Scroll-wound filter element configuration

Abstract

Embodiments herein relate to a filter device having a vortex spiral wound filter element. In an embodiment, a filter device is included having a first spiral wound filter element. The first scroll-wound filter element may include one or more spacer layers, one or more film layers disposed between the one or more spacer layers, and a plurality of spacer elements. The aspect ratio of height to width of the first scroll-wound filter element may be less than 8: 1. Other embodiments are also included herein.

Description

[0001] This application was filed as a PCT international patent application on October 3, 2023, designating the applicant in all countries as DONALDSON COMPANY, INC., a U.S. national company, and the inventors in all countries as U.S. citizen David D. Lauer, U.S. citizen Benjamin C. Drueke, U.S. citizen David A. Olson, U.S. citizen Connor J. Colling, U.S. citizen Davis B. Moravec, U.S. citizen Matthew P. Goertz, U.S. citizen Nicholas J. Stanley, and U.S. citizen Robert P. McCollam, and claims priority to U.S. Provisional Patent Application No. 63 / 412,801 filed on October 3, 2022 and U.S. Patent Application No. 18 / 375,010 filed on September 29, 2023, the entire contents of which are incorporated herein by reference. Technical Field

[0002]

[0013] Embodiments herein relate to vortex spiral wound filter element configurations. Background Art

[0003] Filter elements help separate solids from liquids and gases and remove any impurities or contaminants that may be present. Filter elements are useful in many applications including purification of chemicals and pharmaceuticals, prevention of cross contamination, health hazards and environmental issues, protection of industrial equipment, beverage clarification (including beer clarification) and providing safe drinking water, agricultural irrigation, swimming pools and aquariums.

[0004] Many filter elements include spacer screens or spacer elements designed to separate various media, such as filter media, depth loaded media, surface loaded media, media with adsorbents, and functionalized media for targeted capture of contaminants and / or desired substances. Despite the existence of various filter elements, there is still a need for improved spacer screens, spacer elements, and filter elements. Summary of the invention

[0005] In a first aspect, a filter device is provided having a first spirally wound filter element having one or more spacer layers, one or more membrane layers disposed between the one or more spacer layers, and a plurality of spacer elements, wherein the first spirally wound filter element has an aspect ratio of height to width of less than 8:1.

[0006] In a second aspect, in addition to one or more of the preceding or subsequent aspects, or as an alternative to certain aspects, the filter device includes second, third and fourth vortex spirally wound filter elements, wherein the second, third and fourth vortex spirally wound filter elements each include: one or more spacer layers, one or more membrane layers disposed between the one or more spacer layers, and a plurality of spacer elements, wherein the aspect ratio of the height to the width of the second, third and fourth vortex spirally wound filter elements is less than 8:1.

[0007] In a third aspect, in addition to one or more of the preceding or subsequent aspects, or as an alternative to certain aspects, the filter device includes fifth, sixth, seventh and eighth vortex spirally wound filter elements, wherein the fifth, sixth, seventh and eighth vortex spirally wound filter elements each include: one or more spacer layers, one or more membrane layers disposed between the one or more spacer layers, and a plurality of spacer elements, wherein the aspect ratio of the height to the width of the fifth, sixth, seventh and eighth vortex spirally wound filter elements is less than 8:1.

[0008] In a fourth aspect, in addition to or in lieu of one or more of the preceding or following aspects, the filter device further comprises a first stack comprising first, second, third and fourth vortex spiral wound filter elements placed in parallel.

[0009] In a fifth aspect, in addition to one or more of the preceding or subsequent aspects, or as an alternative to certain aspects, the filter device further includes a first stack, the first stack comprising first, second, third and fourth vortex spirally wound filter elements placed in parallel, and the filter device further includes a second stack, the second stack comprising fifth, sixth, seventh and eighth vortex spirally wound filter elements placed in parallel.

[0010] In a sixth aspect, in addition to or as an alternative to one or more of the preceding or following aspects, the first stack and the second stack are placed in series.

[0011] In a seventh aspect, in addition to or in lieu of one or more of the preceding or following aspects, the filter device has a height of between two and ten inches.

[0012] In an eighth aspect, in addition to or in lieu of one or more of the preceding or following aspects, the filter device has a height of between three and four inches.

[0013] In a ninth aspect, in addition to or in lieu of one or more of the preceding or following aspects, the filter device has a height of between four and five inches.

[0014] In a tenth aspect, in addition to or in lieu of one or more of the preceding or following aspects, the filter device has a diameter between 5 and 40 inches.

[0015] In an eleventh aspect, in addition to or in lieu of one or more of the preceding or following aspects, the filter device has a diameter between 10 and 24 inches.

[0016] In a twelfth aspect, in addition to or as an alternative to one or more of the preceding or following aspects, a plurality of spacer elements are disposed on one or more sides of one or more spacer layers.

[0017] In a thirteenth aspect, in addition to or as an alternative to one or more of the preceding or following aspects, a plurality of spacer elements are disposed on one or more sides of one or more membrane layers.

[0018] In a fourteenth aspect, in addition to one or more of the preceding or subsequent aspects, or as an alternative to certain aspects, the filtration device further includes one or more support layers disposed between the one or more membrane layers and the one or more spacer layers.

[0019] In a fifteenth aspect, in addition to or in lieu of one or more of the preceding or following aspects, the plurality of spacer elements are arranged in columns and rows.

[0020] In a sixteenth aspect, in addition to or in lieu of one or more of the preceding or following aspects, the plurality of spacer elements are arranged in diagonal columns, in-line columns, or offset rows.

[0021] In a seventeenth aspect, in addition to one or more of the preceding or subsequent aspects, or as an alternative to certain aspects, the plurality of spacer elements comprises various shapes, the various shapes comprising one or more of the following: an airfoil, a triangle, a rhombus, a parallelogram, a trapezium, a kite, a trapezium, a pentagon, a heptagon, an octagon, a hexagon, a circle, an ellipse, a square, a rectangle, and a teardrop.

[0022] In an eighteenth aspect, in addition to or as an alternative to one or more of the preceding or following aspects, the plurality of spacer elements comprises a teardrop shape.

[0023] In a nineteenth aspect, in addition to or as an alternative to one or more of the preceding or following aspects, the plurality of spacer elements comprises an airfoil shape.

[0024] In a twentieth aspect, in addition to or in lieu of one or more of the preceding or following aspects, the plurality of circular spacer elements each comprise a different circumference.

[0025] In a twenty-first aspect, in addition to one or more of the preceding or subsequent aspects, or as an alternative to certain aspects, the shape of the multiple spacer elements arranged along the edge portion of one or more spacer layers is different from the shape of the multiple spacer elements arranged on the remaining portion of one or more spacer layers.

[0026] In the twenty-second aspect, in addition to one or more of the preceding or subsequent aspects, or as an alternative to certain aspects, the shape of the multiple spacer elements arranged along the edge portion of one or more membrane layers is different from the shape of the multiple spacer elements arranged on the remaining portion of one or more membrane layers.

[0027] In a twenty-third aspect, in addition to or in lieu of one or more of the preceding or following aspects, the plurality of spacer elements are arranged in a size gradient.

[0028] In a twenty-fourth aspect, in addition to or as an alternative to one or more of the preceding or following aspects, the plurality of spacer elements are symmetrically distributed.

[0029] In a twenty-fifth aspect, in addition to or as an alternative to one or more of the preceding or following aspects, the plurality of spacer elements are asymmetrically distributed.

[0030] In a twenty-sixth aspect, in addition to or as an alternative to one or more of the preceding or following aspects, the plurality of spacer elements are formed using three-dimensional printing.

[0031] In a twenty-seventh aspect, in addition to one or more of the preceding or subsequent aspects, or as an alternative to certain aspects, the plurality of spacer elements are made of one or more of the following: a UV-cured epoxy resin, a UV-cured polyurethane, a thermoplastic polymer, or a silicone polymer.

[0032] In a twenty-eighth aspect, in addition to one or more of the preceding or following aspects, or as an alternative to certain aspects, the plurality of spacer elements are made of one or more of polydimethylsiloxane or UV-curable polydimethylsiloxane.

[0033] In a twenty-ninth aspect, in addition to one or more of the preceding or subsequent aspects, or as an alternative to certain aspects, the plurality of spacer elements are made of one or more of the following: polyamide, polypropylene, polyurethane, polyethylene, polylactic acid, acrylonitrile butadiene styrene, styrene or a mixture thereof.

[0034] In a thirtieth aspect, in addition to or in lieu of one or more of the preceding or following aspects, the filter device further comprises a core, wherein the one or more vortex spiral wound filter elements are configured to be wrapped around the core.

[0035] In a thirty-first aspect, in addition to or as an alternative to one or more of the preceding or following aspects, the core is hollow.

[0036] In a thirty-second aspect, in addition to or as an alternative to one or more of the preceding or following aspects, the core is solid.

[0037] In a thirty-third aspect, in addition to or as an alternative to one or more of the preceding or following aspects, the core is made of one or more of the following: a polymer, a metal, or a composite material.

[0038] In a thirty-fourth aspect, additionally or alternatively to one or more of the preceding or following aspects, the core has a height of between two and nine inches.

[0039] In a thirty-fifth aspect, in addition to or as an alternative to one or more of the preceding or following aspects, the core has a height of between three and four inches.

[0040] In a thirty-sixth aspect, in addition to or as an alternative to one or more of the preceding or following aspects, the core has a height of between four and five inches.

[0041] In a thirty-seventh aspect, additionally or alternatively to one or more of the preceding or following aspects, the core has a diameter of less than one inch.

[0042] In a thirty-eighth aspect, in addition to or in lieu of one or more of the preceding or following aspects, the core has a diameter of between one and four inches.

[0043] In a thirty-ninth aspect, in addition to or in lieu of one or more of the preceding or following aspects, the filtration device further comprises an impermeable outer wrapper configured to wrap around the one or more vortex-shaped spirally wound filter elements.

