlet from the filter housing; d) a separation plate
located inside the filter housing, said separation plate having a
center hole in communication with the clean fluid outlet; e) an
adaptor plate located in the filter housing, wherein the adaptor
plate is located above the separation plate, and at least one
spacer is provided between said separation plate and said adaptor
plate, wherein a plurality of outlet ports are provided on said
adaptor plate; and f) a plurality of filter elements enclosed in
said filter housing, each of said filter elements comprising a
central void surrounded by filter media, wherein each said filter
element is mounted on said adaptor plate at one of said outlet
ports.
2. The filter system of claim 1, wherein the media is pleated
filter media in a trapezoidal shape with top and bottom sides
parallel to each other and the longer sizes in between the top and
bottom flaring out such that the bottom side is wider than the top
side, the central void being created by the pleated filter media
inside the trapezoid extending from the top side to the bottom
side, wherein each said filter element further comprising a
generally rectangular top cap that is secured to the top side of
the pleated media to maintain a rectangular profile of the filter
element; a generally rectangular bottom cap secured to the bottom
side of the pleated media with a central opening that communicates
with the central void in the pleated filter media; and said bottom
cap is a longer rectangle to accommodate the flare of the
trapezoidal media.
3. The filter system of claim 2, wherein said top cap is solid and
further comprising a handle on the top cap of each of the filter
elements.
4. The filter system of claim 2, further comprising a guide support
mounted at each of the outlet ports on the adaptor plate, wherein
the guide support is perforated, and wherein the guide support
extends into the central void of the filter element.
5. The filter system of claim 1, wherein the filter elements are
wedge-shaped filter elements having a wedge-shaped cross section,
and a plurality of the wedge shaped filter elements are enclosed in
said filter housing in a generally circular arrangement with each
of said wedge shaped filter elements having a central void
surrounded by filter media, a top cap, a bottom cap with an opening
located therein to communicate with the central void in the filter
media that extends from the top cap to the bottom cap; the bottom
cap of each said wedge shaped filter is mounted on the adaptor
plate at one of said outlet ports such that the fluid to be
filtered passes through the filter media into the central void of
the wedge-shaped filter elements, and filtered fluid passes through
the opening in the adaptor plate into the second chamber.
6. The filter system of claim 5, wherein said top cap is a solid
top cap and further comprising a handle on the top cap of each of
said wedge-shaped filter elements.
7. The filter system of claim 5, further comprising a guide support
mounted at each of the outlet ports on the adaptor plate, wherein
the guide support is perforated, and wherein the guide support
extends into the central void of the wedge-shaped filter
element.
8. The filter system of claim 1, wherein the media is selected from
the group of natural media, synthetic media, ceramic media, glass
media and metal media.
9. The filter system of claim 1, wherein the filter media is
selected from the group of pleated or non-pleated media.
10. The filter assembly of claim 1, wherein the filter housing is
generally cylindrical and the separation plate is generally
circular mounted inside the housing.
11. The filter assembly of claim 1, further comprising: g) a spider
plate placed above the filters inside the filter housing, the
spider plate having radiating arms from a central hub and arms
generally contacting the top of each of the filters; and h) a
mechanism between the spider cap and the inside of the top of the
housing to secure the spider plate over the filters when the filter
housing is in use.
12. An adaptor device for retrofitting into a pool and spa filter
housing, wherein said pool and spa filter housing having a fluid
inlet, a fluid outlet, and a separation plate inside the filter
housing, wherein the adaptor device comprises: a) an adaptor plate
sized to be placed inside the filter housing above the separation
plate, wherein a plurality of outlet ports are provided on said
adaptor plate to allow fluid to flow through the adaptor plate; and
b) at least one spacer between said separation plate and said
adaptor plate to create a flow path between the adaptor plate and
the separation plate.
13. The adaptor device of claim 12, further comprising a plurality
of guide support, and each of said plurality of guide supports is
mounted on said plurality of outlet ports on the adaptor plate.
14. The adaptor device of claim 13, wherein each of said plurality
of guide supports is perforated.
15. The adaptor device of claim 13, wherein each of said plurality
of guide supports is detachably fastened to the adaptor plate.
16. The adaptor device of claim 13, wherein each said guide support
matches a removable filter element.
17. The adaptor device of claim 16, wherein said removable filter
element has a rectangular or a wedge-shape cross-section.
18. A filter system for filtering pools and spa water, comprising:
a) a filter housing; b) a fluid inlet to the filter housing; c) a
clean fluid outlet from the filter housing; d) an adaptor manifold
located in the filter housing, wherein a plurality of outlet ports
are provided on a top side of said adaptor manifold, and a
connection port is provided on a bottom side of said manifold,
wherein fluid communication is formed between the outlet ports and
the connection port; and e) a plurality of filter elements enclosed
in said filter housing, each of said filter elements comprising a
central void surrounded by filter media, wherein each said filter
element is mounted on said adaptor manifold at one of said outlet
ports.
19. An adaptor device for retrofitting into a pool and spa filter
housing, wherein said pool and spa filter housing having a fluid
inlet, a fluid outlet, and a separation manifold inside the filter
housing, wherein the adaptor device comprises: an adaptor manifold
sized to be placed inside the filter housing above the separation
plate, wherein a plurality of outlet ports are provided on a top
side of said adaptor manifold to allow fluid to flow through the
adaptor manifold, and at least one connection port provided on a
bottom side of said adaptor manifold, wherein the outlet ports are
in fluidic communication with the connection port.
Description
PRIOR RELATED APPLICATIONS
[0001] This application is a Continuation-In-Part of U.S.
application Ser. No. 16/112,023, filed Aug. 24, 2018, which claims
priority to U.S. provisional application Ser. No. 62/550,096 filed
Aug. 25, 2017; this application is also a Continuation-In-Part of
U.S. application Ser. No. 15/901,580, filed Feb. 21, 2018, which
claims priority to U.S. provisional application Ser. No.
62/462,327, filed Feb. 22, 2017, all of which are incorporated
herein in their entirety for all purposes.
FIELD OF THE DISCLOSURE
[0002] The disclosure generally relates to an assembly to
accommodate rectangular or wedge shaped filters in a filter housing
for filtering liquids in pool and spa applications. The filter
media may be pleated media therein that are capable of high
efficiency filtration as well as easy replacement of the filter
element. The rectangular or wedge-shaped filters can also be used
to filter many types of fluids and fluid mixtures.
BACKGROUND OF THE DISCLOSURE
[0003] As the filter of choice for most spas and many smaller above
ground pools, the cartridge filter is enjoying a resurgence in
popularity. The cartridge filter element, an aquatic version of the
pleated filters traps dirt and particles of 25-100 microns or
larger in size. After a period of use, the filter requires cleaning
to function properly. To clean the filter, the cartridge is removed
from the tank and hosed thoroughly, top to bottom, often with a
garden hose. This is done as necessary to remove dirt typically
when the pressure gauge rises 8-10 lbs. and above and the fluid
cannot flow at a proper rate through the filter.
[0004] The life of filter cartridge depends on the condition under
which it is used, and may range from 1 to 3 years depending on the
maintenance schedule. Regularly maintenance is also required to
prevent or mitigate clogging. As a filter ages, the length of time
between necessary cleanings becomes shorter due to algae bloom or
particle build up.
[0005] Currently, most current pool filters are designed to use a
single cylindrical filter cartridge, or up to four cylindrical
filter cartridges. For efficiency purposes, increasing the filter
surface area provides higher filtering efficiency. This cylindrical
cartridge design does not provide the highest surface area
available inside the housing. In the case of four cylindrical
filter cartridges, unused spaces inside the filter housing are
created naturally by the geometry of the housing and the
cartridges. Additionally, cylindrical filter cartridges used inside
a cylindrical filter housing inevitably leaves unused dead space
within the housing.
[0006] Therefore, there is the need for an improved filter design
for pool and spa applications with smaller footprint, higher
filtration performance while being easy to maintain or replace.
