Deionization filter assembly adopting cylinder-in-cylinder design

Abstract

The deionization filter assembly comprises an outer cylinder, an inner cylinder, an end cover and a screen. The outer cylinder includes a first outer end portion and a second outer end portion, and the outer cylinder is configured to receive an outer resin bed. The inner barrel may be positioned within the outer barrel and include a first inner end and a second inner end. The inner cylinder is configured to accommodate an inner resin bed. An end cap may be positioned along a first outer end of the outer barrel and a first inner end of the inner barrel, and the end cap includes an inlet and an outlet. A screen may be positioned between the end cap and the outer and inner barrels.

Description

Cross-references to related patent applications

[0001] This application claims the benefit and priority of Indian Provisional Patent Application No. 202241037391, filed on June 29, 2022, entitled “DEIONIZATION FILTER ASSEMBLY WITH CYLINDER-IN-CYLINDER DESIGN,” the contents of which are incorporated herein by reference in their entirety. field

[0002] The present application relates generally to deionization filter assemblies for removing ions from a fluid. background

[0003] In fuel cell systems, neutralization of ions within coolant can improve the lifetime of the coolant and the fuel cells cooled by the coolant. However, ion exchange resin-based deionization filters can suffer from high pressure drop due to resin bed design and resin underutilization due to suboptimal filter design. Overview

[0004] Various embodiments provide a deionizing filter assembly, which includes an outer cylinder, an inner cylinder, an end cap, and a screen. The outer cylinder includes a first outer end and a second outer end, and the outer cylinder is configured to accommodate an outer resin bed. The inner cylinder can be positioned within the outer cylinder and includes a first inner end and a second inner end. The inner cylinder is configured to accommodate an inner resin bed. The end cap can be positioned along the first outer end of the outer cylinder and the first inner end of the inner cylinder, and the end cap includes an inlet and an outlet. The screen can be positioned between the end cap and the outer cylinder and the inner cylinder.

[0005] Another embodiment of the present disclosure relates to a deionizing filter assembly, which includes an outer barrel, an inner barrel, an outer resin bed, and an inner resin bed. The outer barrel defines an open end and a closed end. The inner barrel is positioned within the outer barrel and radially spaced from the outer barrel to define an annulus between the inner barrel and the outer barrel. The inner barrel defines an inner cavity that is fluidly coupled to the annulus at the closed end of the outer barrel. The outer resin bed is contained within the annular space, and the inner resin bed is contained within the inner cavity.

[0006] Another embodiment of the present disclosure is directed to a method of assembling a deionizing filter assembly. The method includes positioning an inner barrel within an outer barrel to define an annular space between the inner barrel and the outer barrel, and fluidly coupling the annular space to an inner cavity of the inner barrel at a closed end of the outer barrel. The method also includes placing an inner resin bed within the inner cavity and placing an outer resin bed within the annular space.

[0007] These and other features, together with the organization and manner of operation thereof, will become apparent from the following detailed description when taken in conjunction with the accompanying drawings, wherein like elements have like reference numerals throughout the several figures described below. BRIEF DESCRIPTION OF THE DRAWINGS

[0008] Figure 1 is a cross-sectional perspective view of a deionization (DI) filter assembly according to an embodiment.

[0009] Figure 2 yes Figure 1 Exploded view of the DI filter assembly.

[0010] Figure 3 yes Figure 1 A cross-sectional perspective view of the outer and inner barrels of a DI filter assembly.

[0011] Figure 4 yes Figure 1 A perspective view of the screen of a DI filter assembly.

[0012] Figure 5 yes Figure 1 Cross-sectional view of the end cap of a DI filter assembly.

[0013] Fig. 6A is shown positioned within the coolant system Figure 1 Schematic diagram of the DI filter assembly.

[0014] Figure 6B yes Fig. 6A Schematic diagram of the DI filter assembly.

[0015] Figure 7 is a flow chart of a method of assembling a DI filter assembly according to an embodiment. Detailed Description

[0016] Referring generally to the accompanying drawings, various embodiments disclosed herein relate to a deionizing filter assembly that uses ion exchange resins as the primary method for removing organic, inorganic, metallic, and non-metallic ions from a fluid (e.g., a coolant). Since ion exchange resins can be expensive, it is beneficial to fully utilize the full resin capacity before discarding or regenerating the resin. As further described herein, various embodiments of the deionizing filter assembly described herein can (i) maximize or otherwise increase the capacity and utilization of the ion exchange resin, and (ii) reduce pressure drop compared to various conventional deionizing filters.

[0017] Example Deionization Filter Assembly Figure 1 A deionization (DI) filter assembly 10 for removing ions from a fluid is shown according to an example embodiment. The fluid may be, for example, a coolant or water. The coolant may be part of a fuel cell system or similar system using a low conductivity solution.