[0044] In the fortieth aspect, in addition to one or more of the preceding or subsequent aspects, or as an alternative to certain aspects, one or more film layers are made of one or more of the following: cellulose, cellulose with a thermoplastic resin, cellulose with a thermosetting resin, a thermosetting resin, a thermoplastic resin, or a thermoplastic resin.

[0045] In the forty-first aspect, in addition to one or more of the preceding or subsequent aspects, or as an alternative to certain aspects, one or more membrane layers are made of one or more of the following: polyethersulfone, polytetrafluoroethylene, cellulose acetate, polyvinylidene fluoride, polysulfone, nylon, polypropylene, polyethylene and polyester.

[0046] In a 42nd aspect, in addition to or as an alternative to one or more of the previous or following aspects, one or more of the film layers are made of polypropylene.

[0047] In a forty-third aspect, in addition to or in lieu of one or more of the preceding or following aspects, one or more membrane layers have an unrolled length of between 50 and 450 feet.

[0048] In a forty-fourth aspect, in addition to or in lieu of one or more of the preceding or following aspects, the one or more membrane layers have an unrolled length of about 200 feet.

[0049] In a forty-fifth aspect, in addition to or in lieu of one or more of the preceding or following aspects, one or more of the film layers has a width of between two and eight inches.

[0050] In a forty-sixth aspect, in addition to or as an alternative to one or more of the preceding or following aspects, one or more of the film layers has a width of four inches.

[0051] In a 47th aspect, in addition to or in lieu of one or more of the preceding or following aspects, one or more of the film layers has a thickness between 50 and 1000 microns.

[0052] In a 48th aspect, in addition to one or more of the preceding or subsequent aspects, or as an alternative to certain aspects, an adhesive is applied along the length of each one or more spacer layers and each of the one or more film layers, wherein the adhesive is configured to attach each of the one or more spacer layers to each of the one or more film layers.

[0053] In a forty-ninth aspect, in addition to or in lieu of one or more of the preceding or subsequent aspects, the adhesive is applied along a width of between 1 / 8 inch and 1 inch of each of the one or more spacer layers and each of the one or more film layers.

[0054] In a fiftieth aspect, a filter device comprises a vortex spiral wound filter element. The vortex spiral wound filter element comprises one or more spacer screens having flow direction fibers and cross-flow direction fibers, wherein the flow direction fibers are oriented approximately in the direction of flow of a fluid entering the vortex spiral wound filter element, and one or more membrane layers are disposed between the one or more spacer screens.

[0055] In a fifty-first aspect, in addition to or in lieu of one or more of the above or following aspects, the aspect ratio of the filter device's height to width is less than 3:1.

[0056] In a fifty-second aspect, in addition to or in lieu of one or more of the preceding or following aspects, the aspect ratio of the filter device's height to width is less than 10.5:1.

[0057] In a fifty-third aspect, in addition to or in lieu of one or more of the preceding or following aspects, the aspect ratio of the filter device's height to width is less than 12:1.5.

[0058] In a fifty-fourth aspect, in addition to or as an alternative to one or more of the previous or following aspects, one or more spacer screens are made of a polymer, metal or composite material.

[0059] In a fifty-fifth aspect, in addition to one or more of the preceding or subsequent aspects, or as an alternative to certain aspects, one or more spacer screens are made of a thermoplastic polymer, wherein the thermoplastic polymer includes one or more of the following: polypropylene, high-density polyethylene, polyester, nylon or polyphenylene sulfide.

[0060] In the fifty-sixth aspect, in addition to one or more of the preceding or subsequent aspects, or as an alternative to certain aspects, one or more spacer screens include one or more coatings, including an anti-fouling coating, a conductive coating for electrostatic discharge, and a coating containing an adsorbent to target specific contaminants.

[0061] In the fifty-seventh aspect, in addition to one or more of the preceding or subsequent aspects, or as an alternative to certain aspects, the flow direction fibers and the cross-flow direction fibers include various shapes, which may include one or more of the following: circular, polygonal, elliptical, lima bean-shaped, triangular, trilobal, lobular, mushroom-shaped, dog-bone, ribbon-shaped, star-shaped and tubular.

[0062] In a fifty-eighth aspect, in addition to or in lieu of one or more of the preceding or following aspects, the flow direction fibers are between 100 and 500 microns in size.

[0063] In a fifty-ninth aspect, additionally or alternatively to one or more of the preceding or following aspects, the flow direction fibers are 450 microns in size.

[0064] In a sixtieth aspect, in addition to or in lieu of one or more of the preceding or following aspects, the cross-flow direction fibers are between 50 and 300 microns in size.

[0065] In a sixty-first aspect, in addition to or as an alternative to one or more of the above or following aspects, the cross-flow direction fibers are 50 microns in size.

[0066] In a sixty-second aspect, in addition to or as an alternative to one or more of the preceding or following aspects, wherein the flow direction fibers are larger than the cross flow direction fibers.

[0067] In a sixty-third aspect, in addition to or as an alternative to one or more of the previous or following aspects, one or more of the spaced screens have a thickness between 100 and 1000 microns.

[0068] In a sixty-fourth aspect, in addition to or as an alternative to one or more of the previous or following aspects, the thickness of the one or more spaced screens is between 500 and 700 microns.

[0069] In a sixty-fifth aspect, in addition to or in lieu of one or more of the preceding or following aspects, one or more of the spaced screens have an open area between 10 and 90 percent.

[0070] In a sixty-sixth aspect, in addition to or as an alternative to one or more of the preceding or following aspects, the flow direction fibers and the cross flow direction fibers have between 7 and 50 fibers per inch of one or more spaced screens.

[0071] In a sixty-seventh aspect, in addition to or as an alternative to one or more of the preceding or following aspects, the flow direction fibers and the cross fibers have between 8 and 12 fibers per inch of one or more spacing screens.

[0072] In the sixty-eighth aspect, there is provided a method for preparing a vortex spiral wound filter device, the method comprising unfolding a membrane layer and a spacer layer, combining the unfolded membrane layer and the unfolded spacer layer, distributing an adhesive on a portion of the combined membrane layer and the spacer layer, and winding the combined membrane layer and the spacer layer, wherein the spacer layer comprises a plurality of spacer elements, the spacer elements comprising various shapes, the various shapes being selected from at least one of the group consisting of: an airfoil, a triangle, a rhombus, a parallelogram, a trapezoid, a kite, an irregular trapezoid, a pentagon, a heptagon, an octagon and a hexagon.

[0073] In a sixty-ninth aspect, in addition to or as an alternative to one or more of the preceding or following aspects, cantilever-stretched membrane layers and spacer layers are used.

[0074] In a seventieth aspect, in addition to or in lieu of one or more of the preceding or subsequent aspects, the method further comprises a device for unfolding the membrane layer and the spacer layer to alert a user that the membrane layer may be about to run out and needs to be replaced.

[0075] In a seventy-first aspect, in addition to or as an alternative to one or more of the preceding or following aspects, the spacer layer includes a support layer.

[0076] In a seventy-second aspect, in addition to or as an alternative to one or more of the preceding or subsequent aspects, combining the expanded film layer and the expanded spacer layer includes overlapping the expanded film layer and the expanded spacer layer to align one or more edges of each.

[0077] In a seventy-third aspect, in addition to or as an alternative to one or more of the preceding or following aspects, wherein the membrane layer comprises one or more spacer elements on one or more sides of the membrane layer.

[0078] In a seventy-fourth aspect, in addition to or in lieu of one or more of the preceding or following aspects, the portion of the combined film layer and spacer layer that includes the adhesive is the width and length of the overlapping film layer and spacer layer.

[0079] In a seventy-fifth aspect, additionally or alternatively to one or more of the preceding or following aspects, the adhesive is applied about one inch from one or more edges of the overlapping film and spacer layers.

[0080] In a seventy-sixth aspect, in addition to or in lieu of one or more of the preceding or following aspects, the method may further comprise wrapping an overwrap around the combined film layer and spacer layer.

[0081] In a seventy-seventh aspect, in addition to or in lieu of one or more of the preceding or following aspects, the outer packaging comprises a film layer impregnated with an adhesive.

[0082] In a seventy-eighth aspect, in addition to or as an alternative to one or more of the preceding or following aspects, the outer packaging is impermeable.

[0083] In a seventy-ninth aspect, a filtration device comprises a first vortex spirally wound filter element. The first vortex spirally wound filter element comprises one or more filter subassemblies having one or more membrane subassemblies. The one or more membrane subassemblies comprise two or more support layers, one or more membrane layers disposed between the two or more support layers, and a plurality of spacer elements and one or more spacer layers.

[0084] In an eightieth aspect, in addition to or in lieu of one or more of the preceding or subsequent aspects, the filtration device further comprises a second, third, and fourth vortex spirally wound filter element, wherein the second, third, and fourth vortex spirally wound filter element each comprises one or more filter subassemblies and one or more membrane subassemblies. The one or more membrane subassemblies comprise two or more support layers, one or more membrane layers disposed between the two or more support layers, and a plurality of spacer elements and one or more spacer layers.

[0085] In an eighty-first aspect, in addition to or in lieu of one or more of the foregoing or subsequent aspects, the filter device further comprises a fifth, sixth, seventh, and eighth vortex spirally wound filter element, wherein the fifth, sixth, seventh, and eighth vortex spirally wound filter element each comprises one or more filter subassemblies and one or more membrane subassemblies. The one or more membrane subassemblies comprise two or more support layers, one or more membrane layers disposed between the two or more support layers, and a plurality of spacer elements and one or more spacer layers.

[0086] In an eighty-second aspect, in addition to or in lieu of one or more of the preceding or following aspects, the filter device further comprises a first stack. The first stack comprises first, second, third and fourth vortex spiral wound filter elements placed in parallel.

[0087] In an eighty-third aspect, in addition to or in lieu of one or more of the foregoing or subsequent aspects, the filter device further comprises a first stack and a second stack. The first stack comprises first, second, third, and fourth vortex spirally wound filter elements disposed in parallel. The second stack comprises fifth, sixth, seventh, and eighth vortex spirally wound filter elements disposed in parallel.