[0007] There is also the need for an after-market modification that
can readily transform a cylindrical cartridge filter system into a
multi-cartridge filter system.
[0008] Industrial filtration systems generally comprise cartridge
filters located within corresponding filter housings, and fluids to
be filtered (influents) are introduced into the filter housings and
filter elements for the removal of debris, contaminants and
particles. These cartridge filters generally have a cylinder shape
with a hollow core. Influents are supplied either to the hollow
core and flowing outwards through the media of the cartridge
filters (inside to outside) or the influent flows from the outside
of the filter into a core (outside to inside flow), leaving debris,
contaminants and particles at the surface of the media. The
cylindrical cartridge filters of pleated media, while easy to
manufacture and use, do not effectively utilize the space inside
the filter housing.
[0009] Therefore, there is a need for a new filter element and
corresponding filter configuration to increase the volume of fluid
that can be filtered in the same size filter housing, or provide a
filter system that can filter the same volume of fluid or even more
in a smaller housing. The new assembly can be installed in the
commonly used cylindrical filter housing, but can also be used with
filter housings of different shapes that will accommodate a
rectangular filter such as a square or rectangular filter
housing.
SUMMARY OF THE DISCLOSURE
[0010] This disclosure is an efficient filter assembly that can
also include an adaptor device that transforms a single
cylindrical-cartridge filter vessel or a quadruple-cartridge filter
vessel as used in the pool and spa application into a multi-filter
element device in order to increase the filter surface area over
the same vessel, improve filtration performance, and reduce the
difficulty to service or replace the filter cartridges. With the
adaptor device, the conventional pool and spa filter housing that
uses cylindrical filter cartridges can be readily converted to use
rectangular- or wedge-shaped filter elements. These rectangular or
wedge-shaped filter elements can effectively reduce the dead space
inside the filter housing, thereby increase the filtration surface
area and improve filtration efficiency and reducing the energy and
maintenance cost.
[0011] In one aspect of this disclosure, a filter system is
described, comprising: a filter housing; a fluid inlet to the
filter housing; a clean fluid outlet from the filter housing; a
separation plate located inside the filter housing, said separation
plate having a center hole in communication with the clean fluid
outlet; e an adaptor plate located in the filter housing, wherein
the adaptor plate is located above the separation plate, and at
least one spacer is provided between said separation plate and said
adaptor plate, wherein a plurality of outlet ports are provided on
said adaptor plate; a plurality of filter elements enclosed in the
filter housing, each filter element comprising a central void
surrounded by a filter media for outside to inside flow, wherein
each filter element is mounted on the adaptor plate at one of said
outlet ports.
[0012] In another aspect of this disclosure, an adaptor device for
retrofitting in a filter housing is described, wherein the pool
filter housing has a fluid inlet, a fluid outlet, and a separation
plate located inside the filter housing. The adaptor device
comprises: an adaptor plate sized to be placed inside the filter
housing, wherein a plurality of outlet ports are provided on said
adaptor plate to allow fluid to flow through the adaptor plate; and
at least one spacer between the separation plate and the adaptor
plate.
[0013] In one embodiment, the media of the filters is pleated
filter media in a trapezoidal shape with top and bottom sides
parallel to each other and the longer sizes in between the top and
bottom flaring out such that the bottom side is wider than the top
side, the central void being created by the pleated media inside
the trapezoid extending from the top side to the bottom side,
wherein each said filters further comprising a solid generally
rectangular top cap that is secured to the top side of the pleated
media to maintain a rectangular profile of the filter; a generally
rectangular bottom cap secured to the bottom side of the pleated
media with a central opening that communicates with the central
void in the pleated media; and the bottom cap is a wider rectangle
to accommodate the flare of the trapezoidal media. In another
embodiment the media is a rectangular shape.
[0014] In one embodiment, the filter elements are wedge shaped
filter elements, and a plurality of the wedge shaped filter
elements are enclosed in the filter housing in a generally circular
arrangement with each of said wedge shaped filter elements having a
central void surrounded by filter media, a solid top cap, a bottom
cap with an opening located therein to communicate with the central
void in the filter media that extends from the top cap to the
bottom cap; the bottom cap of each said wedge shaped filter is
mounted on the adaptor plate at one of the outlet ports such that
the fluid to be filtered passes through a layer of filter media
into the central void of the wedge shaped filter element and
filtered fluid passes through the opening in the adaptor plate.
[0015] In one embodiment, a handle is provided on the top cap of
each of the filter elements.
[0016] In one embodiment, the filter system further comprises a
guide support mounted at each of the outlet ports on the adaptor
plate. In one embodiment, the guide support is perforated, and
wherein the guide support extends into the central void of the
filter element. In one embodiment, the each of the guide supports
is detachably fastened or mounted to the adaptor plate.
[0017] In one embodiment, the media is selected from the group of
natural media, synthetic media, ceramic media, glass media and
metal media. In one embodiment, the filter media is selected from
the group of pleated or non-pleated media. In one embodiment, the
filter media is a polyester spun-bonded pleated media.
[0018] In one embodiment, the filter elements have openings in both
the top cap and the bottom cap. Therefore, to properly seal the top
cap during operation, the filter assembly further comprises a plate
or a spider cap placed above the filters inside the filter housing.
The plate is secured over the top cap of the filters to prevent
fluid entry once the filter housing is closed. Alternatively a
spider cap that has radiating arms from a central hub and arms
generally contacting the top cap of each of the filter elements can
be used when a circular array of filters such as wedge shaped
filters are use; and a mechanism between the plate or spider cap
and the inside of the top of the housing to secure the spider plate
over the filters when the filter housing is in use.
[0019] The generally rectangular shaped filter of this disclosure
comprises a rectangular shaped top cap, a rectangular shaped bottom
cap, and filter media extending between the top cap and the bottom
cap. The filter media can be pleated or non-pleated depth media.
The pleated filter media can be a single sheet of filter folded
into pleats and connected to provide a central void inside the
pleats without other openings or bypass. The pleated media can have
multiple layers of the same or different materials depending on the
desired filter. Two rows of pleats are formed along the longer
sides of the rectangle. At the shorter end of the rectangle there
can be one layer of non-pleated media or small pleats. The
rectangular arranged pleated media creates a central void. The
bottom cap has a central outlet communicating with the central void
created by the pleated media. A filter support can also be provided
within the inside the central void to maintain the longitudinal
integrity of the filter elements, as well as guiding the insertion
of the filter elements. The filter support is preferably made of a
rigid material. The filter support can be perforated to allow fluid
flow inside the void created by the pleated media. The top cap also
can have a handle for easier insertion/removal of individual filter
elements and the handle can fold down on the top cap. In some
embodiments, the rectangular filter element may have openings in
the top and/or bottom cap. A separate cover for the top opening or
hold-down mechanism, such as a spider cap, may be provided to seal
off the opening in the top of the filter.
[0020] When a filter vessel does not need to be fitted with an
adaptor, this invention includes the filter assembly utilizing a
plurality of rectangular shaped filter elements in a filter housing
(also referred to as a vessel) that is typically cylindrical, but
could be used with filter housings of different shapes that will
accommodate a rectangular filter such as a square or rectangular
filter housings. This description will refer to the typical
cylindrical housing, but other shapes may be used. A plurality of
the rectangular shaped filter elements are arranged compactly
inside a filter housing with space for fluid flow around and in
between the filter elements.