[0018] The DI filter assembly 10 includes an outer cylinder 20, an inner cylinder 40, a screen 60 and an end cap 80. Optionally, the DI filter assembly 10 may further include a pressure release mechanism 90, such as Figure 6B Further details are given in Figure 1 In the embodiment of the present invention, the outer barrel 20 and the inner barrel 40 are concentric (i.e., the inner barrel 40 is positioned and contained within the outer barrel 20 and shares the same central axis with the outer barrel 20), thereby forming a barrel-in-barrel design of the DI filter assembly 10. The outer barrel 20 and the inner barrel 40 are connected together by a single end cap (i.e., end cap 80) and a single screen (i.e., screen 60). The configuration of the inlet 81 of the end cap 80 (particularly, the inlet 81 is tangentially positioned relative to the outer barrel 20) guides the fluid 19 to flow tangentially into the outer barrel 20. The configuration of the outlet 82 of the end cap 80 (particularly, the taper of the outlet 82) reduces pressure loss.

[0019] The outer barrel 20 includes an outer resin cartridge or bed 32 and is configured to accommodate the outer resin cartridge or bed 32. The outer resin bed 32 is positioned in the annular space 30 (i.e., the area radially located between the outer barrel 20 and the inner barrel 40). The annular space 30 is filled with the outer resin bed 32 (in a uniformly distributed manner in a specific embodiment). Optionally, the outer resin bed 32 can extend along the entire height of the inner side of the outer barrel 20.

[0020] The inner barrel 40 includes an inner resin box or bed 52 and is configured to accommodate the inner resin box or bed 52. The inner barrel 40 defines an inner cavity 34 filled with the inner resin bed 52 (in a uniformly distributed manner in certain embodiments). The inner resin bed 52 may optionally extend along the entire height of the inner side of the inner barrel 40. Figure 1In the embodiment of the present invention, the height 39 of the annular space 30 and the inner barrel 40 is approximately equal to the height 43 of the inner cavity 34 (e.g., the inner barrel 40 extends along the entire height of the annular space 30). The inner cavity 34 is fluidly coupled to the annular space 30 through a passage at the second outer end 22 (e.g., the closed end) of the outer barrel 20. The passage connecting the annular space 30 and the inner region of the inner barrel 40 also accommodates a uniform distribution of resin from the resin bed (e.g., from the outer resin bed 32 and / or from the inner resin bed 52).

[0021] The outer resin bed 32 and the inner resin bed 52 each include an ion exchange resin including both an anion resin and a cation resin in a predetermined mixing ratio. Each of the outer resin bed 32 and the inner resin bed 52 includes a plurality of resin beads. The outer resin bed 32 and the inner resin bed 52 (or the outer cartridge 20 and the inner cartridge 40) can be optionally removed and replaced from the rest of the DI filter assembly 10.

[0022] like Figure 1 As shown, fluid 19 flows tangentially into DI filter assembly 10 through inlet 81 of end cap 80, flows axially downward through screen 60 and into outer resin bed 32 and through annular space 30, flows radially inward through passages connecting outer resin bed 32 and inner resin bed 52, flows axially upward through inner resin bed 52 within inner barrel 40 (thereby making a 180° turn as the fluid moves between outer resin bed 32 and inner resin bed 52), and flows axially upward back through screen 60 and through outlet 82 of end cap 80. Thus, during operation, the flow direction of the fluid completely changes its axial direction (i.e., approximately 180°) within outer barrel 20. Each of these components is further described herein.

[0023] The outer cylinder 20, the inner cylinder 40, the screen 60 and the end cap 80 are assembled together (eg, by adhesive (eg, glue) or by threads (on each of the components) (eg, Figure 1 As shown in FIG. 1 ), to form at least one filter assembly seal. Figure 1 As shown, an outer seal is formed between the outer protrusion 29 of the outer barrel 20, the outer impression 64 of the screen 60, and the end cap outer circumferential wall 84 of the end cap 80. An inner seal is formed between the inner protrusion 49 of the inner barrel 40, the inner impression 66 of the screen 60, and the end cap inner circumferential wall 86 of the end cap 80. Each of these components is further described herein. The outer seal and the inner seal prevent fluid (e.g., coolant) or resin beads from leaking out of the DI filter assembly 10, prevent resin beads from escaping from the DI filter into the coolant circuit, prevent resin beads from migrating between the outer barrel 20 and the inner barrel 40 (through the first outer end 21 and the first inner end 41), and fluidly separate the inlet 81 and the outlet 82 of the end cap 80 when assembled.

[0024] The DI filter assembly 10 can be mounted, for example, using a C clamp or using a dedicated backing plate with bolt features. It should be understood that other mounting methods can be used in various embodiments. The orientation of the DI filter assembly 10 within the fuel cell system can be in any direction because the ribs 46 (as further described herein) and the overall geometry and design features of the DI filter assembly 10 ensure that flow bypass is not generated.