[0088] In an eighty-fourth aspect, in addition to or in lieu of one or more of the preceding or following aspects, the first stack and the second stack are placed in series.

[0089] In an eighty-fifth aspect, in addition to or in lieu of one or more of the preceding or following aspects, a plurality of spacer elements are disposed on one or more sides of one or more spacer layers.

[0090] In an eighty-sixth aspect, in addition to or in lieu of one or more of the preceding or following aspects, a plurality of spacer elements are disposed on one or more sides of one or more membrane layers.

[0091] In the eighty-seventh aspect, in addition to one or more of the preceding or subsequent aspects, or as an alternative to certain aspects, the plurality of spacer elements comprise various shapes, the various shapes comprising one or more of the following: an airfoil, a triangle, a rhombus, a parallelogram, a trapezoid, a kite, an irregular trapezoid, a pentagon, a heptagon, an octagon, a hexagon, a circle, an ellipse, a square, a rectangle, and a teardrop.

[0092] In an eighty-eighth aspect, additionally or alternatively to one or more of the preceding or following aspects, the plurality of spacer elements comprises an airfoil shape.

[0093] In an eighty-ninth aspect, in addition to or in lieu of one or more of the preceding or following aspects, the plurality of spacer elements are arranged in a size gradient.

[0094] In a ninetieth aspect, in addition to or as an alternative to one or more of the preceding or following aspects, the plurality of spacer elements are symmetrically distributed.

[0095] In a ninety-first aspect, in addition to or as an alternative to one or more of the preceding or following aspects, the plurality of spacer elements are asymmetrically distributed.

[0096] In a ninety-second aspect, additionally or alternatively to one or more of the preceding or following aspects, the filtration device has an aspect ratio of height to width of less than 3:1.

[0097] In a ninety-third aspect, additionally or alternatively to one or more of the preceding or following aspects, the filtration device has an aspect ratio of height to width of less than 10.5:1.

[0098] In a ninety-fourth aspect, additionally or alternatively to one or more of the preceding or following aspects, the filtration device has an aspect ratio of height to width of less than 12:1.5.

[0099] In a ninety-fifth aspect, additionally or alternatively to one or more of the preceding or following aspects, the filtration device has an aspect ratio of height to width of less than 8:1.

[0100] In the ninety-sixth aspect, in addition to one or more of the preceding or subsequent aspects, or as an alternative to certain aspects, the two or more spacer layers include two or more spacer screens, wherein the spacer screens have flow direction fibers and cross-flow direction fibers, wherein the flow direction fibers are oriented approximately in the flow direction of the fluid entering the vortex spiral wound filter element.

[0101] This summary summarizes some of the teachings of the present application and is not intended to be an exclusive or exhaustive treatment of the subject matter. Additional details can be found in the detailed description. Other aspects will become apparent to those skilled in the art upon reading and understanding the following detailed description and viewing the accompanying drawings, each of which should not be construed as limiting. The scope of this article is defined by the appended claims and their legal equivalents. BRIEF DESCRIPTION OF THE DRAWINGS

[0102] Various aspects may be more fully understood in conjunction with the following drawings (figures), in which:

[0103] Figure 1A is a top view of a filtration device according to various embodiments herein.

[0104] Figure 1B is a side perspective view of a filter device according to various embodiments herein.

[0105] Figure 2 is a schematic diagram of a filter element according to various embodiments herein.

[0106] Figure 3A is a schematic diagram of two filter subassemblies according to various embodiments herein.

[0107] Figure 3B are cross-sectional views of four filter subassemblies according to various embodiments herein.

[0108] Figure 4A is a cross-sectional view of a filter element according to various embodiments herein.

[0109] Figure 4B is a cross-sectional view of a filter element according to various embodiments herein.

[0110] Figure 5 is a schematic diagram of a filter element according to various embodiments herein.

[0111] Fig. 6A is a schematic diagram of parallel filter elements according to various embodiments herein.

[0112] Figure 6B is a schematic diagram of an in-line filter element according to various embodiments herein.

[0113] Fig. 7A is a cross-sectional view of a stack of filter elements according to various embodiments herein.

[0114] Figure 7B is a cross-sectional view of a stack of filter elements according to various embodiments herein.

[0115] Figure 8 is a schematic diagram of a spacer screen according to various embodiments herein.

[0116] Fig. 9 is a side view of a spacer screen according to various embodiments herein.

[0117] Fig. 10A is a top-down view of a spacer element layer according to various embodiments herein.

[0118] Fig. 10B is a side view of a spacer element layer according to various embodiments herein.

[0119] Fig. 10C is a side view of a spacer element layer according to various embodiments herein.

[0120] Fig.11A is a top-down view of a spacer element layer according to various embodiments herein.

[0121] Fig. 11B is a side view of a spacer element layer according to various embodiments herein.

[0122] Fig.12 is a top-down view of a spacer element layer according to various embodiments herein.

[0123] Fig.13 is a top-down view of a spacer element layer according to various embodiments herein.

[0124] Fig.14 is a top-down view of a spacer element layer according to various embodiments herein.

[0125] Fig.15A is a top-down view of a spacer element layer according to various embodiments herein.

[0126] Fig. 15B is a schematic diagram of a spacer element layer according to various embodiments herein.

[0127] Fig.16A is a top-down view of a spacer element layer according to various embodiments herein.

[0128] Fig. 16B is a side view of a spacer element layer according to various embodiments herein.

[0129] Fig.17 is a top-down view of a spacer element layer according to various embodiments herein.

[0130] Fig.18 is a top-down view of a spacer element layer according to various embodiments herein.

[0131] Fig.19 is a top-down view of a spacer element layer according to various embodiments herein.

[0132] Fig. 20 is a flow chart illustrating a method of making a vortex spiral wound filter device according to an embodiment.

[0133] Fig.21 is a graph showing the effect of spacer layer thickness on membrane surface area according to an embodiment.

[0134] Fig. 22 is a graph showing the effect of spacer layer thickness on membrane surface area according to an embodiment.

[0135] Fig.23 is a graph showing the effect of the number of spacer layers on the pressure drop according to an embodiment.

[0136] Fig.24 is a graph showing the effect of the size of the spacer layer on the pressure drop according to an embodiment.

[0137] Fig.25 is a graph showing the effect of membrane layer length on pressure drop according to an embodiment.

[0138] Fig.26 is a graph showing the effect of membrane length on flux according to an embodiment.

[0139] Fig. 27 is a graph showing the effect of element diameter on several properties according to an embodiment.

[0140] Fig.28 is a graph showing the effect of element length on several characteristics according to an embodiment.

[0141] Fig.29 is a graph showing the effect of core diameter on several properties according to an embodiment.

[0142] Fig.30 is a graph showing the effect of spacer screen thickness on several properties according to an embodiment.

[0143] Although the embodiments are susceptible to various modifications and alternative forms, the details thereof have been shown by way of example and drawings and will be described in detail. However, it should be understood that the scope of this document is not limited to the described aspects. On the contrary, it is intended to cover modifications, equivalents and substitutes that fall within the spirit and scope of this document. DETAILED DESCRIPTION

[0144] Filtration device

[0145] The present invention relates to a filter device having a vortex spiral wound filter element, and a method for producing a vortex spiral wound filter element. The vortex spiral wound filter element may include one or more membrane layers disposed between one or more spacer layers. The spacer layers provide a favorable flow path throughout the filter element, which not only serves to provide adequate contaminant removal, but also limits the amount of pressure drop experienced by the entire filter element during use.

[0146] The aspect ratio of the height to the width of the vortex spiral wound filter element can be less than 8:1. It has been found that reducing the height of the filter element while increasing the width provides enough available media to provide sufficient contaminant removal while reducing the amount of pressure drop experienced. When the flow rate through the filter element is high, reducing the height of the filter element while increasing the width can be particularly desirable. However, it has been further found that reducing the flow rate through the filter element can limit the amount of pressure drop experienced, thereby allowing a larger filter element height to be used when necessary.

[0147] The vortex spiral wound filter element may include a plurality of spacer elements disposed on one or more membrane layers and / or spacer layers. The use of spacer elements may provide significant benefits regarding filtration performance. For example, spacer elements may provide structural support for the membrane layers in the filter medium and prevent the membrane layers from collapsing into the flow channel of the filter device. In addition, spacer elements may reduce the pressure drop experienced and allow pollutants to be loaded into the depths of the channel generated by the spacer elements. Spacer elements may include various shapes and sizes and may be disposed on the membrane layers and / or spacer layers in various ways described in more detail below.

[0148] The vortex spiral wound filter element may further include one or more spacer screens. The spacer screens may provide many benefits to the filter device. In particular, the spacer screens may provide additional support for the membrane layer and prevent the membrane layer from collapsing into the flow channel. In addition, the spacer screens may include flow direction fibers oriented in the direction of fluid flow, which is in sharp contrast to traditional spacer screens including fibers oriented at a 45 degree angle to the fluid flow. Importantly, it has been found that orienting the flow direction fibers in the direction of fluid flow reduces the amount of turbulence caused by the fluid flow, thereby reducing the amount of pressure drop experienced.

[0149] Reference now Figure 1A , shows a top view of a filter device according to various embodiments herein. The filter device 100 may include a filter element 102 wrapped around a core 106. The filter device may also include an impermeable outer wrapper 104. Once the desired amount of filter element media is wrapped around the core 106, the filter element 102 may be wrapped with an impermeable outer wrapper 104 that maintains compression and provides structural support.

[0150] In some embodiments, core 106 can provide structural support for filter element 102 and prevent filter element 102 from compressing and collapsing inwards during use. In some embodiments, core 106 can be solid form. In other embodiments, core 106 can be hollow form. For example, core 106 can be a rod or a tube. Hollow core 106 can be conducive to the application of multiple filter elements stacked in parallel. When filter elements are stacked in parallel, hollow core 106 can allow cleaning liquid to flow through the next filter element in parallel from one filter element. Hollow core and solid core can be used for single element, series element or parallel element that are not in the same housing. For example, solid core and hollow core can be used for single element that is not in the same housing and is attached to manifold.