[0021] In another embodiment, three-dimensional wedge-shaped filter
elements are used in place of the cylindrical filter cartridge or
multiple cylindrical cartridges. The three-dimensional wedge-shaped
filter element in this disclosure comprises a wedge-shaped top cap,
a wedge-shaped bottom cap, and pleated filter media extending
between the top cap and the bottom cap. The filter media can be a
single sheet of filter media folded into pleats, providing a
central void inside the pleats for the filtered fluid. The pleated
filter media extends from the wedged shaped top cap to the
wedge-shaped bottom cap. Both caps have side edges the approximate
same length and shorter end and longer end to form a wedge. Two
rows of pleats gradually decreasing in size from larger to smaller
pleats extends from the longer end of the wedge to the smaller end
of the wedge with at least one layer of media connecting the outer
most largest pleats and the smallest inner pleats providing
continuous layer of media forming a central void inside the pleats
which can be wedge, triangular or round depending on the pleat
configuration. The pleated filter media can be a single sheet of
filter folded into pleats, providing a central void inside the
pleats. The pleated media can have multiple layers of the same or
different materials depending on the desired filter. In some
embodiments, the media does not need to be pleated and can be solid
media. The bottom cap has a central outlet communicating with the
central void created by the pleated media through which the
effluent or clean fluid passes. A filter support can also be
provided inside the void, extending also from the top cap to the
bottom cap to maintain the longitudinal integrity of the filter
elements, as well as guiding the insertion of the filter elements.
The filter support can be perforated to allow fluid flow inside the
void created by the pleated media. The top cap also may have a
handle for easier insertion/removal of individual filter elements.
In some embodiments, the wedge-shaped filter element may have
openings in the top and/or bottom cap. A separate cover for the top
opening or hold down mechanism may be provided to seal off the
opening in the top of the filter.
[0022] In this disclosure, the rectangular shaped filter element
can be replaced with a wedge-shaped filter element in order to
increase the surface area of filters, provided that ports or
openings in the adaptor plate are configured according to the type
and number of filter element used for outflow of clean fluid.
[0023] The filter elements are arranged to maximize the filtration
area inside the filter housing, which also increases the filter
capacity, i.e. the amount of fluid the filter is capable of
filtering at a given time. The filter housing has fluid inlet for
fluid to enter into the housing that contains the plurality of
rectangular shaped filter elements. A conventional separation plate
or manifold is provided inside the filter housing sealably secured
to the outlet. The conventional separation plate is designed for a
cylindrical cartridge filter system, having a central hole to
accommodate the cylindrical filter cartridge. The conventional
filter housing has the separation plate located near the bottom of
the housing to support a manifold that is fluidically connected to
a clean fluid outlet. Alternatively, for a conventional filter
housing that has four cylindrical cartridges, a manifold having
sealed connection with both the cartridges and the clean fluid
outlet is placed at the bottom of the filter housing.
[0024] In the case of a separation plate, after installing the
adaptor plate and spacer on top of the separation plate, the
cylindrical filter cartridge can be converted into a
multi-cartridge filter system. The adaptor plate being close to the
separation plate with spacer in between the two plates, therefore
the space inside the filter housing remains available for
installing a plurality of filter elements. The spacer is preferably
a ring with substantially the same circumference as the inner
circumference of the filter housing, and with the spacer between
the adaptor plate and the separation plate, any fluid flowing
through the ports in the adaptor plate would then be directed to
the central hole of the separation plate, thus maintaining the
filtration efficiency.
[0025] In the case where a conventional hollow manifold is used to
receive and connect with multiple cylindrical filter cartridges, an
adaptor manifold can be used. The adaptor manifold of this
disclosure comprises a plurality of openings matching the
rectangular- or wedge-shaped filter elements, and each opening is
in fluid communication with a connection port on the other side of
the manifold. The connection port sealingly couples with the clean
fluid outlet of the filter housing, such that the
water-to-be-filtered enters the filter housing through the inlet,
undergoing an outside-in filtration through the rectangular- or
wedge-shaped filter elements, and finally the filtered water flows
through the manifold and exits the filter housing through the clean
fluid outlet. The adaptor manifold of this disclosure can replace
the conventional manifold entirely, as the adaptor manifold can be
manufactured to fit with existing housing and clean fluid
outlet.
[0026] For adaptor plates, filter receivers are mounted thereon,
which provides a plurality of ports allowing fluid to flow through
the adaptor plate. The rectangular shaped filter elements are
inserted or otherwise secured in filter receivers that also have
openings that communicate with the opening in the bottom caps. The
ports in the adaptor plate communicate with the openings in the
filter receivers. The filter supports are mounted on the filter
receivers and extend into the central void of each rectangular
shaped filter without hampering fluid flow from the central void of
the rectangular shaped filter and through the openings in the
separation plate.
[0027] The rectangular shaped filter may include a mesh enclosing
the filter media. The dirty fluid is introduced into the filter
housing through a fluid inlet. The fluid then passes through the
filter media into the central void of the rectangular shaped
filters and the filtered fluid passes through the opening in the
bottom cap and the corresponding opening in the separation plate. A
chamber is provided in the filter housing below the separation
plate to collect the filtered clean fluid. A clean fluid outlet in
the filter housing is located in this chamber for allowing the
filtered fluid to collect and remove clean fluid from the filter
housing. This embodiment is used for outside to inside flow.
[0028] This invention also includes methods for filtering fluid by
introducing fluid to be filtered into a filter housing with a
plurality of rectangular or wedge-shaped filters for pool and spa
applications. Then, passing the fluid through filter media of the
rectangular shaped filters into a central void provided therein.
Further collecting the filtered fluid from the central void of each
rectangular shaped filter into an adaptor manifold or an adaptor
plate, followed by removing the filtered fluid from the filter
housing. Alternatively, the fluid introduced into the filter
housing can be introduced into a central void located in each of
the rectangular shaped filters and further passed through a layer
of media surrounding the void. The fluid is collected from the
filter housing and recirculated with a pump to the pool.
[0029] As used herein, "influent" or "dirty fluid" or "dirty water"
means the fluid to be introduced to and filtered by the filter.
[0030] As used herein "inside to outside flow" means fluid flowing
from the inside of a filter to the outside of the filter and can be
used interchangeably with "inside to out" or" inside out".
[0031] As used herein "outside to inside flow" means fluid flowing
from the outside of a filter to the inside and can be used
interchangeably with "outside in".
[0032] As used herein, "effluent" or "clean fluid" means the clean
filtered water already passing through the filter media.
[0033] The use of the word "a" or "an" when used in conjunction
with the term "comprising" in the claims or the specification means
one or more than one, unless the context dictates otherwise.
[0034] The term "about" means the stated value plus or minus the
margin of error of measurement or plus or minus 10% if no method of
measurement is indicated.
[0035] The use of the term "or" in the claims is used to mean
"and/or" unless explicitly indicated to refer to alternatives only
or if the alternatives are mutually exclusive.
[0036] The terms "comprise", "have", "include" and "contain" (and
their variants) are open-ended linking verbs and allow the addition
of other elements when used in a claim.
[0037] The phrase "consisting of" is closed, and excludes all
additional elements.
[0038] The phrase "consisting essentially of" excludes additional
material elements, but allows the inclusions of non-material
elements that do not substantially change the nature of the
invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0039] FIG. 1A shows the adaptor plate used with a conventional
separation plate in a pool or spa filter housing.
[0040] FIG. 1B is a perspective view showing a plurality of filter
supports mounted on the adaptor plate through receivers.
[0041] FIG. 1C is a perspective view showing the relationship
between the adaptor plate and the separation plate.
[0042] FIG. 1D is a perspective view showing a spider cap placed on
top of the rectangular filter elements.
[0043] FIG. 1E is a perspective view showing a conventional filter
assembly with four cylindrical filter cartridges and a
manifold.
[0044] FIG. 1F is a perspective view showing an embodiment of this
disclosure, in which an adaptor manifold is used along with
rectangular-shaped filter elements.
[0045] FIG. 1G is a perspective view showing the adaptor
manifold.
[0046] FIG. 2A is a schematic perspective view of a rectangular
shaped filter element of this invention.
[0047] FIG. 2B is a cut away cross section wherein pleated filter
media is cut out to reveal the perforated support.
[0048] FIG. 2C is a side view of a preferred embodiment showing a
trapezoid-shaped filter element wherein the width of the filter
element is gradually increased toward the bottom.