[0025] Example outer cylinder like Figure 1 and Figure 3 As shown, the outer barrel 20 surrounds, contains and encloses the inner barrel 40. As further described herein, the inner barrel 40 is radially spaced from the outer barrel 20, thereby forming an inner region referred to herein as the annular space 30. Figure 1 As shown, the annular space 30 is radially positioned between the outer cylinder 20 and the inner cylinder 40 to allow fluid to flow in the annular space 30 .

[0026] like Figure 1-Figure 3 As shown, the outer cylinder 20 includes a first outer end 21 (e.g., a first outer axial end, an outer open end, etc.) and a second outer end 22 (e.g., a second outer axial end and an outer closed end, etc.) and extends axially between the first outer end 21 and the second outer end 22. Figure 3 As shown, the first outer end 21 of the outer cylinder 20 is open to the fluid flowing through the outer cylinder 20, so that the fluid can flow into and out of the outer cylinder 20 through the first outer end 21. The second outer end 22 of the outer cylinder 20 is closed to the fluid flowing through the outer cylinder 20, so that the fluid cannot flow into or out of the outer cylinder 20 through the second outer end 22.

[0027] The outer barrel 20 includes an outer barrel circumferential wall 24 extending circumferentially around the central axis 36 of the DI filter assembly 10 and around the inner barrel 40. The outer barrel circumferential wall 24 extends axially between the first outer end 21 and the second outer end 22. The outer barrel 20 also includes a lower wall 23 positioned along the second outer end 22 of the outer barrel 20 and closing the second outer end 22 of the outer barrel 20.

[0028] like Figure 1-Figure 3 As shown, the outer cylinder 20 includes an outer protrusion 29 along the first outer end 21 of the outer cylinder circumferential wall 24. The outer protrusion 29 (e.g., an outer radial protrusion, etc.) is positioned along the outer surface of the outer cylinder circumferential wall 24 and extends radially outward from the outer surface of the outer cylinder circumferential wall 24 along the peripheral edge of the outer cylinder circumferential wall 24 at the first outer end 21. Figure 1As shown, the outer protrusion 29 defines an outer groove 28 along the first outer end 21, which is configured to receive the outer stamping portion 64 of the screen 60, the lower extension 89 of the end cover 80, and a gasket (not shown) or other sealing member to form an outer seal between the outer cylinder 20, the screen 60 and the end cover 80.

[0029] Example inner cylinder like Figure 1 and Figure 3 As shown, the inner cylinder 40 is positioned, received and mounted within the outer cylinder 20 such that the inner cylinder 40 and the outer cylinder 20 are concentric with each other in a cylinder-in-cylinder arrangement. The cylinder-in-cylinder arrangement increases the effective resin bed height of the DI filter assembly 10. For example, compared with Figure 1 Compared to various conventional axial flow DI filter assemblies of approximately the same package height, the diameter of the DI filter assembly 10 is slightly larger, but because the fluid flows through the outer barrel 20 and then flows through the inner barrel 40 in the opposite direction (and through the annular space 30 along a first path that is substantially the same height as the second path through the lumen 34), the effective height of the resin bed is effectively doubled. Compared to various conventional axial flow DI filter assemblies having approximately the same effective height of the resin bed, the overall package height of the DI filter assembly 10 is significantly smaller, and the overall diameter of the DI filter assembly 10 is only slightly increased. The diameters of the outer barrel 20 and the inner barrel 40 are sized so that the cross-sectional flow area of ​​the inner barrel 40 (e.g., the lumen 34) is approximately equal to the cross-sectional flow area of ​​the annular space 30.

[0030] like Figure 1-Figure 3 As shown, the inner cylinder 40 includes a first inner end 41 and a second inner end 42 and extends axially between the first inner end 41 and the second inner end 42. Figure 1 As shown, both the first inner end 41 and the second inner end 42 of the inner barrel 40 are open, so that fluid can flow into the inner barrel 40 through the second inner end 42 and flow out of the inner barrel 40 through the first inner end 41 .

[0031] The inner barrel 40 includes an inner barrel circumferential wall 44 that extends circumferentially around the central axis 36 of the DI filter assembly 10 and extends substantially parallel to (and within) the outer barrel circumferential wall 24. The inner barrel circumferential wall 44 is open to fluid flowing axially through the inner barrel circumferential wall 44 from the second inner end 42 and through the first inner end 41. Figure 1-Figure 3 As shown, the inner barrel 40 includes an inner protrusion 49 along the first inner end 41 of the inner barrel circumferential wall 44. The inner protrusion 49 (e.g., inner radial protrusion, etc.) is positioned along the outer surface of the inner barrel circumferential wall 44 and extends radially outward from the outer surface of the inner barrel circumferential wall 44 along the peripheral edge of the inner barrel circumferential wall 44 at the first inner end 41. Figure 1As shown, the inner protrusion 49 defines an inner groove 48 along the first inner end 41, which is configured to receive the inner embossing portion 66 of the screen 60, the lower end of the end cover inner circumferential wall 86 of the end cover 80, and a gasket (not shown) to form a sealing portion between the inner cylinder 40, the screen 60 and the end cover 80.