[0151] The core 106 can be made of various materials. For example, the core 106 can be made of polymers, metals, composite materials, etc. In some embodiments, the core 106 can be made of polypropylene. The height of the core 106 can be two inches, three inches, four inches, five inches, six inches, seven inches, eight inches or nine inches, or can fall within the range of any of the foregoing. In some embodiments, the height of the core 106 can be between three and four inches. In other embodiments, the height of the core 106 can be between four and five inches. The diameter of the core 106 can be less than one inch. For example, the diameter of the core 106 can be 1 / 4 inch, 1 / 2 inch or 3 / 4 inch, or can fall within the range of any of the foregoing. Alternatively, the diameter of the core 106 can be one inch, two inches, three inches or four inches, or can fall within the range of any of the foregoing. In some embodiments, the diameter of the core 106 can be between 1 / 2 inch and two inches. It should be understood that increasing the height of the core 106, thereby increasing the height of the filter element 102, can increase the pressure drop experienced. Therefore, it may be desirable to increase the diameter of the filter element 102 to avoid this result.

[0152] In some embodiments, the filter element 102 may include one or more spacer layers disposed between one or more membrane layers. The membrane layers may be made of various materials. For example, the membrane layers may be made of polymers, glass, composite materials, etc.

[0153] In some embodiments, the membrane layer may include a material sufficient to generate a fiber membrane layer. For example, the membrane layer may include cellulose, cellulose with a thermoplastic resin, cellulose with a thermosetting resin, and the like. In some embodiments, the membrane layer may include a thermoplastic polymer, such as polypropylene. In some embodiments, the membrane layer may include a material that can form a vortex spiral winding design but is traditionally difficult to use for a pleated design. For example, the membrane layer may include a thermosetting resin, a thermoplastic resin, and a thermoplastic polymer, such as polyethersulfone (PES), polytetrafluoroethylene (PTFE), cellulose acetate, polyvinylidene fluoride (PVDF), polysulfone (PS), nylon, and polypropylene, polyethylene, polyester, and the like. For example, the membrane layer may include a meltblown film and a wet film, such as Synteq by Donaldson Company Inc. TM XP medium.

[0154] The membrane layer and the spacer layer can each have an extended length of 50 feet, 100 feet, 150 feet, 200 feet, 250 feet, 300 feet, 350 feet, 400 feet, or 450 feet, or can fall within any range between the aforementioned. For example, the extended length of the layer can be approximately 200 feet. The layer can have various widths. In some embodiments, the width of the layer can be two inches, three inches, four inches, five inches, six inches, seven inches, or eight inches, or can fall within any range between the aforementioned. For example, the width of the layer can be four inches. In addition, the thickness of the layer can be different. In some embodiments, the thickness of the layer can be 50 microns, 100 microns, 150 microns, 200 microns, 250 microns, 300 microns, 350 microns, 400 microns, 450 microns, 500 microns, 550 microns, 600 microns, 650 microns, 700 microns, 750 microns, 800 microns, 850 microns, 900 microns, 950 microns or 1000 microns, or can fall within the range of any of the foregoing. It is worth noting that the thicker the layer, the shorter the length of the unfolded layer can be, so as to be rolled into the filtration device with a fixed diameter.

[0155] In some embodiments, the spacer layer is used to provide structural support for the filter element 102. In various embodiments, the spacer layer may include a support layer including a spacer screen and / or a scrim as described in more detail below. In various embodiments, alternatively or additionally, the spacer layer may include a spacer element attached to one or both sides of the membrane layer, as described in more detail below.

[0156] The filter element 102 may be volutely spiral wound about the core 106. A basic volutely spiral wound filter is shown in US Patent No. 3,962,097, the entire contents of which are incorporated herein by reference. The embodiments described herein may be constructed in accordance with the teachings of US Patent No. 3,962,097.

[0157] Reference now Figure 1B , shows a side perspective view of a filter device according to various embodiments herein. Figure 1B A generally axial direction of fluid flow is shown through the filter element 102. The filter element 102 has a height and a diameter.

[0158] Filter 100 can have various sizes. The height of filter 100 can be two inches, three inches, four inches, five inches, six inches, seven inches, eight inches, nine inches or ten inches, or can fall in the aforementioned range between any. In some embodiments, the height of filter 100 can be the height between three inches and four inches. In some embodiments, the height of filter 100 can be the height between four inches and five inches. The diameter of filter 100 can be 2 inches, 5 inches, 10 inches, 15 inches, 20 inches, 25 inches, 30 inches, 35 inches or 40 inches, or can fall in the aforementioned range between any. In some embodiments, the diameter of filter 100 can be between 16 inches and 24 inches. For example, the diameter of filter 100 can be between 10 and 24 inches. More particularly, the diameter of filter 100 can be 16 inches. It should be understood that increasing the height of filter 100 can increase the pressure drop experienced. In some embodiments, the height of the filter device 100 can be less than 6 inches to minimize the amount of pressure drop experienced. Notably, the shorter the height of the filter device 100, the greater the flow rate of the fluid through the filter device 100 without affecting the amount of pressure drop experienced. In other embodiments, if the height of the filter device 100 is greater than 6 inches, the rate at which the fluid flows through the filter device 100 can be reduced to minimize the impact of the pressure drop experienced.

[0159] The filter device 100 has an aspect ratio, i.e., a ratio of height to width. In some embodiments, the aspect ratio of the filter device may be similar to an ice hockey puck (1:3), a Frisbee (1:10.5), or a pizza box (1.5:12), or may fall within, above, or between any of the aforementioned ranges. For example, the aspect ratio may be 1:6, 1:5, 1:4, 1:2, 1:1, 6:3, or 4:16. In some embodiments, the aspect ratio of the filter device may be higher, such as 2:1, 3:1, 4:1, 5:1, 6:1, 7:1, 8:1, 9:1, 10:1, or may fall within any of the aforementioned ranges below or between.

[0160] Reference now Figure 2 , a schematic diagram of a filter element during a winding process is shown according to various embodiments herein. As shown, the filter element 200 may include a membrane layer 202, on top of which a spacer layer 204 is disposed, followed by a membrane layer 206 and a spacer layer 208. It should be understood that although Figure 2 Two membranes and two spacer layers are depicted, but more layers are contemplated herein. For example, the membrane layers and / or spacer layers of the filter element 200 may each include three, four, five, six, seven, eight or more layers. In some embodiments, the membrane layer 202 and the membrane layer 206 may be made of the same material. In other embodiments, the membrane layer 202 and the membrane layer 206 may be made of different materials. Similarly, in some embodiments, the spacer layer 204 and the spacer layer 208 may be made of the same material. In other embodiments, the spacer layer 204 and the spacer layer 208 may be made of different materials. In some embodiments, the membrane layers 202, 206 and the spacer layers 204, 208 may all be made of the same material, which is beneficial for the manufacture of the filter element 200 because the adhesive used may be wetted similarly to all layers. In other embodiments, one or more of the membrane layers 202, 206 and the spacer layers 204, 208 may be made of a different material than the other layers, which may add separate functionality such as increased wettability in process fluids, anti-fouling, or limiting bacterial growth.

[0161] In some embodiments, membrane layer 202, spacer layer 204, membrane layer 206 and spacer layer 208 can be wound around core 210 in a vortex spiral. Compared with the traditional pleated filter element with the same outer diameter as filter element 200, the layer of vortex spiral winding filter element 200 can increase the surface area of ​​the membrane layer to twice or more. It is worth noting that the surface area of ​​the membrane layer that can be incorporated into the filter element of a given outer diameter is determined by the thickness of the membrane layer, the thickness of the flow channel defining the height of the spacer layer, and the diameter of the core. Increasing the membrane surface area can have many benefits. Some benefits include lower pressure drop loss, longer filter life, higher flux, more efficient use of membranes, and smaller filter size.

[0162] Reference now Figure 3A , a schematic diagram of two filter subassemblies is shown according to various embodiments herein. Figure 2 The example of Fig. 3 includes a spacer layer between each membrane layer, but the example of Fig. 3 shows a spacer layer separating the membrane subassemblies, wherein each membrane subassembly includes a membrane supported by two support layers and sandwiched between the two support layers. In another embodiment, each membrane is supported by a support layer. Options for the support layer include a scrim layer and a screen layer. The combination of the membrane subassembly and the spacer layer is referred to as a filtration subassembly in this article.

[0163] To form the vortex spiral wound filter element 300, the second filter subassembly 330 may be disposed on top of the first filter subassembly 332. The first filter subassembly 332 may include a first membrane subassembly 334 and a first spacer layer 302. The first membrane subassembly 334 may include a first membrane layer 304 disposed on top of a first support layer 314 and a second support layer 316 disposed on top of the first membrane layer 304. The first spacer layer 302 may be disposed on top of the first membrane subassembly 334. A first adhesive 336 may be applied along the length of the first support layer 314, the first membrane layer 304, and the second support layer 316. The adhesive 336 may be used to attach the first membrane layer 304 to the first support layer 314 and the first membrane layer 304 to the second support layer 316 to form the first membrane subassembly 334. The second adhesive 306 may be applied along the opposing lengths of the first spacer layer 302 and the first adhesive 336 of the first membrane subassembly 334. The second adhesive 306 can be used to attach the layers of the first membrane subassembly to each other and to attach the first membrane subassembly 334 to the first spacer layer 302 to form the first filter subassembly 332. Adhesives 306, 336 can also be used to provide an impermeable seam. It should be understood that it is valuable to ensure the integrity of the seam. Preventing seam leakage can improve the performance of the filter device and ensure its proper function. The seam can have various widths. In some embodiments, the seam width can be 1 / 8 inch, 1 / 4 inch, 1 / 2 inch, 3 / 4 inch or 1 inch, or can fall within the aforementioned arbitrary range. For example, the width of the seam can be 1 / 2 inch. It should be understood that it is desirable to minimize the size of the seam to increase the surface area of ​​the available vortex spiral wound filter element 300.

