Channel flow filter

Details Channel flow filter Channel flow filter

1999-08-13

2001-08-14

Spitzer, Robert H. (Department: 1724)

Gas separation: processes

Solid sorption

C095S143000, C096S135000, C096S153000, C096S154000, C055S497000, C055S514000, C055S521000, C055S528000, C055SDIG005

Reexamination Certificate

active

06273938

ABSTRACT:

FIELD OF THE INVENTION
The present invention relates to multi-layer filtration media having a plurality of continuous, tortuous channels.
BACKGROUND OF THE INVENTION
Filter structure for the removal of undesirable elements from a fluid or vapor has developed through the years to take advantage of newly developed materials and techniques. The introduction of non-woven webs as filter material subsequently led to the formation of pleated and corrugated structures from the non-woven materials in order to increase the surface area of the filter material exposed to the fluid, as well as decrease the pressure drop or resistance as the fluid passed through the material. Numerous techniques for the corrugation and use of corrugated non-woven webs have been developed as described, for example, in U.S. Pat. No. 5,753,343 (Braun et al.), including stacking of multiple layers of corrugated and non-corrugated material. In such previously developed examples, emphasis has typically been on increased surface area by using corrugations or channels formed from the filter material to pass straight across or through the ultimate filter.
Although improvements have been made to increase filter efficiency and decrease filter pressure drop or resistance, an ongoing need exists to still further provide improvements in these areas. Additionally, the development of new and different filter materials presents an ongoing challenge to utilize such materials effectively to produce efficient and cost effective filter applications. Further, improved adsorbent filters with increased efficiency at a desired pressure drop, or reduced pressure drop at a desired efficiency are also needed.
BRIEF SUMMARY OF THE INVENTION
The present invention meets the ongoing need for improvements in filter efficiency and pressure drop by providing filtration media possessing high efficiency and low pressure drop. The filtration medium includes a plurality of filtration layers at least some of which have a multi-dimensional channel pattern formed therein. The channel pattern includes a plurality of continuous, non-straight or tortuous channels formed across the filtration layer and a multi-dimensional edge at each end of the plurality of channels. The filtration medium may be configured as a stack of the filtration layers with the channel pattern and multi-dimensional edges forming a plurality of inlets open through a first face of the stack, a plurality of outlets open through a second face of the stack, and a corresponding plurality of disruptive fluid pathways passing from the inlets through the stack to the outlets.
Each channel of the plurality of channels may be formed as a smoothly undulating curve that is parallel to the other channels of the pattern. The plurality of channels may be formed with a radiused cross-section producing the multi-dimensional edge as a smoothly undulating curve. Alternatively, the channels may be formed as irregular, non-parallel curves. For example, the shape of a channel and the cross-sectional area of that channel may vary along its length. Additionally, the shape and cross-section of channels on a single layer of filtration media, or adjacent layers of media, can also vary. The channels may be formed by embossing, molding or other suitable methods.
The first and second faces of the filtration media may be opposite one another, adjacent one another, or may include a third face. The faces may be parallel or non-parallel as needed for a particular filter application. The filtration layers may include some layers having the channel pattern formed therein and some layers without a channel pattern formed therein, such as a planar sheet. These layers may be alternated when stacked to produce the filtration medium.
The filtration medium may be formed from various types of filtration material, including non-woven material and particulate loaded material. In one embodiment, a carbon loaded multi-layer BMF web formed the filtration layer producing a filtration medium capable of removing undesirable vapors and odors from a fluid.
The filtration medium of the present invention is highly versatile, allowing for numerous variations in channel configurations, layer configurations and stack configurations to produce a filter having the desired characteristics for a filter application. In addition, the filtration medium of the present invention may be formed with an efficiency similar to a conventional filter, but with a much lower pressure drop, or may be formed with a pressure drop similar to a conventional filter but with a much higher efficiency.


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