[0032] exist Figure 1 In the depicted embodiment, the inner cylinder 40 extends along the entire inner length of the outer cylinder 20. In particular, the inner cylinder 40 extends between the inner surface of the lower wall 23 of the outer cylinder 20 and the first outer end 21 of the outer cylinder 20. In order to maintain the position of the inner cylinder 40 within the outer cylinder 20, the inner cylinder 40 includes at least one inner cylinder rib 46 (preferably a plurality of ribs 46), such as Figure 1-Figure 3 In one embodiment, the ribs 46 are radially spaced apart from one another around the outer surface of the inner barrel circumferential wall 44. The ribs 46 extend axially along the entire axial length of the inner barrel 40 between the first inner end 41 and the second inner end 42.

[0033] like Figure 1-Figure 3 As shown, each of the ribs 46 includes an axial rib portion 45 and an elevation rib portion 47. In other embodiments, the axial rib portion 45 can be formed by a separate rib that is separate from the elevation rib portion 47. The axial rib portion 45 (e.g., axial ribs, etc.) helps maintain the concentricity of the inner barrel 40 and the outer barrel 20. The axial rib portion 45 extends radially outward from the outer surface of the inner barrel circumferential wall 44 and is sized and configured to abut the inner surface of the outer barrel circumferential wall 24 (when assembled). The axial rib portion 45 radially spaces the inner barrel circumferential wall 44 and the outer barrel circumferential wall 24 to form the annular space 30.

[0034] The raised rib portion 47 (e.g., a raised rib, etc.) extends axially downward from the bottom of the inner barrel circumferential wall 44 (along the second inner end portion 42) and is sized and configured to abut the inner (upper) surface of the lower wall 23 of the outer barrel 20 (when assembled). Thus, the raised rib portion 47 axially spaces the inner barrel circumferential wall 44 from the inner surface of the lower wall 23 of the outer barrel 20 (axially raises the inner barrel circumferential wall 44 above the inner surface of the lower wall 23 of the outer barrel 20) to form a flow channel connecting the outer resin bed 32 in the annular space 30 and the inner resin bed 52 in the inner region of the inner barrel 40, as shown in FIG. Figure 1 and Figure 3 shown.

[0035] The height of the raised rib portion 47 (i.e., the distance between the bottom of the inner barrel circumferential wall 44 and the opposite end of the raised rib portion 47) is sized so that the cylindrical flow area formed between the annular space 30 and the inner cavity 34 (due to the raised rib portion 47) is approximately equal to or slightly larger than the cross-sectional area of ​​the inner barrel circumferential wall 44. This arrangement reduces flow restriction at the transition between the annular space 30 and the inner cavity 34.

[0036] Example Screen The screen 60 traps the resin beads of the outer resin bed 32 and the inner resin bed 52 within the outer cylinder 20 and the inner cylinder 40 during coolant flow. The screen 60 is inert to ions and fluids (e.g., coolant). The screen 60 can diffuse any eddy currents from the tangential inlet of the fluid before the fluid enters the outer resin bed 32, which can improve flow performance in some cases. According to various embodiments, the screen 60 is a wire mesh screen.

[0037] like Figure 1 As shown, a mesh or screen 60 may be positioned axially between the inner and outer barrels 20, 40 and the end cap 80. In particular, the screen 60 may be positioned along the first outer end 21 of the outer barrel 20 and the first inner end 41 of the inner barrel 40 and along the bottom side of the end cap 80.

[0038] The screen 60 covers the entire first outer end 21 of the outer barrel 20 and the entire first inner end 41 of the inner barrel 40. Since the outer barrel 20 is closed along the second outer end 22 (having the lower wall 23), the DI filter assembly 10 includes only one single screen (i.e., the screen 60) shared between the inlet end and the outlet end of the combined resin bed. By using a single screen 60 for both the outer barrel 20 and the inner barrel 40, the DI filter assembly 10 forms a less complex seal between the inlet and outlet sides of the outer resin bed 32 and the inner resin bed 52.

[0039] In one embodiment, the screen 60 comprises a single piece that covers the entire first outer end 21 of the outer barrel 20. In other embodiments, the screen 60 comprises two screen portions separated from each other, wherein the first screen covers the end of the annular space 30 (along the first outer end 21) and the second screen covers the first inner end 41 of the inner barrel 40. In various embodiments, the open area of ​​the screen 60 (i.e., the open area between two wires of the screen 60 or both the first screen and the second screen) is at least 50% smaller than the smallest resin bead in the outer resin bed 32 and the inner resin bed 52, which can prevent the loss of resin beads from the DI filter assembly 10 during operation.