[0164] The second filtration subassembly 330 may include a second membrane subassembly 338 and a second spacer layer 310. The second membrane subassembly 338 may include a third support layer 318, a second membrane layer 308, and a fourth support layer 320. The second membrane layer 308 may be disposed on top of the third support layer 318, and the fourth support layer 320 may be disposed on top of the second membrane layer 308. The second spacer layer 310 may be disposed on top of the second membrane subassembly 338. A third adhesive 340 may be applied along the length of the third support layer 318, the second membrane layer 308, and the fourth support layer 320. The third adhesive 340 may be used to attach the third support layer 318 to the second membrane layer 308, and to attach the fourth support layer 320 to the second membrane layer 308 to form the second filtration subassembly 330. The fourth adhesive 312 may be applied along the opposing lengths of the third adhesive 340 of the second spacer layer 310 and the second membrane subassembly 338. The fourth adhesive 312 can be used to attach the second membrane subassembly 338 to the second spacer layer 310 to form the second filter subassembly 330, and can also be used to attach the components of the second membrane subassembly 338 to each other. Adhesives 312, 340 can also be used to provide an impermeable seam as discussed above about the first filter subassembly 332. Then, the first filter subassembly 332 and the second filter subassembly 330 can be longitudinally wound around the core 328 to form a filter element. It should be understood that the second membrane subassembly 338 can be composed of the first membrane subassembly 334 folded back on itself, wherein the first spacer layer 302 is plugged between the folds of the first membrane subassembly 334. As used herein, a membrane layer can also be referred to as a media layer, and various types of media can be used. In addition, the support layer can be a scrim layer or a spacer screen, and various types of media can be used.

[0165] Each spacer layer 302, 310 is adhered to an adjacent membrane assembly layer at one side edge in the machine direction, while the other side edge of the spacer layer in the machine direction is not adhered to the adjacent membrane assembly to allow entry or exit from the flow channel. The next spacer layer in the filter element is adhered to the adjacent membrane assembly at the side edge on the opposite side of the filter element from the previous spacer layer. For example, the first spacer layer 302 is adhered to the adjacent first membrane subassembly 334 at the second adhesive 306 on the left side of the filter element 300, and the second spacer layer 310 is adhered to the second membrane subassembly 338 by the fourth adhesive 312 on the right side of the filter element 300. In some embodiments, the adhesives 306, 312, 336 and 340 may include an epoxy resin or a polyurethane, such as commercially available adhesive UR3543 available from H.B. Fuller Company, having a place of business in St. Paul, Minnesota, USA, or an adhesive available from the ELANTAS Group AD-6411, which has a place of business in Hamburg, Germany. In some embodiments, adhesives 306, 312, 336, and 340 may include any adhesive that can wet both the spacer layer and the membrane layer without flowing through either layer. In addition, adhesives 306, 312, 336, and 340 may include any adhesive that can fill the voids in the spacer layer and the membrane layer material to prevent any leakage paths or filter bypass. It is worth noting herein that the appropriate adhesive to be used depends on the specific materials of the spacer layer and the membrane layer.

[0166] Reference now Figure 3B , a cross-sectional view of four filter subassemblies is shown according to various embodiments herein. A first filter subassembly 342, a second filter subassembly 344, a third filter subassembly 346, and a fourth filter subassembly 348 are stacked together and wrapped around a core to form a filter element. The machine direction of the layers is entered Figure 3B Each of the first filter subassembly 342 , the second filter subassembly 344 , the third filter subassembly 346 , and the fourth filter subassembly 348 may include a membrane subassembly 350 and a spacer layer 352 .

[0167] In some embodiments, the membrane subassembly 350 may include a first support layer (such as a first scrim layer), a membrane layer, and a second support layer (such as a second scrim layer). In other embodiments, the membrane subassembly 350 may include a membrane layer. In other embodiments, the membrane subassembly 350 may include a membrane layer and a single support layer (such as a first scrim). The components of the membrane subassembly 350 may be attached to each other using a first adhesive 354. As shown, the first adhesive 354 may be applied in the machine direction along the edge length of the first support layer, the membrane layer, and the second support layer. The first adhesive 354 may be used to attach the membrane layer to the first support layer and the second support layer to form the membrane subassembly 350. The first adhesive 354 may generate a seam 356. During the manufacturing process, the generated seam 356 is larger than the seam in the final product. By generating a larger seam 356 during the manufacturing process, sufficient adhesion between the first support layer, the membrane layer, and the second support layer can be ensured. Once sufficient adhesion is achieved, the seam 356 may be trimmed along the cutting line 358 to remove excess unusable dielectric layers.

[0168] In some embodiments, a second adhesive 360 ​​may be applied along the length of the membrane subassembly 350 and the spacer layer 352 at an edge opposite to the location of the first adhesive 354. The second adhesive 360 ​​may be used to attach the membrane subassembly 350 to the spacer layer 352, as well as to attach the components of the membrane subassembly to each other. The second adhesive 360 ​​may create a seam 362. During the manufacturing process, the seam 362 created is larger than the seam in the final product. By creating a larger seam 362 during the manufacturing process, sufficient adhesion between the membrane subassembly 350 and the spacer layer 352 may be ensured. Once sufficient adhesion is achieved, the seam 362 may be trimmed along the cut line 364 to remove excess unusable dielectric layer.

[0169] It has been described how the first adhesive 354 and the second adhesive 360 ​​adhere the layers of the first filter subassembly 342. This approach is repeated in the second, third, and fourth filter subassemblies 344, 346, and 348. Figure 3A As discussed, Figure 3B As can be seen in FIG. 1 , each spacer layer 352 is adhered to an adjacent membrane subassembly 350 at one side edge in the machine direction, while the other side edge in the machine direction of the spacer layer is not adhered to the membrane subassembly to allow entry or exit from the flow channel.

[0170] In some embodiments, forming a vortex spiral filter element produces a filter element with axial flow. Figure 4A , a cross-sectional view of a filter element is shown according to various embodiments herein. As shown, a fluid can enter a filter element 400 through a membrane layer 402 that has not yet been closed by a generated seam. Then, the fluid can flow axially through the filter element 400 and exit through an adjacent membrane layer 404 that has not yet been closed by a generated seam.

[0171] In some embodiments, if the spacer layers are identical and the membrane layers are isotropic, equal forces may be applied when the fluid flows through the filter element 400 and when the fluid is backwashed through the filter element 400. Referring now to Figure 4B , a cross-sectional view of a filter element is shown according to various embodiments herein. As shown, a fluid can enter the filter element 400 through a membrane layer 402 that has not yet been closed by a generated seam. The fluid can then flow axially through the filter element 400 and leave through an adjacent membrane layer 404 that has not yet been closed by a generated seam. It should be understood that the flow path length is the same regardless of whether the fluid is flowing through the filter element 400 in a forward or reverse direction.

[0172] Reference now Figure 5 , a schematic diagram of a filter element is shown according to various embodiments herein. Figure 5Other illustrations are provided of the path of fluid flow through the filter element 500. In particular, fluid may enter through membrane layer 502 and exit through adjacent membrane layer 504. The axial flow pattern may provide forward and reverse fluid flow, thereby generating the same flow path length, thereby enhancing the performance of the filtration device.

[0173] By creating a filter element with axial flow, it provides the opportunity to place multiple filter elements in parallel, e.g. Fig. 6A As shown, a schematic diagram of parallel filter elements 600, 602, 604 is shown according to various embodiments of the present invention. In addition, it creates an opportunity to place multiple filter elements in series, such as Figure 6B As shown, a schematic diagram of a series filter element 606, 608, 610 is shown according to various embodiments herein. It should be understood that placing multiple filter elements in parallel or in series can allow the filter element to be directly connected to an existing pipeline without the need for a larger multi-filter housing. The ability to perform both series and parallel options allows for simple customization options for different applications. Different membrane layers and spacer layers can be used in any particular filter in a series and parallel manner, which is beneficial to the application.

[0174] The axial flow permit provides additional opportunities for placing individual filter elements in parallel and for placing the resulting filter element stacks in series, e.g. Fig. 7A and Figure 7B Now refer to Fig. 7A , a cross-sectional view of a filter element stack 700, 702 is shown according to various embodiments of this paper. As shown, single filter elements 704, 706, 708 are placed in parallel and form a filter element stack 700. Similarly, single filter elements 710, 712, 714 are placed in parallel and form a filter element stack 702. In some embodiments, more than three filter elements can be formed into a filter element stack. For example, in various embodiments, four filter elements, five filter elements, six filter elements, seven filter elements, eight filter elements or nine filter elements can be formed into a filter element stack. In one embodiment, the restriction of the filter element along the fluid flow path is increasing. For example, filter elements 708 and 714 can be coarse filter elements, filter elements 706 and 712 can be medium filter elements, and filter elements 704 and 710 can be fine filter elements.

[0175] Two filter element stacks 700 and 702 may be placed in series. This creates an axial fluid flow through the filter element stacks 700, 702, as indicated by the arrows. Figure 7B , a cross-sectional view of a filter element stack 700 , 702 is shown according to various embodiments herein. Figure 7BHow the backwash fluid flows through the filter element stacks 700, 702 is illustrated, as indicated by the arrows. In some embodiments, more than two filter element stacks may be placed in series. For example, in various embodiments, three filter element stacks, four filter element stacks, five filter element stacks, six filter element stacks, seven filter element stacks, eight filter element stacks, or nine filter element stacks may be placed in series.