[0049] FIG. 2D is a bottom cross-sectional view of a rectangular
shaped filter element of this disclosure with pleated filter shown
and the bottom cap.
[0050] FIG. 2E is a bottom view of a bottom cap of a rectangular
shaped filter element.
[0051] FIG. 2F is a partial vertical cross-sectional view the lower
end of the rectangular shaped filter and the bottom cap.
[0052] FIG. 3A is a partial cross-section showing of a filtration
flow for outside to inside in filtering.
[0053] FIG. 3B is a cross section of the fluid flow with the
trapezoid-shaped filter element as an example.
[0054] FIG. 3C is a cross sectional view of the filter support.
[0055] FIG. 3D is a schematic view of the trapezoid-shaped filter
elements inside a filter housing with flow-direction outside to
inside.
[0056] FIG. 3E is a longitudinal cross-sectional view in the filter
housing of the filter of FIG. 5A showing the filter.
[0057] FIG. 4A is a schematic perspective view of a wedge-shaped
filter element of this invention.
[0058] FIG. 4B is a cut away cross section wherein pleated filter
media is cut out to reveal the perforated support.
[0059] FIG. 4C is a side view of a wedge-shaped filter element
showing the top cap and the bottom cap with the attachment to the
separation plate.
[0060] FIG. 4D is a cross-sectional view of a wedge-shaped filter
element and bottom cap with pleated filter shown as it sets in the
cap.
[0061] FIG. 4E is a bottom view of a bottom cap of a wedge-shaped
filter element of this disclosure.
[0062] FIG. 4F is a top view of an adaptor plate of this disclosure
for wedge-shaped filters.
[0063] FIG. 4G is an alternative embodiment of the disclosure with
a spider plate shown that can be used with a swimming pool or spa
filter housing.
[0064] FIG. 5 is a comparison between the configuration of multiple
filter elements for pool and spa application of this disclosure and
a conventional filter configuration using Pentair Clean &
Clear.RTM. Plus filter elements.
DETAILED DESCRIPTION
[0065] The present disclosure describes a novel retrofitting
adaptor assembly to be used in a conventional single cylindrical
cartridge or multiple cylindrical cartridge pool filter systems.
The water in pool and spa applications is continuously filtered
with the pumping system is turned on. In a typical pool and spa
filtration system there is a strainer through which the water
passed that catches larger debris such as leaves prior to entering
the filter vessel. Then the water is pumped into a filter vessel.
This detailed description illustrates the adaptation of the filter
housing that uses a single filter vessel as well as the version
with multiple cylindrical filters. Alternatively, the internal
parts of a filter housing can be modified to adopt different
designs. In the case of a newly built pool or spa, the filter
housing does not need to be retrofitted.
[0066] The detailed explanation of the assembly and method of this
invention may be made with reference to the drawings. The drawings
are also illustrative and not necessarily to scale. The size of the
rectangular shaped filters used in this invention can be made to
the desired size according to needs. The following examples are
intended to be illustrative only, and not unduly limit the scope of
the appended claims.
[0067] Please refer to FIG. 1A which is an exploded view of the
disclosure, which shows the adaptor plate 105 as used in a
conventional cylindrical cartridge pool filter system that
comprises: a filter housing 101 having a removable top 102 of the
filter housing that provides access to the filters for cleaning; an
inlet 111 for introducing fluid to be filtered, in this case pool
and spa water that is located above a separation plate 103 and
adaptor plate 105 further described below; an outlet nozzle 113 for
discharging filtered clean water. The separation plate 103 is
placed about the inner circumference of the filter housing shown at
104 in the exploded view and the separation plate 103 would support
a conventional cylindrical filter cartridge (not shown). A spacer
133 (discussed in more detail in FIG. 1C) is provided between the
separation plate 103 and the adaptor plate 105 to allow fluid
communication between the plates. The conventional single or
quadruple cylindrical filter cartridge(s) typically has a central
void surrounded by cylindrical filter media, a top cap that covers
one end of the cylindrical filter media, and a bottom cap that
surrounds the cylindrical filter media to maintain the shape of the
cylindrical filter and has a central opening in the cap to allow
for outside to inside flow through the filter. There is fluid
communication between the central void of the filter cartridge and
the central hole of the separation plate. The retrofitting adaptor
plate 105 of this disclosure is placed in the housing 102 just
slightly above 104 where the separation plate 103 is located to
allow fluid flow, and has openings that match the end caps of the
plurality of rectangular filter elements shown in FIG. 1A.
[0068] As seen in FIG. 1A, there are six (6) rectangular-shaped
filter elements 109 arranged inside the tubular housing 101. Each
filter element 109 has a top cap 121 and a bottom cap 123
respectively located at the top and bottom of the filter media to
maintain the shape and integrity of the filter element 109, and
avoid any fluid bypass by securing the filtration media to the top
and bottom caps. Also provided for each filter element 109 is a
generally rectangular receiver 108 mounted on the adaptor plate 105
for the end cap of each filter element. The receiver 108 may have a
filter support 125 which is a rigid material extending from and
secured to the base of the receiver sized to fit inside the void of
the filter element 109 (shown in FIG. 1B) for easily inserting the
filter element 109 and securing to the adaptor plate 105. The
filter supports preferably allow fluid flow through the rigid
material. The adaptor plate 105 has six (6) outlet ports 115 into
which the receiver 108 can be inserted. Details of the filter
element 109 and the receiver 108 will be described below with
regard to FIGS. 2A-F. By retrofitting the conventional pool filter
housing with the adaptor plate 105, six rectangular-shaped filter
elements 109 can now be used to improve filtration efficiency
without having to change the entire filtration system.
[0069] To release any trapped air inside the housing, a vent tube
171 and corresponding air screen 173 are also provided inside the
housing.
[0070] Please refer to FIG. 1B, which shows a plurality of filter
supports 125, each mounted on the adaptor plate 105 through a
corresponding receiver 108. The adaptor plate 105 has a plurality
of ports 115 arranged in a predetermined pattern that allows the
installation of corresponding filter elements. Each of the receiver
108 is secured to the adaptor plate 105 by using bolts 161 and bolt
holes 163 on the adaptor plate 105. However, the receiver 108 may
be secured preferably removably to the adaptor plate 105 by other
means known to persons having ordinary skills in the art. An O-ring
seal 165 is also provided between each receiver 108 and the adaptor
plate 105 in order to ensure no water leakage between the two.
[0071] The filter supports 125 are flat and sized to be inserted
into a central void of the filter element 109. The matching size
and shape of the filter support 125 and the central void of the
filter element 109 allows a user to easily align the filter element
109 into the correct position. In one embodiment, the filter
support 125 is it remains in the filter housing as an integral of
the filter assembly, as opposed to being disposable along with the
filter cartridges to be disposed of.
[0072] Referring now to FIG. 1C, which shows the relationship
between the adaptor plate 105 and the separation plate 103. As can
be seen, a spacer ring 133 is placed between the separation plate
103 and the adaptor plate 105. The spacer ring 133 provides
sufficient space between the two plates 103, 105, such that when
the adaptor plate 105 is retrofitted in a filter housing, the fluid
flowing through the ports 115 can coalesce and flow through the
central hole 131 of the separation plate 103. Without the spacer
ring, the minimum space between the plates 103, 105 would not allow
fluid flowing through the ports in the adaptor plate 105 to quickly
flow through the central hole of the separation plate 103. If the
distance between the plates is too large, there would be less space
available inside the filter housing for the filter elements.