[0040] like Figure 1 and Figure 4As shown, the screen 60 includes an outer embossed portion 64 and an inner embossed portion 66. Figure 1 As shown, the outer stamping 64 is sized and positioned to be received within the outer groove 28 and to form a seal with the outer protrusion 29 of the outer barrel 20. The inner stamping 66 is sized and positioned to be received within the inner groove 48 and to form a seal with the inner protrusion 49 of the inner barrel 40. The outer stamping 64 and the inner stamping 66 may each have a U-shaped or V-shaped cross-section extending circumferentially around the central axis 36, depending on the desired configuration and assembly process.

[0041] like Figure 4 As shown, the screen 60 is continuous in the area defined by the outer embossing 64. Thus, the screen 60 extends radially between the outer embossing 64 and the inner embossing 66 and is continuous between the outer embossing 64 and the inner embossing 66. In addition, the inner area defined by the inner embossing 66 is completely filled by the screen 60.

[0042] Example End Cap like Figure 1 As shown, the end cap 80 is axially positioned on top of the screen 60 and is positioned along the first outer end 21 of the outer barrel 20 and the first inner end 41 of the inner barrel 40 to join the outer barrel 20 and the inner barrel 40 together. Since the outer barrel 20 is closed along the second outer end 22 (having the lower wall 23), the DI filter assembly 10 includes only a single end cap (i.e., the end cap 80).

[0043] like Figure 1 and Figure 5 As shown, the end cap 80 includes an inlet 81 (e.g., an inlet channel) and an outlet 82 (e.g., an outlet channel), and the fluid flows into the DI filter assembly 10 (e.g., into the annular space 30) through the inlet 81, and the fluid flows out of the DI filter assembly 10 (e.g., from the inner cavity 34) through the outlet 82. The inlet 81 and the outlet 82 can have internal or external threads, or can be quickly connected using a tube and a clamp. In other embodiments, a different connection mechanism is used to fix the tube to the inlet 81 and / or the outlet 82. The end cap 80 positions the inlet 81 and the outlet 82 on the same side of the outer barrel 20 and the inner barrel 40 (i.e., along the first outer end 21 and the first inner end 41).

[0044] like Figure 1 As shown, the end cap 80 includes an end cap outer circumferential wall 84 that is radially aligned with the outer barrel circumferential wall 24 of the outer barrel 20 and extends circumferentially around the center of the end cap 80 (particularly around the end cap inner circumferential wall 86). Figure 1 and Figure 5As shown, the end cap 80 includes an end cap inner circumferential wall 86 (e.g., a partition wall) that fluidly separates the inlet 81 and the outlet 82. The end cap inner circumferential wall 86 is positioned within and surrounded by the end cap outer circumferential wall 84. The lower portion of the end cap inner circumferential wall 86 is configured to be received within the inner groove 48 of the inner barrel 40 and the inner embossing portion 66 of the screen 60, and when assembled with the inner barrel 40 and the screen 60, the lower portion of the end cap inner circumferential wall 86 forms a seal with the inner surface of the inner protrusion 49 and the inner embossing portion 66.

[0045] like Figure 5 As shown, the end cap 80 includes an upper wall 83 located along the top end portion of the end cap outer circumferential wall 84 and the top end portion of the end cap inner circumferential wall 86. Therefore, the end cap outer circumferential wall 84 and the end cap inner circumferential wall 86 each extend from the inner (bottom) surface of the upper wall 83 of the end cap 80. The upper wall 83 extends radially between the end cap outer circumferential wall 84 and the end cap inner circumferential wall 86.

[0046] like Figure 1 As shown, the inlet 81 of the end cap 80 extends tangentially to the end cap outer circumferential wall 84, thereby directing the fluid entering the DI filter assembly 10 to flow tangentially into the screen 60 and the outer resin bed 32 in the outer barrel 20. By directing the fluid to enter the DI filter assembly 10 tangentially, the fluid 19 is uniformly and evenly distributed at the inlet 81 to flow to and throughout the outer barrel 20, thereby ensuring that the fluid 19 flows uniformly through the annular space 30 and the outer resin bed 32 (and subsequently into the inner barrel 40) and improving resin utilization.

[0047] like Figure 5 As shown, the outlet 82 of the end cap 80 is positioned at the radial center of the end cap 80 so that the outlet 82 is concentric with the outer barrel 20 and the inner barrel 40. The central axis (e.g., central axis 36) of the outlet 82 is oriented (e.g., rotated) to be offset by about 90° relative to the central axis of the inlet 81. The inner surface 38 of the outlet 82 is formed from the top end portion (e.g., Figure 1 The first inner end portion 41 in the end cap extends radially inwardly and is continuous, streamlined, and axially tapers from the inner circumferential wall 86 of the end cap to have a gradual profile. Through the gradual profile of the outlet 82, the outlet 82 is a fluid (e.g., Figure 1 The flow of the fluid 19 in the inner cylinder (eg, Figure 1 The transition from the width of the inner cavity 34 in the outlet 82 to the width of the outlet 82 becomes smooth. The taper of the outlet 82 allows for uniform flow distribution at the portion of the inner resin bed 52 near the outlet 82, reduces the total pressure drop or loss on the inner resin bed 52 at the outlet 82, and ensures that the inner resin bed 52 near the outlet 82 is fully utilized.