[0176] Interval screen

[0177] The filter device described herein may include one or more support layers, the support layer including a spacer screen. In various embodiments, the filter device may include multiple spacer screen layers. For example, the filter device may include one, two, three, four, five or six layers of spacer screens. In some embodiments, the filter device may include two layers of spacer screens. If the filter device includes more than one layer of spacer screens, the spacer screens may be separated by membrane layers and / or spacer elements, which will be described in more detail below.

[0178] The spacing screen can be made of various materials. In various embodiments, the spacing screen can be made of woven fabric, nonwoven fabric, partial woven fabric or other materials that can define the fluid flow path. For example, the spacing screen can be made of polymer, metal, composite material etc. In some embodiments, the spacing screen can include thermoplastic polymers, such as polypropylene, high-density polyethylene (HDPE), polyester, nylon and polyphenylene sulfide (PPS). In some embodiments, the spacing screen can include coating. In various embodiments, the spacing screen can include antifouling coating, conductive coating for electrostatic discharge and contain adsorbent with coating for specific pollutants.

[0179] The spacer screen can be used for various purposes. For example, the spacer screen can provide support for one or more layers of membrane. The support of the membrane layer can help to generate a channel for fluid flow in the filter device, thereby preventing the membrane from collapsing when the fluid is introduced into the filter device. In addition, the spacer screen can be designed to minimize the channel pressure drop that the filter device experiences when the fluid is introduced. Reducing the pressure drop can help improve the performance of the filter device and reduce the total energy consumption.

[0180] Reference now Figure 8, a schematic diagram of a spacing screen is shown according to various embodiments of the present invention. The spacing screen 800 may include cross-flow direction fibers 802 and flow direction fibers 804. In this case, the flow direction refers to the direction in which the fluid flows through the filter element, and the cross-flow direction refers to the direction perpendicular to the fluid flowing through the filter element. It should be understood that although fibers 802 and 804 are described as cross-flow direction fibers and flow direction fibers, respectively, the exact orientation of cross-flow direction fibers 802 and flow direction fibers 804 may not be completely in the direction of fluid flow and cross-fluid flow. When the spacing screen 800 is manufactured or used to manufacture the filter element, the cross-machine direction is approximately equal to the flow direction, and the machine direction is approximately equal to the cross-flow direction. In this case, the machine direction refers to the direction in which the material is unfolded when being fed into the screen manufacturing machine, and the cross-machine direction refers to the direction perpendicular to the machine direction. It is worth noting that the spacing screen 800 may be advantageously oriented to generate flow direction fibers 804 and cross-flow direction fibers 802 for the following reasons. First, the turbulence caused by the fluid flowing through the filter device is reduced. This is particularly true compared to the conventional orientation of spacer screens in a filter, which places the spacer screens at approximately a 45 degree angle to the fluid flowing through the device. Secondly, reducing turbulence can reduce the amount of pressure drop experienced. Finally, an increase in the amount of contaminants loaded into the filter can be experienced.

[0181] In some embodiments, the orientation of flow direction fiber 804 is approximately consistent with the flow direction of the fluid entering the filter, and the orientation of cross flow direction fiber 802 is approximately perpendicular to the flow of the fluid entering the filter.Should be understood that the term "approximately" used herein can refer to any angle less than 45 degrees.In some embodiments, the orientation of flow direction fiber 804 can be 0 degree angle, 5 degree angle, 10 degree angle, 15 degree angle, 20 degree angle, 25 degree angle, 30 degree angle, 35 degree angle or 40 degree angle with the flow of fluid, or can fall into the aforementioned scope arbitrarily.For example, the orientation of flow direction fiber 804 can be 5 degree to 10 degree angle with the flow of fluid.In some embodiments, the orientation of cross flow direction fiber 802 can be 0 degree angle, 5 degree angle, 10 degree angle, 15 degree angle, 20 degree angle, 25 degree angle, 30 degree angle, 35 degree angle or 40 degree angle with the flow perpendicular to fluid, or can fall into the aforementioned scope arbitrarily. For example, the orientation of the cross-flow direction fibers 802 can be at an angle between 5 and 10 degrees perpendicular to the flow of the fluid. In contrast, the orientation of the screen fibers of many prior art systems is about 45 degrees to the flow direction. In the embodiments described herein, the fibers of the spacer screens are not positioned at a 45 degree angle to the flow direction.

[0182] In some embodiments, cross-flow direction fibers 802 are positioned to hold flow direction fibers 804 in a desired position. Fig. 9 Shown is a side view of a spacer screen according to various embodiments herein.

[0183] In various embodiments, the cross-flow direction fibers 802 and the flow direction fibers 804 can have a variety of shapes. For example, the cross-flow direction fibers 802 and the flow direction fibers 804 can be circular, polygonal, oval, lima bean-shaped, triangular, trilobal, lobular, mushroom-shaped, dog-bone-shaped, ribbon-shaped, star-shaped, tubular, etc. It should be understood that the shape of the flow direction fibers 804 and the cross-flow direction fibers 802 can affect the amount of pressure drop experienced.

[0184] In various embodiments, the fiber size of flow direction fiber 804 and cross flow direction fiber 802 may be the same. In other embodiments, the size of flow direction fiber 804 and cross flow direction fiber 802 may be different. In some embodiments, flow direction fiber 804 may be larger than cross flow direction fiber 802. It should be understood that larger flow direction fiber 804 is advantageous because flow direction fiber 804 can generate and maintain open channels (not shown) in the filter device to allow fluid to flow through the filter device. In addition, larger flow direction fiber 804 and / or flow direction fiber 804 of the same size as cross flow direction fiber 802 can reduce the pressure drop experienced when fluid flows through the filter device. Similarly, smaller cross flow direction fiber 802 is advantageous because smaller fibers minimize the surface area on the interval screen 800, which can capture particles and reduce the performance of the filter device, and minimizing the surface area on the interval screen 800 can also reduce the amount of viscous resistance, thereby minimizing the pressure drop.

[0185] In some embodiments, the flow direction fibers 804 can be 25 microns, 50 microns, 100 microns, 200 microns, 250 microns, 300 microns, 350 microns, 400 microns, 450 microns, 500 microns, 600 microns, 700 microns, 800 microns, 900 microns or 1000 microns in size, or can fall within the aforementioned range of any. In some embodiments, the flow direction fibers 804 can be between 300 microns and 700 microns in size. For example, the flow direction fibers 804 can be 450 microns. In other embodiments, the flow direction fibers 804 can be between 500 microns and 1000 microns in size. For example, the flow direction fibers 804 can be 750 microns in size. In some embodiments, cross flow direction fiber 802 can be 25 microns, 50 microns, 100 microns, 150 microns, 200 microns, 250 microns, 300 microns, 400 microns, 500 microns, 600 microns, 700 microns, 800 microns, 900 microns or 1000 microns large, or can fall in the aforementioned scope between any.In some embodiments, cross flow direction fiber 802 can be large between 25 microns and 100 microns.For example, cross flow direction fiber 802 can be 50 microns.In other embodiments, cross flow direction fiber 802 can be large between 300 microns and 600 microns.For example, cross flow direction fiber 802 can be 500 microns large.

[0186] In various embodiments, the thickness of the spacer screen 800 can be 100 microns, 200 microns, 300 microns, 400 microns, 500 microns, 600 microns, 700 microns, 800 microns, 900 microns or 1000 microns, or can fall within any range therebetween. For example, the thickness of the spacer screen 800 can be between 500 and 700 microns. It is worth noting that the thickness of the spacer screen 800 should be large enough to generate sufficient channels to prevent pressure drops when the fluid flows through the filter device, but should not be too large so that the spacer screen 800 cannot be wound up.

[0187] In some embodiments, the open area of ​​the spacing screen 800 can be between 10 and 90 percent. In this case, the open area refers to the average percentage of the cross-sectional area that is not blocked by the cross-flow direction fibers 802 and the flow direction fibers 804 and can therefore be used for fluid flow. Therefore, in some embodiments, the total average fiber diameter of the flow direction fibers 804 and the cross-flow direction fibers 802 can block 10, 20, 30, 40, 50, 60, 70, 80 or 90 percent of the open area of ​​the spacing screen 800, or can fall within the aforementioned arbitrary range. For example, the total average fiber diameter of the flow direction fibers 804 and the cross-flow direction fibers 802 can block 60 percent of the open area of ​​the spacing screen 800. It is worth noting that the higher the open area percentage in the spacing screen 800, the greater the load of particles, and the less structural support provided to define the flow channel. In some embodiments, the flow direction fibers 804 and the cross flow direction fibers 802 may have 7 fibers, 8 fibers, 9 fibers, 10 fibers, 11 fibers, 12 fibers, 13 fibers, 14 fibers, 15 fibers, or 16 fibers per inch of the screen 800. For example, the flow direction fibers 804 and the cross flow direction fibers 802 may have 8 to 12 fibers per inch of the screen. In other embodiments, the flow direction fibers 804 and the cross flow direction fibers 802 may have 15 fibers, 20 fibers, 25 fibers, 30 fibers, 35 fibers, 40 fibers, 45 fibers, or 50 fibers per inch of the screen 800.

[0188] Scrim layer

[0189] The filter device described herein may include one or more support layers, the support layer including a scrim layer. In various embodiments, the filter device may include multiple scrim layers. For example, the filter device may include one, two, three, four, five, six, seven, eight, nine, or ten scrim layers. In some embodiments, each membrane layer may be sandwiched between the first and second scrim layers. In some embodiments, the filter device may include four scrim layers. If the filter device includes more than one scrim layer, the scrim layers may be separated by membrane layers and / or spacer layers, as described in detail above.

[0190] The scrim layer can be made of a variety of materials. In various embodiments, the scrim layer can be made of woven fabrics, nonwoven fabrics, partially woven fabrics, or other materials that can define a fluid flow path. For example, the scrim layer can be made of polymers, metals, composite materials, etc. In some embodiments, the scrim layer can include thermoplastic polymers such as polypropylene, high-density polyethylene (HDPE), polyester, nylon, and polyphenylene sulfide (PPS). In some embodiments, the scrim layer is made of commercially available products, including Tekton 3151C or 3091L, both available from Berry Global, Inc., Evansville, Indiana.