[0073] Referring now to FIG. 1D, which shows the alternative
embodiment where a closure plate 141 is used. In this embodiment,
each of the filter element 109 has an open top cap 151,
manufactured with an opening 153. Here both the open top cap 151
and bottom cap (not shown) have an opening so that a user can
easily install the filter element into the filter housing. However,
to provide for outside-to-inside flow, the top cap must be securely
covered to block flow into the top cap. The closure plate 141 is
designed to cover the openings 153 of the top cap 151 of each
filter element 109. Specifically, the closure plate 141 further
comprises a protrusion 145 corresponding to each filter that is
shaped and sized to fit snuggly into the openings 153 on the top
caps 151 to completely cover the openings 153. Optionally, several
cutouts 147 can be provided on the closure plate 141 for a user to
easily see the top caps and place plate 141 to cover the openings
153 accordingly. A plurality of springs 143 are also provided such
that when the filter housing is closed, sufficient force is applied
to the closure cap 141 to ensure that the openings 153 on the top
caps 151 will be covered. However, other mechanical closures may be
used as known to this skilled in the art.
[0074] Also referring to FIGS. 2A-C, which show the perspective
views of the rectangular shaped filter element 109. The rectangular
shaped filter element 109 is generally comprised of a top cap 121,
a bottom cap 123, and the media 201 extending from the top cap 121
to the bottom cap 123. The top cap 121 is optionally provided with
a handle 211 that can be folded on top of the cap and provide a
more compact profile for the installed rectangular shaped filter.
The filter media 201 is preferably pleated to increase filtration
area and filtration capacity. There is central void in the media
surrounded by media (not shown in FIG. 2A). The rectangular shaped
filter is mounted on the adaptor plate 105 in a rectangular shaped
filter receiver 108 that has lips 208 extending upwardly from the
adaptor plate to receive the outlet connector 225 on the bottom
cap.
[0075] The filter media material is not limited and can be
customized depending on the type of filtration. The media may be
pleated media of cellulose and other natural media or synthetic
media including but not limited to polypropylene, polyester, nylon,
PTFE, PPS, ECTFE and PVDF. The pleated media may be one layer of
material or multiple layers of different materials depending on the
needs for filtration or separation. Other types of media including
non-pleated depth media polypropylene, polyester, nylon, PTFE, PPS,
PVDF, ECTFE, cellulose fiber, glass fiber, and woven wire mesh and
ceramic media could be used. The filter media may be single use and
disposable or reusable after cleaning.
[0076] Referring now to FIG. 2B, which is a cut away of the cross
section of the rectangular shaped filter 109 as shown in FIG. 2A.
In FIG. 2B, the filter is shown with a closed top cap 121 with a
handle, but the top cap can be closed without a handle or open and
used with a closure plate as described above in FIG. 1D. The top
cap 121 and the bottom cap 123 are securely attached to the media
201. Lip 212 on the top cap encloses the outer top edge of the
media and inner lip 213 on the top cap encloses and secures the
inner top edge of the media to the top cap 121. Outer lip 222 on
the bottom cap encloses the outer bottom edge of the media and
inner lip 224 on the bottom cap encloses the bottom inner edge of
the media. In addition, the media is securely potted, thermally
bonded, glued or otherwise firmly attached to the top and bottom
caps.
[0077] An alternative embodiment is described with reference to
FIGS. 1E-1G, and similar parts will be referred to by the same
reference numbers. FIG. 1E shows a conventional filter housing 101,
in which four cylindrical filter cartridges 183 are located. The
cylindrical filter cartridges 183 are accompanied by a matching top
cap 181 to cover the top openings, and a bottom manifold 185. The
bottom manifold 185 has openings 187 on its top, and the openings
187 are in fluid communication with the hollow core 184 of the
filter cartridges 183. On the bottom side of the manifold 185 there
is a connection port (not shown) that is sealingly coupled with the
outlet nozzle 113. Channels are provided within the manifold 185 to
enable fluid communication between the openings 187 and the
connection port.
[0078] FIG. 1F shows the adaptor manifold 195 in place of the
manifold 185 in FIG. 1E. The adaptor manifold 195 is shaped to also
fit inside the filter housing, and a plurality of outlet ports 197
are provided on the top side of the adaptor 195 in order to
accommodate the plurality of rectangular- or wedge-shaped filter
elements 109. The adaptor manifold 195 also has a connection port
on the bottom side thereof (See FIG. 1G, reference number 193) that
forms a sealed connection with the outlet nozzle 113. Channels are
formed within the manifold 195 such that the filtered water from
each of the filter elements 109 flowing through the outlet ports
197 can coalesce and exit the filter housing through the connection
port to the outlet nozzle 113. Unlike cap 181 in FIG. 1E, the
rectangular filter elements 109 each has a solid top cap 121, which
optionally can further include a handle (not shown, discussed below
with regard to FIGS. 2A-C) for ease of removal.
[0079] FIG. 2B also shows the bottom cap outlet connector 225 being
inserted into the filter receiver 108 that is in turn mounted on
the adaptor plate (not shown in FIG. 2C). The O-ring 226 can be
provided on the bottom of filter receiver 108 to provide a secure
seal with the adaptor plate. However, other secure attachments can
be used as well. O-ring 165 (also shown in FIG. 1B) is provided at
the bottom of the receiver 108 to prevent water leakage. Other
seals or sealing mechanisms can also be used.
[0080] The media has a central void 205 which is shown in the cut
away view with layers of filter media 201 shown on each side of the
void 205. In the preferred embodiment the filter support 125, which
is preferably perforated, is inserted in the central void 205 of
the media 201 for both maintaining the physical integrity of the
filter element, as well as providing flow path for the filtered
fluid within the void. The perforated support 125 can be made of
any rigid and light material to support the overall weight and
pressure within the pleated filter media. Non-limiting examples
include plastic, metals, fiberglass reinforced plastics, and
ceramics.
[0081] The shape of the perforated support 125 can also be tapered,
i.e. the size being gradually increased to the bottom. The
advantage of this tapered support is easier removal of the filter
element because the inside of the filter element 109 will be less
likely interfere with the support 125 when a user is pulling the
filter element upward to remove from the filter housing using the
handle 121 provided on the top cap.
[0082] Referring to FIG. 2C, which shows a preferred embodiment of
the rectangular shape filter element 109 of this disclosure. As
shown in FIG. 2C, the rectangular shape filter element 200 has a
trapezoid shaped side profile, i.e. the cross-sectional area
increases from top to bottom. The outlet connector 225 is shown as
an integral part of the bottom cap 123 and extending therefrom.
This is different from the receiver 108 in FIG. 2B that is in turn
used to engage with the adaptor plate. Also, O-ring 226 is provided
on the outer circumference of the outlet connector 225 that is used
to secure the rectangular shaped filter in place in adaptor plate
105.
[0083] The rectangular shaped filter elements effectively reduce
the dead space created by circular filter elements. In addition,
the trapezoidal shape allows easier insertion/removal of the filter
elements. The rectangular shape also a can be aligned easily in
rows if a specific orientation is required for the filter elements
to function properly.
[0084] Referring now to FIG. 2D, which shows the horizontal
cross-section view near the bottom of the rectangular shaped filter
element 109. The filter element 109 comprises pleated filter media
201 surrounding a central void 205 to allow the filtered fluid to
flow through the pleated media and to exit from the void to an
opening 223 located in the bottom cap 123. In this cross-section,
it can be seen that the pleated filter media 201 can be one single
sheet of filter media folded continuously around the center,
forming an inside void 205, where filtered fluid flows, and the
fluid collects inside the void 205 before exiting the filter
element through the opening 223 on the bottom cap. The outer lip of
the bottom cap is shown at 222 and the inner lip 224 is shown that
enclose the ends of the media 201 (see also FIG. 2B). The pleated
media extending from the rectangular shaped top cap to the
rectangular shaped bottom cap with two rows of pleats 201a and 201b
on the long sides of the rectangle and with a layer of media 201c
and 201d on the short sides connecting 201a and 201b, creating a
generally central void 205 inside the pleats. The inner lip 224 is
shown in this view. The top cap 121 and bottom cap 221 maintains
the rectangular shape of the filter element. In addition, a mesh
(not shown) can enclose the filter media to maintain the generally
rectangular shape. Alternatively, an outer band can be secured
around the circumference of the filter element. The mesh can be
made of a polymeric or other material that will maintain its
integrity when in contact with the fluids to be filtered. Each of
the filter element 109 has a top cap and a bottom cap to maintain
the shape and integrity thereof. The water to be filtered flows
from outside the filter element across the filter media into the
central void.