[0048] like Figure 1 and Figure 5 As further shown in FIG. 1 , the end cap 80 includes at least one end cap rib 88 to support the screen 60. Preferably, the end cap 80 includes a plurality of end cap ribs 88 forming an end cap rib structure. The end cap rib 88 is positioned within the outlet 82 and extends axially downward from the inner surface of the outlet 82 and radially inward from the inner surface of the end cap inner circumferential wall 86. The end cap ribs 88 are spaced apart from each other in the center of the end cap 80.

[0049] like Figure 1 and Figure 5 As shown, the end cap 80 includes an outer lip 87 extending radially outward from the outer surface of the end cap outer circumferential wall 84 (along the lower end of the end cap outer circumferential wall 84, opposite to the upper wall 83). When assembled with the outer barrel 20, the outer lip 87 extends radially over the entire outer groove 28 formed by the outer protrusion 29 of the outer barrel 20.

[0050] The end cap 80 also includes a lower extension 89 extending axially downward from the bottom surface of the outer lip 87 and positioned radially outward relative to the end cap outer circumferential wall 84. The lower extension 89 can be received within the outer groove 28 of the outer barrel 20 and the outer stamping 64 of the screen 60, and when assembled with the outer barrel 20 and the screen 60, the lower extension 89 forms a seal with the inner surface of the outer protrusion 29 and the outer stamping 64. In some embodiments, the DI filter assembly 10 includes a sealing member (e.g., a gasket, an O-ring, etc.) disposed within the inner surface of the outer protrusion 29 to facilitate sealing between the screen 60, the outer barrel 20, and the inner barrel 40.

[0051] Example Pressure Relief Mechanism like Fig. 6A As shown, in one embodiment, the DI filter assembly 10 is positioned downstream of the coolant pump 96 and upstream of the fuel cell stack 98. According to some embodiments, the DI filter assembly 10 includes a pressure relief mechanism 90, such as Figure 6B A flow bypass or pressure relief valve or mechanism 90 may be positioned within the end cap 80. The pressure relief mechanism 90 may be, for example, a simple orifice, a spring loaded valve, an umbrella valve, or a duckbill valve.

[0052] In one embodiment, the pressure relief mechanism 90 is mounted directly into the main coolant line and is positioned in series with the fuel cell stack 98. The pressure relief mechanism 90 is configured to bypass any excess flow to the fuel cell stack and allow only a portion of the coolant flow (which is appropriate for the design based on the cross-sectional flow area and / or porosity of the resin bed, for example) to flow through the outer resin bed 32 and the inner resin bed 52. The pressure relief mechanism 90 effectively controls the flow rate of the fluid through the outer resin bed 32 and the inner resin bed 52, and can be configured to provide an optimized flow rate through the DI filter assembly 10 that maximizes the ion exchange capacity.

[0053] The pressure relief mechanism 90 is configured to reduce the risk of resin overpacking, which can result in high pressure pulses that can degrade the performance of the DI filter assembly 10. In certain embodiments, the pressure relief mechanism 90 is configured to bypass the fluid flow between the inlet 81 and the outlet 82 when the applied pressure through the resin bed in the axial direction (e.g., through the resin bed in the flow direction, etc.) is greater than or equal to a bypass threshold pressure (e.g., about 2 bar, etc.) to avoid resin overloading, which can increase the pressure drop variation across the resin bed and reduce resin utilization. Resin overpacking occurs when the upstream fluid pressure of the fluid compresses the outer resin bed 32 or the inner resin bed 52 and increases the packing density (or reduces the porosity) of the outer resin bed 32 or the inner resin bed 52. Increasing the loading density increases the resistance to the flow of the fluid (e.g., coolant), thereby reducing the amount of fluid flow that can pass through the DI filter assembly 10.

[0054] Example method to assemble a DI filter assembly refer to Figure 7 , shows a method 100 of assembling a DI filter assembly according to an embodiment. The method 100 may be used to form Figure 1 DI filter assembly 10. In other embodiments, method 100 may include additional, fewer, and / or different operations.