[0191] The scrim layer can be used for a variety of purposes. For example, the scrim layer can provide support for the membrane layer. The supported membrane layer can prevent the membrane layer from collapsing into the flow channel during use of the filter device. The scrim layer can further provide support for the membrane layer to prevent the membrane layer from collapsing into the flow channel during backwashing of the filter device. In addition, the scrim layer allows for the use of higher fluid pressures during forward and backwashing.

[0192] In various embodiments, the thickness of the scrim layer can be 100 microns, 200 microns, 300 microns, 400 microns, 500 microns, 600 microns, 700 microns, 800 microns, 900 microns or 1000 microns, or can fall within the range of any of the foregoing. For example, the thickness of the scrim layer can be between 500 and 700 microns.

[0193] Spacer element

[0194] The filter device described herein may include one or more spacer layers, and the spacer layer includes a spacer element layer. In some embodiments, the filter device may include one, two, three, four, five or six layers of spacer elements. For example, the filter device may include two layers of spacer elements. The layer of spacer elements may be arranged on one side or both sides of the filter membrane. It should be understood that in a filter device with more than one layer of spacer elements, the layer of spacer elements may be separated by a layer of membrane and / or spacer screen between each spacer element layer.

[0195] In various embodiments, the filter device may include one or more layers of spacer elements and one or more layers of spacer screens. For example, the filter device may include a layer of spacer elements and a layer of spacer screens. It should be understood that the membrane layer may separate the spacer element layer from the spacer screen layer. For example, again referring to Figure 2, the filter element 200 may include a membrane layer 202, a spacer layer 204 including a spacer element, followed by a membrane layer 206, and a spacer layer 208 including a spacer screen. In some embodiments, the spacer element may be disposed on the membrane layer 202 and / or 206 without a separate spacer layer 204 therebetween. In some embodiments, the spacer element may be disposed on the membrane layer 202 and / or 206 with a separate spacer layer 204 therebetween. It should be understood that the spacer element may be disposed on one side of the membrane layer 202 and / or 206. In other embodiments, the spacer element may be disposed on both sides of the membrane layer 202 and / or 206. In other embodiments, the spacer screen may include one or more spacer elements disposed thereon. For example, the spacer screen may include one side having one or more spacer elements disposed thereon. Alternatively, the spacer screen may include two sides having one or more spacer elements disposed thereon. In other embodiments, the spacer layer may include a mixture of spacer screens and spacer elements. For example, one side of the spacer layer may include a spacer screen and the other side may include a spacer element.

[0196] The spacer element layer may include multiple spacer elements within the layer. In some embodiments, the spacer element may be arranged on one side of the layer. In other embodiments, the spacer element may be arranged on both sides of the layer. It should be understood that if the spacer element is arranged on both sides of the layer, the arrangement mode on each side of the layer may be the same or different. In addition, the shape of the spacer element on each side of the layer may be the same or different. These spacer elements can be used for various purposes. For example, the spacer element can generate a flow channel to provide support for one or more layers of membrane. It is worth noting that providing structural support for the layer of the membrane is important for generating channels in the filter device to allow the fluid to flow, thereby preventing the membrane from collapsing when the fluid is introduced into the filter device. It is further worth noting that the flow channel must be large enough to prevent blocking during use, therefore, it is believed that the flow channel width should be at least 10 times larger than the maximum size of the pollutant particles to be filtered. In addition, the flow channel can be designed to guide the flow of fluid to achieve a uniform flow field. In addition, the spacer element can reduce the pressure drop experienced by the filter device when the fluid is introduced. Reducing the pressure drop can help improve the performance of the filter device and reduce the total energy consumption. In addition, by providing a position indication for folding or applying an adhesive, the spacer element can be used as a manufacturing aid during the assembly of the filter device. Other purposes include allowing particle loading deep into the channels created by the spacer elements, minimizing the amount of particle loading onto the column in both forward and reverse fluid flow, assisting in filter device seams by placing the spacer elements in an arrangement that enables proper welding / bonding or acting as the actual bonding adhesive, and allowing for fouling.

[0197] In some embodiments, the overall size of the spacer element layer can be similar to that described above about the spacer screen. For example, in some embodiments, the thickness of the spacer element can be between 100 microns, 200 microns, 300 microns, 400 microns, 500 microns, 600 microns, 700 microns, 800 microns, 900 microns and 1000 microns, or can fall in the aforementioned arbitrarily range. For example, the thickness of the spacer element can be 560 microns thick. An example of a spacer element with a thickness of 560 microns is SWM part number NO2015 90PP-NAT, available from SWM International, which is owned by Mativ and has a place of business in Alpharetta, Georgia, USA.

[0198] In other embodiments, the thickness of the spacer element may be 890 microns thick.An example of a spacer element having an element thickness of 890 microns is SWM part number 410-000322, available from SWM International, owned by Mativ, having a place of business in Alpharetta, Georgia, USA.

[0199] It should be understood that the thickness of the spacer elements is directly related to the overall width of the flow channel generated by the spacer elements. The spacer elements can be arranged in columns and rows on the spacer medium. For example, in various embodiments, the spacer elements can be arranged in diagonal columns. In other embodiments, the spacer elements can be arranged in straight columns. In some embodiments, the spacer elements can be arranged in offset rows. In some embodiments, the spacer elements can generate a micro-patterned outer surface of the spacer medium. In some embodiments, the spacer elements can be spaced one millimeter, two millimeters, three millimeters, four millimeters, or five millimeters, or can fall within any range between the foregoing.

[0200] The spacer elements can be in various shapes. For example, the spacer elements can be circular, elliptical, airfoil, triangular, rhombus, rectangular, square, parallelogram, trapezoid, kite, irregular trapezoid, teardrop, pentagon, heptagon, octagon, hexagon, etc. For example, now refer to Fig. 10A, a top-down view of a spacer element layer is shown according to various embodiments herein. The circular spacer elements 1002 can be arranged in rows on the spacer medium 1000. In some embodiments, the circumference of the circular spacer elements 1002 can be the same. In other embodiments, the circumference of the circular spacer elements 1002 can be different. For example, the circular spacer elements 1002 arranged at or near the top of the spacer medium 1000 can be larger than the circular spacer elements 1002 arranged at or near the bottom of the spacer medium 1000. Without being bound by theory, it is believed that arranging the spacer elements in a gradient can help maximize the flux and loading that can occur in the filtration device. In some embodiments, the height of the circular spacer elements 1002 can be the same, such as Fig. 10B , a side view of a spacer element layer is shown according to various embodiments herein. In other embodiments, the height of the circular spacer element 1002 may be different, such as Fig. 10C , a side view of a spacer element layer is shown according to various embodiments herein. In some embodiments, the circular spacer elements 1002 may be symmetrically distributed on the spacer medium 1000. In other embodiments, the circular spacer elements 1002 may be asymmetrically distributed on the spacer medium 1000.

[0201] In some embodiments, the spacer elements may be oval in shape. Oval shaped spacer elements may be beneficial because the symmetrical shape may reduce turbulence and particle loading in both forward and reverse fluid flow directions. Fig.11A A top-down view of a spacer element layer according to various embodiments herein is shown. The oval spacer elements 1102 may be arranged in rows on the spacer medium 1100. Referring now to Fig. 11B , shows a side view of a spacer element layer according to various embodiments herein. As shown, the heights of the elliptical spacer elements 1102 can be the same. In some embodiments, the elliptical spacer elements 1102 can have similar sizes and can be arranged in a manner similar to that described above with respect to Fig. 10A The described method is set on the spacing medium 1100. For example, Fig.12 A top-down view of a spacer element layer according to various embodiments herein is shown. Fig.12 As shown, the elliptical spacing elements 1202 disposed at or near the top of the spacing medium 1200 can be larger than the elliptical spacing elements 1202 disposed at or near the bottom of the spacing medium 1200. Alternatively, the elliptical spacing elements 1302 can be disposed on the spacing medium 1300 so that the elliptical spacing elements 1302 are offset from each other, such as Fig.13 , a top-down view of a spacer element layer is shown according to various embodiments herein. In other embodiments, the elliptical spacer elements 1402 can be arranged in diagonal rows on the spacer medium 1400, such as Fig.14, a top-down view of a spacer element layer is shown according to various embodiments herein.

[0202] The spacing medium may include one or more spacing element shapes. Fig.15A , a top-down view of a spacer element layer is shown according to various embodiments herein. In some embodiments, spacer medium 1500 can include two spacer element shapes. As shown, spacer medium 1500 can include elliptical spacer elements 1504 and rectangular spacer elements 1502. Rectangular spacer elements 1502 can be used to provide structural support for spacer medium 1500 when spacer medium 1500 is wound up. Providing structural support for spacer medium 1500 can help the generated channel to remain open and prevent channel collapse, especially on the downstream side of the filter device. For example, the elliptical spacer elements 1504 at or near the bottom of spacer medium 1500 can be supported by rectangular spacer elements 1502 when wound up. Fig. 15B Schematic diagrams of spacer element layers according to various embodiments herein are shown. Fig. 15B The back side of the spacing medium 1500 is shown when the spacing medium 1500 is wound up.

[0203] In some embodiments, the spacer element may be teardrop-shaped. The teardrop-shaped spacer element may be beneficial in maintaining pressure throughout the filter device and may help release particles when the filter device is backwashed. Fig.16A , a top-down view of a spacer element layer according to various embodiments herein. Teardrop-shaped spacer elements 1602 can be arranged in a row on the spacer medium 1600. In some embodiments, the teardrop-shaped spacer elements 1602 can have the same length and width. In other embodiments, the teardrop-shaped spacer elements 1602 can have different lengths and widths. For example, the teardrop-shaped spacer elements 1602 arranged at or near the top of the spacer medium 1600 can be larger than the teardrop-shaped spacer elements 1602 arranged at or near the bottom of the spacer medium 1600. Now referring to Fig. 16B , shows a side view of a spacer element layer according to various embodiments herein. As shown, the teardrop-shaped spacer elements 1602 can be the same height. In other embodiments, the teardrop-shaped spacer elements 1602 can be different heights. In some embodiments, the teardrop-shaped spacer elements 1602 can be arranged in a similar manner to that described above with respect to Fig. 10A The described method is arranged on the spacing medium 1600.