[0085] Referring now to FIG. 2E, which shows a perspective view of
the inside of the bottom cap 123 and the opening 223 without media.
The inner lip 224 is shown defining the opening 223.
[0086] Referring to FIG. 2F, which shows a partial cross section
view of the bottom section of a rectangular shaped filter element
of this disclosure. This figure illustrates how the pleated filter
media 201 interfaces with the bottom cap 123. Lip 222 is provided
on the bottom cap to enclose the outer bottom edge of the media.
Lip 224 is provided on the bottom cap to enclose the inner bottom
edge of the media. The outlet connector 225 is shown on extending
from the bottom cap. O-ring 226 is provided on the outer
circumference of the outlet connector 225 that is used to secure
the rectangular shaped filter in place on the filter receiver
108.
[0087] The filtration process will be described with reference to
FIGS. 3A-E. Referring now to FIGS. 3A-B, which is an illustration
of the outside to inside filtration flow using rectangular shaped
filter elements. FIG. 3A only shows portions of the filter housing
and the proportion may be varied for better illustration. FIG. 3B
illustrates the filtration flow of the rectangular shape filter
element having trapezoid profile. The water from the pool or spa is
introduced through a fluid inlet 111 of the filter vessel 101 in
the vessel wall. The water then flows through a layer of the filter
media 201 of one of the rectangular shaped filters, and the clean
fluid flows through the central void 205 inside the filter media
(indicated by the flow arrows in the drawing) which void 205 has
the perforated support 103 inserted therein. The fluid then flows
through the opening 223 in the bottom cap 123 that communicates
with the filter receiver 108 mounted on adaptor plate 105. This
view also shows optional stiffeners 204 mounted on the bottom face
of the filter receiver 108 to provide additional stability to the
perforated support 125. The outlet cap 225 of the bottom cap of
each of the rectangular shaped filters is inserted in the upwardly
projecting lips on the filter receiver 108 mounted on the top of
adaptor plate. The opening in the bottom cap communicates with a
corresponding outlet port 115 in the adaptor plate 105, thus
providing fluid communication from the central void 205 with the
filtered fluid through the adaptor plate to the chamber below in
the filter housing.
[0088] This is an outside to inside flow direction, where the
filter opening 223 for the filtered fluid is located at the bottom
cap 123 of the filter element 200. The fluid flows from outside of
the filter media 201 to the center void 205, and eventually exits
the rectangular shaped filter 109 through the filter opening 223 in
the bottom cap. The bottom cap outlet connector 225 is secured into
the filter receiver 108 on the adaptor plate via the O-ring 226.
The O-ring 226 can provide a better seal between the bottom cap 123
and the filter receiver 108 to avoid fluid bypass. Also, the O-ring
or gasket seal can provide a resistance signal for the user that
once the resistance is overcome, the filter element is installed in
place.
[0089] Conventional housings can be retrofitted with a new adaptor
plate of the current invention to accommodate rectangular shaped
filters above the adaptor plate used for cylindrical filters. The
new adaptor plate should have the correct outer diameter to fit
inside the filter housing and accommodate the length of filter
elements can fit into the housing.
[0090] FIG. 3C is a cross-section of the of perforated support 125
showing a preferred embodiment that is made of two perforated
rectangular rigid sheets mounted on either side of the opening in
the filter receiver 108 so as not to impede the filter flow. The
tops of the perforated sheets meet. Narrow side panels 206 are
between the perforated sheets extending from the top of the filter
receiver 108 to the top of the perforated sheets (see FIG. 3D).
[0091] In a preferred embodiment, additional stiffeners 204 as
shown in FIG. 3A are provided between the perforated sheets and are
mounted on top of the filter receiver 308 inside the perforated
support 125. The O-ring 165 on the bottom of the filter receiver is
shown in this view. It is noted that the wedge-shaped filter
elements operate in a similar fashion, and the following discussion
will use the rectangular shaped filter element and matching adaptor
plate as examples. The more detailed discussion on wedge-shaped
filter element can be found in U.S. application Ser. No.
16/112,023, which is incorporated in its entirety for all
purpose.
[0092] Referring to FIG. 3D, which is a schematic view of a filter
assembly having the rectangular filter elements 200 as installed in
a filter housing 101. For ease of reference only seven (7)
rectangular filters are shown in the schematic. The number of
filter elements 109 in this figure is only for illustrative
purpose, and the actual number of filter elements 109 will depend
on many factors, such as the size of the filter housing, the fluid
flow rate, the particulates to be filtered, and the nature of the
fluid. One filter element has been removed to show the construction
of the filter assembly with a perforated support 125. The adaptor
plate 105 has a plurality of filter receivers 108 to receive the
bottom caps 123 of the rectangular shaped filters 109 with openings
(not shown) matching the filter opening in the bottom caps 123 for
each filter element 109. Also, the perforated support 125 is
mounted to and extending from the filter receiver 108, and this
configuration also facilitates installation and removal of
individual filter elements 109 because the perforated support 125
also serves as a "guiding rail" matching the center void (not shown
here) of each filter elements 109. The perforated supports 125 are
mounted on the filter receivers 108 without impeding the fluid flow
through the outlet ports (see FIG. 1B).
[0093] This configuration for outside-in flow is also shown in FIG.
3E. This view does not show the removable top 102 of the filter
vessel that is secured during the filtration process. The lid may
be removed to replace and/or clean the rectangular shaped filters
aided by the use of a handle to place and remove the filters. Also
the trapezoidal shape of the filter is helpful in removal, because
the wider base of the filter is not impeded by the rectangular
support, making it easier to reach the pleats and clean the
filters. At the start of filtration, the fluid to be filtered is
introduced through the dirty fluid inlet 111 into an empty filter
vessel, and then fills the filter vessel from the adaptor plate 205
upwards. When the fluid level reaches the filter media 201, the
fluid flows across the filter media 201 and into the center void of
the filter elements 109. The filtered fluid that has passed through
the filter media then flows through the outlet openings (223 in
FIG. 2E) in the bottom caps 123 of filter elements 109, through the
corresponding openings in the filter receivers 108, and through the
outlet ports (115 in FIG. 1B) on the adaptor plate 105, and
eventually exiting the filter housing through a outlet pipe 160
that is fluidically connected to the clean fluid outlet nozzle 113
at the bottom of the filter vessel.
[0094] In addition, the increased number of filtered fluid openings
in the adaptor plate effectively reduces the pressure drop across
the filter, therefore also increases the filter efficiency. As well
known in the field, excessive pressure drop adversely affects a
filter's performance. Therefore, by increasing the flow-through
space on the adaptor plate, it is possible to achieve an optimal
level of pressure drop for better filter performance. Additionally,
lower starting pressure drop allows for longer filter life and
lower energy consumption to perform the filtration. Increased
filtration surface allows for higher flow rate, thus enabling
faster pool cleaning.
[0095] As can be seen in FIGS. 3D and 3E, the profile of each
filter element is designed so that the dead space within the filter
housing is kept to a minimum with multiple rectangular shaped
filters. The space not occupied by the filter elements allows the
dirty fluid to flow inside the housing, but does not create
undesirable turbulent flow. The top caps 121 and bottom caps 123 do
not prevent fluid from passing through the longitudinal axis of the
filter media 201. The tapered or trapezoidal shape aids in
providing a flow path to all of the media without creating
turbulent flow. This configuration also maximizes the filtration
surface area provided by each rectangular shape filter element with
the novel configuration of pleated filter media.
[0096] As described herein, the rectangular-shaped filter element
and retrofitting a plurality of rectangular shaped filters in a
cylindrical filter housing to achieve a more efficient filtration
is preferred. However, a wedge-shaped filter element can be used.