[0055] Operation 102 includes positioning the inner barrel within the outer barrel to define an annular space between the inner barrel and the outer barrel. Operation 102 includes positioning the inner barrel within the outer barrel so that the annular space is fluidly coupled to the inner cavity of the inner barrel. In one embodiment, operation 102 includes coaxially aligning the inner barrel with the outer barrel by engaging at least one axial rib of the inner barrel with the inner wall of the outer barrel's outer barrel circumferential wall (or engaging at least one axial rib of the outer barrel with the outer surface of the inner barrel's inner barrel circumferential wall). In one embodiment, operation 102 includes engaging at least one rib of the inner barrel (e.g., a raised rib, a raised rib portion of an axial rib, etc.) extending axially away from the inner barrel's inner barrel circumferential wall at the closed end of the outer barrel with the lower wall of the outer barrel so that the inner barrel circumferential wall is axially spaced from the lower wall.

[0056] Operation 104 includes placing an inner resin bed within the inner cavity. In one embodiment, operation 104 includes inserting a wire mesh containing resin beads into the inner cavity of the inner barrel such that the inner resin bed completely fills the inner cavity of the inner barrel.

[0057] Operation 106 includes placing an outer resin bed in the annular space between the inner barrel and the outer barrel. In one embodiment, operation 106 includes inserting a wire mesh containing resin beads into the annular space to completely fill the annular space. In some embodiments, operation 106 includes inserting the inner resin bed into the outer barrel simultaneously with the outer resin bed (e.g., with the inner barrel, etc.).

[0058] Operation 108 includes placing a screen on the inner and outer cylinders at the open end of the outer cylinder. In one embodiment, operation 108 includes inserting the outer embossing portion of the screen into the outer groove formed in the outer cylinder, and inserting the inner embossing portion of the screen into the inner groove of the inner cylinder. In some embodiments, operation 108 includes sealingly engaging the screen with the inner and outer cylinders. In other embodiments, operation 108 includes inserting a first screen into the inner cylinder and inserting a second screen separated from the first screen into the outer cylinder.

[0059] Operation 110 includes coupling the end cap to the inner barrel and the outer barrel such that the screen is axially disposed between (i) the end cap and (ii) the inner barrel and the outer barrel. In one embodiment, operation 110 includes coaxially aligning an outlet of the end cap with the inner barrel and / or the outer barrel. In one embodiment, operation 110 includes inserting a lower extension of the end cap into an outer groove of the outer barrel to sealingly engage the end cap with the outer barrel.

[0060] Unless otherwise stated, each of the various embodiments disclosed herein may have any of the aspects, features, components and / or configurations of the other embodiments.

[0061] As used herein, the term "approximately" and similar terms are intended to have a broad meaning consistent with common and accepted usage by those of ordinary skill in the art to which the subject matter of the present disclosure belongs. As used herein, the term "approximately" refers to ±5% of a reference measurement, position, or dimension. Those skilled in the art who review this disclosure should understand that these terms are intended to allow description of certain features described and claimed without limiting the scope of these features to the precise numerical ranges provided. Therefore, these terms should be interpreted as indicating that insubstantial or insignificant modifications or changes to the subject matter described and claimed are considered to be within the scope of the invention as described in the appended claims.

[0062] The terms "coupled," "attached," and similar terms as used herein mean that two components are directly joined to one another. Such joining may be fixed (eg, permanent) or movable (eg, removable or releasable).

[0063] References herein to element positions (eg, "top," "bottom," etc.) are only used to describe the orientation of the various elements in the drawings. It should be noted that the orientation of the various elements may be different according to other exemplary embodiments, and such variations are intended to be encompassed by the present disclosure.

[0064] It is important to note that the structure and arrangement of various exemplary embodiments are merely illustrative. Although only a few embodiments are described in detail in the present disclosure, it will be readily appreciated by those skilled in the art who consult the present disclosure that many modifications (e.g., changes in the size, dimensions, structure, shape and ratio of various elements, the value of parameters, the installation arrangement, the use of materials, colors, orientations, etc.) are possible without substantially departing from the novel teachings and advantages of the subject matter described herein. For example, the position of the element may be reversed or otherwise changed and the nature or quantity of the discrete element or position may be changed or varied. According to alternative embodiments, the order or sequence of any process or method steps may be changed or rearranged. Other substitutions, modifications, changes, and omissions may also be made in the design, operating conditions, and arrangement of various exemplary embodiments without departing from the scope of the present invention.

Claims

1. A deionizing filter assembly, comprising: an outer barrel, the outer barrel comprising a first outer end and a second outer end, the outer barrel being configured to receive an outer resin bed; an inner barrel positionable within the outer barrel and comprising a first inner end and a second inner end, the inner barrel being configured to house an inner resin bed; an end cap positionable along the first outer end of the outer barrel and the first inner end of the inner barrel, and comprising an inlet and an outlet; and A screen is positionable between the end cap and the outer barrel and the inner barrel.

2. The deionizing filter assembly according to claim 1, wherein: The first outer end of the outer cylinder is open to the fluid flowing through the outer cylinder, and the second outer end of the outer cylinder is closed to the fluid flowing through the outer cylinder.

3. The deionizing filter assembly according to claim 2, wherein: When assembled, the inner barrel extends between an inner surface of a lower wall located along the second outer end of the outer barrel and the first outer end of the outer barrel.

4. The deionizing filter assembly according to claim 1, wherein: The inner barrel includes an axial rib portion extending radially away from an outer surface of the inner barrel and a raised rib extending axially away from the second inner end of the inner barrel.

5. The deionizing filter assembly according to claim 1, wherein: The end cover comprises an end cover outer circumferential wall, the end cover outer circumferential wall is radially aligned with the outer barrel circumferential wall of the outer barrel, and the inlet of the end cover extends tangentially to the end cover outer circumferential wall.

6. The deionizing filter assembly according to claim 1, wherein: The end cover comprises an end cover outer circumferential wall, the end cover outer circumferential wall is radially aligned with the outer barrel circumferential wall of the outer barrel, and the outlet of the end cover is axially tapered from the end cover outer circumferential wall.

7. The deionizing filter assembly according to claim 1, wherein: The screen is positionable along the first outer end of the outer barrel and the first inner end of the inner barrel.

8. The deionizing filter assembly according to claim 7, wherein: The screen includes: (i) an outer stamped portion positioned to be received within an outer groove at the first outer end of the outer barrel, and (ii) an inner stamped portion positioned to be received within an inner groove at the first inner end of the inner barrel.

9. The deionizing filter assembly of claim 1 , further comprising a pressure release mechanism configured to bypass fluid flow between the inlet and the outlet when an applied pressure across the inner resin bed and the outer resin bed is greater than or equal to a bypass threshold pressure.

10. A deionizing filter assembly comprising: an outer barrel defining an open end and a closed end; an inner barrel positioned within the outer barrel and radially spaced from the outer barrel to define an annular space therebetween, the inner barrel defining an inner cavity fluidly coupled to the annular space at the closed end of the outer barrel; an outer resin bed, the outer resin bed being contained within the annular space; and An inner resin bed is contained within the inner cavity.

11. The deionizing filter assembly according to claim 10, wherein the inner cylinder comprises: The circumferential wall of the inner cylinder; and At least one raised rib extends axially away from the inner barrel circumferential wall, the at least one raised rib axially spacing the inner barrel circumferential wall from the closed end of the outer barrel to define a flow passage between the annular space and the inner cavity.

12. The deionizing filter assembly according to claim 10, wherein: The height of the inner cylinder is approximately equal to the height of the annular space.

13. The deionizing filter assembly according to claim 10, wherein: The inner barrel includes an inner barrel circumferential wall that is open to fluid flowing axially through the inner barrel circumferential wall from a first inner end of the inner barrel to a second inner end of the inner barrel.

14. The deionizing filter assembly according to claim 10, wherein: The outer cylinder comprises an outer cylinder circumferential wall, and the inner cylinder comprises: The circumferential wall of the inner cylinder; and At least one axial rib radially extends away from the inner cylinder circumferential wall, and the at least one axial rib radially spaces the inner cylinder circumferential wall and the outer cylinder circumferential wall apart to form the annular space.

15. The deionizing filter assembly according to claim 10, further comprising: an end cap coupled to the inner barrel and the outer barrel at the open end of the outer barrel; and A screen is positioned between the end cap and the outer cylinder and the inner cylinder.

16. The deionizing filter assembly according to claim 15, wherein: The end cap comprises: The outer circumferential wall of the end cover is radially aligned with the outer circumferential wall of the outer cylinder, an inlet extending tangentially to the outer circumferential wall of the end cap, and An outlet is axially tapered from the outer circumferential wall of the end cover.

17. The deionizing filter assembly according to claim 15, wherein: The screen includes: (i) an outer stamped portion positioned within an outer groove at an opening of the outer barrel, and (ii) an inner stamped portion positioned within an inner groove at a first inner end of the inner barrel.

18. A method of assembling a deionizing filter assembly, comprising: positioning an inner barrel within an outer barrel to define an annular space between the inner barrel and the outer barrel, and such that the annular space is fluidly coupled to an interior cavity of the inner barrel at a closed end of the outer barrel; placing an inner resin bed within the inner cavity; and An outer resin bed is placed within the annular space.

19. The method according to claim 18, further comprising: placing a screen on the inner cylinder and the outer cylinder at an open end of the inner cylinder and an open end of the outer cylinder; and An end cap is coupled to the inner barrel and the outer barrel such that the screen is axially disposed between (i) the end cap and (ii) the inner barrel and the outer barrel.

20. The method according to claim 19, wherein: Positioning the inner barrel within the outer barrel includes engaging at least one rib of the inner barrel with a lower wall of the outer barrel at the closed end of the outer barrel, the at least one rib of the inner barrel extending axially away from an inner barrel circumferential wall of the inner barrel such that the inner barrel circumferential wall is axially spaced from the lower wall.

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