The rectangular or wedge-shaped filters can be used in the standard
size cylindrical filter housings as used in filtering pool or spa
water, but can also be manufactured to any size desired. The size
of the filters shown herein is for illustrative purposes. Filter
housings that are manufactured to accommodate cylindrical filters
can be retrofitted to accommodate a plurality of rectangular shaped
filter elements.
[0097] An alternative embodiment using wedge-shaped filter elements
is now described with reference to FIGS. 4A-J. FIG. 4A shows a
perspective view of the alternative wedge-shape filter element 409
of this disclosure. As seen in FIG. 4A, the wedge-shaped filter
element 409 generally comprises a top cap 421 (shown in this view
with a handle 511), a bottom cap 423, and the filter media 501 that
may be pleated and extends from the top cap 421 to the bottom cap
423. Also referring to FIG. 4D, the top and bottom caps may have
curved outer edges 512 and 522 as shown in FIG. 5D and shorter
curved inner edges 513 and 523 respectively. In FIG. 4A part of the
adaptor plate 405 is generally shown that is located inside the
filter vessel on which the wedge-shaped filter element 409 is
mounted is shown and will be discussed in further detail below.
[0098] Referring now to FIG. 4B, which is a cut away
cross-sectional view of the wedge-shaped filter element of this
disclosure, part of the pleated filter media is cut out to view the
perforated support 425. The perforated support 425 is secured to
and extends upwardly from and is secured to an adaptor plate in the
filter vessel. As discussed with regard to FIG. 4D below, the
pleated filter media has a void 530 in the middle where this
perforated support 425 is located for both maintaining the physical
integrity of the filter element, as well as providing flow path for
the filtered fluid within the void in the filter media. The
perforated support 425 can be made of any rigid and light material
to support the overall weight and pressure within the pleated
filter media. Non-limiting examples include plastic, reinforced
plastic, ceramics and metals.
[0099] One layer of pleated media 501 is shown in the cross section
that is part of the continuous pleated media surrounding the
perforated support 425. The bottom cap 423 is shown in cross
section and has an outer lip 424 that extends upward to enclose the
bottom edge of the pleated media 501. The top cap 421 also has an
outer lip 414 that extends downward and encloses the upper edge of
the pleated media 501. The ends of the filter media abuts the
inside of each of the caps and is secured with an adhesive, potting
resin or compounds or any other type of bonding known to those
skilled in the art, or the cap can be formed directly on the
pleated media by a resin or plastic without using any adhesive.
FIGS. 4A and 4B show bottom cap 423 that includes an outlet
connector 525 with O-ring 526. The outlet connector 525 that
extends from bottom cap 423 is sealably received and secured in
filter receiver 408 that is shown as a wedge-shaped lip extending
upwardly from the adaptor plate 405. When the wedge-shaped filter
element is placed over the perforated support 425, the bottom cap
423 is secured on the adaptor plate 405 via the O-ring 228 into the
filter receiver 408, ensuring that the effluent can flow from the
void 430 through the opening in the adaptor plate. Other secure
attachments can be used as well.
[0100] FIG. 4D is a horizontal cross section near the bottom of the
wedge-shaped filter element showing the pleated filter media 501
with the pleat size that increases in width toward the longer end
of the wedge-shaped filter element to increase filtration area and
filtration capacity. In this cross-section, it can be seen that the
pleated filter media 501 can be one or more sheets of filter media
folded continuously around the center forming an central inside
void 430, into which the filtered fluid flows from outside to
inside flow, and the fluid and remains inside the void 430 before
exiting the filter element through an opening 530 in the bottom cap
423. The pleated media extends from the wedged shaped top cap to
the wedge shaped bottom cap with two rows of pleats gradually
decreasing in size from larger to smaller pleats from the outer
side of the wedge to the smaller inner side of the wedge with a
layer of media connecting the outer most largest pleats to the
smallest inner pleats providing a generally central void inside the
pleats.
[0101] Referring now to FIG. 4E, which shows a perspective view of
the inside of the bottom cap 423 and the opening 530 without media.
The bottom cap has an inner lip 524 defining the opening 530 that
the media surrounds. The top cap 421 and bottom cap 423 maintains
the wedge shape of the filter element. The ends of the filter media
abuts the inside of each of the caps and is secured with an
adhesive, potting resin or compounds or any other type of bonding
known to those skilled in the art.
[0102] FIG. 4F is a top perspective view illustration of the
adaptor plate 405 that is securely mounted inside a filter vessel
with eight (8) filter receivers that sealably receive the outlet
connectors 525 on the bottom caps of each of eight (8) wedge shaped
filter elements. There are eight (8) filter receivers 408 that also
define outlet ports 415 for each of the openings 430 in the bottom
caps for the wedge-shaped filter elements.
[0103] FIG. 4G is another embodiment of the outside in flow that
can be adapted for uses including swimming pool filters and other
applications. The filter housing 401 is shown with a series of
wedge-shaped filter elements (one of which is indicated at numeral
408) arranged under a spider plate 441. Instead of or in addition
to the top caps for each of the wedge-shaped filter elements, a
single spider plate 441 is used. The spider plate 441 has a central
hub with radiating arms that are securely placed over each of the
wedge-shaped filter elements inside filter housing. The fluid flow
is outside to inside flow as previously described with respect to
the rectangular shaped filter elements. Typically the filter
housings for swimming pools are in two pieces with the top housing
401a and the bottom portion of the housing 401b that are secured
together in a tight circumferential seal at 401c. The top housing
401a can be removed after the fluid is drained from the housing to
access the filters. The fluid, which in the case of swimming pools
would be water, enters typically through two inlets 411a and 411b
located on the bottom portion of the housing 401b. The water flows
through the wedge shaped filter elements from outside to inside and
is collected in the central voids and the effluent or clean water
flows though the fluid outlets of each wedge shaped filter element
in the bottom cap, one of which is referenced as numeral 423, that
are in communication with the internal void of the wedge shaped
filter elements and also communicate through openings in the
adaptor plate. The wedge-shaped filter element bottom cap is
inserted sealably into bottom cap receiver 408 on the adaptor plate
405, which can be placed closely on top of a separation plate (not
shown) that was previously used for the single cylindrical filter
cartridge. The clean filtered water accumulates under the adaptor
plate 405 and exits the filter housing 401 through outlet 406.
[0104] Table 1 compares various parameters for cellulose pleated
media rectangular shaped filters compared to cylindrical filters in
filter vessels with typical diameters. The data is for cellulose
pleated media, but the results of natural media or synthetic
polyester media are expected to be equivalent and have the same or
similar benefits of cellulose. The rectangular shaped filters are
better in every regard including the number of filters contained in
the vessel, the total filter media surface. The increase in media
surface is proportional to the increase in filter efficiency.
TABLE-US-00001 TABLE 1 Comparison of Rectangular Filter to
Cylindrical Filter Cartridges with Natural Media Cellulose Vessel
Diameter (inches) 18 24 30 36 42 48 Conventional Cylindrical 4 8 13
21 29 37 Filters cartridge per vessel diameter (#) Rectangular
Filters per vessel 6 11 19 30 38 50 diameter (#) Conventional
cylindrical 272 544 884 1428 1972 2516 filter cartridge surface
area (ft.sup.2) Rectangular Filter Surface 750 1375 2375 3750 4750
6250 Area per Vessel Diameter (ft.sup.2) Surface area (ft.sup.2)
increase 176% 153% 169% 163% 141% 148% Rec. Filters over
Cylindrical Filter (%) Surface area (ft.sup.2) increase 2.76x 2.53x
2.69x 2.63x 2.41x 2.48x Rec. Filters over Cylindrical Filter by
multiple (x)
[0105] The same data is presented in Table 2 for pleated
polypropylene media. The same or similar results can be expected
for other synthetic media.
TABLE-US-00002 TABLE 2 Comparison of Rectangular Filter to
Cylindrical Filter Cartridges with Multi-layered Synthetic Media
Vessel Diameter (inches) 18 24 30 36 42 48 Conventional Cylindrical
4 8 13 21 29 37 Filters cartridge per vessel diameter (#)
Rectangular Filters per vessel 6 11 19 30 38 50 diameter (#)
Conventional cylindrical 248 496 806 1302 1798 2294 filter
cartridge surface area (ft.sup.2) Rectangular Filter Surface 507
930 1606 2535 3211 4225 Area per Vessel Diameter (ft.sup.2) Surface
area (ft.sup.2) increase 104% 87% 99% 95% 79% 84% Rec. Filters over
Cylindrical Filter (%) Surface area (ft.sup.2) increase 2.04x 1.87x
1.99x 1.95x 1.79x 1.84x Rec. Filters over Cylindrical Filter by
multiple (x)
[0106] Table 3 shows the filtration performance using the adaptor
plate of this disclosure to install multiple rectangular filters as
compared to conventional cylindrical cartridge filter design of
different length. Specifically, Clean & Clear.RTM. Plus filters
of different lengths as used in conventional pool filter system,
where the numbers denote the length of the filter cartridge. The
results are also shown in FIG. 5.
TABLE-US-00003 TABLE 3 Comparison of filter performance Vessel CCP
CCP Invicta Flow Vessel Filter Filter Invicta Invicta Invicta
Invicta Pentair Rate Cartridge Surface Flux Surface Surface Area
Flux Flux Rate Vessel Rating Length Area Rate Area Area Increase
Rate Reduction Model (gpm) (in) (ft.sup.2) (gpm/ft.sup.2)
(ft.sup.2) (ft.sup.2) (%) (gpm/ft.sup.2) (%) CCP240 90 14.055 240
0.38 56.2 337.3 40.6% 0.267 28.9% CCP320 120 20.000 320 0.38 80.0
480.0 50.0% 0.250 33.3% CCP420 150 26.125 420 0.36 104.5 627.0
49.3% 0.239 33.0% CCP520 150 32.125 520 0.29 128.5 771.0 48.3%
0.195 32.6%
[0107] As can be seen in Table 3 and FIG. 5, the filter system of
this disclosure has 37%, 46%, 45% and 44% surface area increase
comparing to CCP240, CCP320, CCP420 and CCP520, respectively. This
shows that for the same filter housing, by retrofitting with the
adaptor plate and rectangular/wedge shaped filter elements of this
disclosure, a significantly improved filter efficiency can be
achieved.
[0108] There is more than a 50%-75% increased orifice area for
fluid flow for the rectangular shaped filters, which translates
into lower overall differential pressure. The greater
cross-sectional open area in the adaptor plate in the cylindrical
housing using the rectangular element results in lower pressure
drop across the adaptor plate as well as more open area for
additional flow if so desired. A lower starting differential
pressure allows a longer operation cycle between replacing filter
elements. For example, assuming a conventional filter vessel using
circular filter elements where the starting differential pressure
is 5 PSID and the maximum pressure being 35 PSID, this means there
is a 30 PSID window for impurities to accumulate on the filter
media. However, if the starting differential pressure can be
reduced to 2 PSID by the trapezoid shaped filter elements, then the
window is expanded by 3 PSID, which means longer operational life
before the filter elements need to be replaced.
[0109] Table 4 shows the comparison of turnover capacity between
the conventional cylindrical filters (CCP240, CCP320, CCP420,
CCP520 on the left half) and the adaptor manifolds with rectangular
or wedge-shaped filter of this disclosure (Invicta filters on the
right half).
TABLE-US-00004 TABLE 4 Comparison of Turnover Capacity Invicta
Vessel CCP CCP CCP Vessel Invicta Invicta Invicta Invicta Flow
Turnover Turnover Turnover flow Turnover Turnover Turnover Turnover
Pentair Rate Capacity Capacity Capacity rate Capacity Capacity
Capacity Capacity Vessel Rating (gallons) (gallons) (gallons)
rating (gallons) (gallons) (gallons) increase Model (gpm) 8 hours
10 hours 12 hours (gpm) 8 hour 10 hours 12 hours (%) CCP240 90
43,200 54,000 64,800 126 60,718 75,897 91,076 40.55% CCP320 120
57,600 72,000 86,400 180 86,400 108,000 129,600 50% CCP420 150
72,000 90,000 108,000 235 112,860 141,075 169,290 56.75% CCP520 150
72,000 90,000 108,000 289 138,780 173,475 208,170 92.75%
[0110] As can be seen in Table 4, the turnover capacity using the
adaptor manifold and rectangular/wedge shaped filter of this
disclosure has at least 40.55% increase over the conventional
cylindrical filters, and can have as much as 92.75% increase,
almost doubling the turnover capacity in the CCP520 vessel model.
This increase in turnover capacity again indicates that the adaptor
manifold and rectangular/wedge shaped filters of this disclosure
can provide more efficient filtration for pool and spa
applications. Additionally, a smaller vessel can be used for a
larger pool. For example. A CCP320 vessel with Invicta can be used
in place of the larger CCP420 vessel while still providing equal or
greater performance as compared to the conventional cylindrical
filter design.
[0111] The differential pressure is the main driving force for
fluid flow inside the filter housing. The fluid would flow along
the path of least resistance, which generally starts at the bottom
of the filter elements as the filter vessel fills up with fluid.
This fluid flow continues, but as the filter media accumulates
impurities toward the bottom of the filter element, the
differential pressure at that location increases as well. As soon
as the differential pressure is higher than other parts of the
filter element, fluid flow would change direction to the lowest
resistance, even if the differential is only 0.01 PSI. This dynamic
fluid flow, along with the more compact interior inside the filter
housing allows less turbulent flow, more even flow throughout the
entire filter element and surface area at one time. The additional
surface area provided by this novel shape reduces the face velocity
of the fluid through the filter media. This lower face velocity
results in less resistance or pressure drop across the media
allowing for the lower pressure drop and increased dirt and
particulate loading capacity in the filter elements. The benefits
in additional dirt and particulate holding capacity is due to lower
face velocities that are understood by one skilled in the art.
[0112] For example, Darcy's law provides that flux rate (J) is used
to measure a filter's efficiency, being defined as
J = .DELTA. P ( R m + R c ) .mu. ##EQU00001##
in which: J: liquid flux .DELTA.P: trans-filter media pressure Rm:
resistance of the filter media Rc: resistance of the filter cake
.mu.: liquid viscosity
[0113] NSF is the regulatory agency for pool and spa filters, and
NSF 50 is the standard for design and testing the filters. NSF 50
dictates a maximum flux rate of 0.375 gpm/sq ft. It is known that
the lower the flux rate, the less energy is required to drive the
fluid through the filter due to the lower pressure loss across the
filter. Lowering the flux rate can also increase life of the
filter. Alternatively, if one opts to increase the flux rate of the
filter system of this disclosure up to the maximum 0.375
gpm/ft.sup.2, the footprint and size of the filter housing can be
reduced.
[0114] As shown in Table. 3, the filter system of this disclosure
also has 28.9%, 33%, 33%, and 32.6% flux rate reduction comparing
to CCP240, CCP320, CCP420 and CCP520, respectively. This again
shows the retrofitting filter system of this disclosure provides
better filtration efficiency as compared to the conventional pool
filter system.
[0115] Another advantage of the disclosure is the possibility of
having a lower profile filter vessel that will be more attractive
in a garden setting that is often the setting of a pool or spa. The
more efficient filtration would allow for the use of a shorter
filter vessel that has the filtration capability of a taller
conventional filter. The shorted filter vessel can be placed more
easily behind shrubbery or landscaping features. Also, the short
filter vessel will be easier to access. Moreover, the use of guide
supports with the filter elements allows for the possibility to
configure the filter housing horizontally if desired.
* * * * *