[0204] In various embodiments, the spacer element layer may include spacer elements of different shapes in the seam region of the spacer element layer. It should be understood that the spacer elements in the seam region having different shapes than the remaining spacer elements in the spacer medium can help prevent the spacer elements from nesting with a second spacer element layer when the layers of the filter device are wound. Fig.17 , a top-down view of a spacer element layer is shown according to various embodiments herein. Oval spacer elements 1702 may be disposed in a row on a spacer medium 1700, while left-slanted rectangular spacer elements 1704 may be disposed on the spacer medium 1700 at seams 1706. In other embodiments, right-slanted rectangular spacer elements 1804 may be disposed on the spacer medium 1800, such as Fig.18 , a top-down view of a spacer element layer is shown according to various embodiments herein.

[0205] In various embodiments, a variety of spacing element shapes can be used in the spacing medium. Fig.19 , a top-down view of a spacer element layer is shown according to various embodiments herein. As shown, the spacer medium 1900 may include an elliptical spacer element 1902, a diamond-shaped spacer element 1904, and a triangular spacer element 1906. In addition, a rectangular spacer element 1908 may be disposed in a seam area 1910 of the spacer medium 1900. Including a variety of shapes in the spacer medium 1900 may be beneficial to improving the structure (not the device) of the spacer element layer or the overall filter device. In addition, including a variety of shapes may help improve the overall performance of the filter device.

[0206] 3D printing process for forming spacer elements

[0207] The spacer elements described herein can be formed directly on the membrane using an additive manufacturing process, referred to herein as three-dimensional (3D) printing. Spacer elements generated using 3D printing can include structural geometries that cannot be achieved using other manufacturing techniques, including techniques with high aspect ratios.

[0208] Material handling is also reduced when the spacer elements are formed directly on the membrane or filter media.

[0209] Material of spacer element

[0210] The spacer element layer can be made of various materials that are chemically compatible with the membrane layer. For example, the spacer element layer can be made of polymers, metals, composite materials, etc. For example, the spacer element layer can include UV-cured epoxy resins, UV-cured polyurethanes, and silicone polymers. For example, the material can include, but is not limited to, polydimethylsiloxane (PDMS) and UV-cured PDMS. The material can include, but is not limited to, thermoplastic polymers, including, but not limited to, polyamides, polypropylene, polyurethanes, polyethylene, polylactic acid, acrylonitrile butadiene styrene, styrene, and copolymers, mixtures, or derivatives thereof.

[0211] It should be understood that the spacing elements can be constructed of a variety of materials that can withstand a range of pressures, temperatures and chemical conditions in the environments in which they are used in operation. The spacing elements can further be constructed of materials at least as strong as the filter media or membranes on which they are deposited.

[0212] The material of the spacer element may include additives, including chemical additives and particulate additives. The additives may inhibit scaling, inhibit biological growth, act as adsorbents, catalyze reactions, act as further functionalized chemical treatment agents, or perform two or more of these functions.

[0213] Method for assembling a filter device

[0214] Many different methods are contemplated herein, including, but not limited to, methods of manufacture, methods of use, etc. Aspects of the filtration devices described elsewhere herein may be performed as operations of one or more methods according to various embodiments herein.

[0215] Reference now Fig. 20 , a flow chart of a method 2000 for preparing a vortex spiral wound filter device according to an embodiment is shown. In some embodiments, the method 2000 can be performed by a machine. In other embodiments, the method 2000 can be performed manually.

[0216] In some embodiments, the method 2000 may include deploying the membrane material and the spacer layer 2002. In some embodiments, a cantilevered deploying membrane material may be used. In some embodiments, the deploying device may alert the user that the membrane material is running out and needs to be replaced. In some embodiments, the spacer layer material may include a spacer element layer. In other embodiments, the spacer layer material may include a spacer screen.

[0217] In some embodiments, method 2000 can include combining the expanded film material and the expanded spacer layer material 2004. In some embodiments, combining the expanded film material and the expanded spacer layer material can include overlapping the materials such that edges of each material are aligned.

[0218] In some embodiments, the membrane material may include spacer elements on one or both sides of the membrane material.

[0219] In some embodiments, method 2000 may include dispensing an adhesive as described in more detail above on overlapping material 2006. In some embodiments, the adhesive may be dispensed over a portion of the overlapping material. For example, the adhesive may be applied to the width and length of the overlapping material. In some embodiments, the adhesive may be applied approximately one inch from the edge of the overlapping material. In some embodiments, the machine may be programmed to shut down after a sufficient amount of adhesive has been applied.

[0220] In some embodiments, method 2000 may include repeating the above steps to generate a second overlapping material set 2008 .

[0221] In some embodiments, method 2000 may include combining a first overlapping material group and a second overlapping material group 2010. In some embodiments, combining the first overlapping material group and the second overlapping material group may include overlapping the groups so that the edges of each group are aligned. It is worth noting that when the material groups overlap, the lengths of the overlapping materials with adhesive should not overlap.

[0222] In some embodiments, method 2000 may include winding the set of overlapping materials 2012. In some embodiments, the overlapping materials may be wound around a core positioned longitudinally along the width of the overlapping materials. In some embodiments, the overlapping materials may be wound in a spiral. In some embodiments, the overlapping materials may be wound until a desired spiral diameter is achieved.

[0223] In some embodiments, the method 2000 can include, once the desired diameter is obtained, using a hot knife to cut the layer of wrapping material 2014. In other embodiments, scissors can cut the layer of wrapping material.

[0224] In some embodiments, method 2000 may include wrapping an outer packaging 2016 around a wrapping material layer. In various embodiments, the outer packaging may include a film layer soaked with an adhesive. In some embodiments, the outer packaging (also referred to as an impermeable packaging) may wrap around the wrapping material layer for one or more turns. For example, the outer packaging may wrap around the wrapping material layer for two turns.

[0225] Example

[0226] Example 1: Effect of spacer layer thickness on membrane surface area

[0227] Modeling was used to compare the 320 micron thick spacer layer and the 640 micron thick spacer layer with the Donaldson Company LifeTecTM Filters were compared.

[0228] refer to Fig.21 , a graph showing the effect of spacer layer thickness on membrane surface area is shown according to an embodiment. Fig.21 It is shown that when using a spacer layer with a thickness of 320 microns and 640 microns in a filter device, the filter is TM The overall surface area of ​​the membrane increases compared to the surface area.

[0229] refer to Fig. 22 , a graph showing the effect of spacer layer thickness on membrane surface area is shown according to an embodiment. Fig. 22 As shown, as the outer diameter of the filter layer increases, the surface area of ​​the membrane increases. Specifically, when a spacer layer with a thickness of 320 microns is used, the surface area of ​​the membrane is greater than that of LifeTec TM The filter is approximately eight times larger. When using a spacer layer with a thickness of 640 microns, the membrane surface area is greater than that of LifeTec TM The filter is about five times larger.

[0230] Example 2: Effect of the number of spacer layers on the pressure drop of the filtration device

[0231] The effect of one insulation layer on the pressure drop experienced by the filtration device was compared to two insulation layers.

[0232] Reference now Fig.23 , a graph showing the effect of the number of spacer layers on pressure drop is shown according to an embodiment. The graph illustrates that one spacer layer results in a significant increase in pressure difference at a lower flow volume compared to two spacer layers.

[0233] Example 3: Effect of spacer size on pressure drop of filtration device

[0234] The effect of the spacer size on the pressure drop experienced by the filtration device was compared.

[0235] Reference now Fig.24 , a graph showing the effect of spacer size on pressure drop is shown according to an embodiment. The graph illustrates that a spacer that is 1.4 inches tall and 3 inches wide ("Experimental Wide") experiences a lower pressure differential than a spacer that is 3 inches tall and 1.5 inches wide ("Experimental High").

[0236] Example 4: Modeling the effect of membrane length on pressure drop and flux

[0237] Model the effect of membrane layer length on the pressure drop experienced.

[0238] Reference now Fig.25, a graph showing the effect of wrap layer length on pressure drop is shown according to an embodiment. The graph illustrates that after one inch, as the length of the wrap layer increases, the pressure drop experienced also increases.

[0239] Reference now Fig.26 , a graph showing the effect of wound film length on flux is shown according to an embodiment. The graph illustrates that shorter diameter four inch and two inch high membrane filters experience much greater flux than a 10 inch membrane filter.

[0240] Example 5: Effect of element, core and spacer screen dimensions on various properties

[0241] If the target terminal pressure drop is known, the unit membrane surface area for a specific application can be determined by performing a flat plate test on the application fluid. The flat plate test will determine the basic membrane performance. If the required application volume of the fluid to be filtered is known, the amount of membrane surface area of ​​the filter is directly proportional to the amount of fluid that the flat plate can filter.

[0242] S 预测 = Predicted membrane surface area

[0243] S 平板 = Flat membrane surface area

[0244] V 平板 = Fluid volume for terminal pressure drop in flat plate test

[0245] V 应用 = Target application volume to be filtered

[0246]

[0247] When the desired height, membrane thickness, screen thickness, and core diameter are known, this information can be used to determine the outer diameter of the element.

[0248] refer to Fig. 27 , a graph showing the effect of element diameter on several properties is shown according to an embodiment. The graph illustrates that as element diameter increases, pressure drop, dielectric loss and channel loss decrease, while membrane surface area increases.

[0249] refer to Fig.28 , a graph showing the effect of element length on several characteristics is shown according to an embodiment. The graph illustrates that as element length increases, pressure drop, channel loss, and surface area increase, while dielectric loss decreases.

[0250] refer to Fig.29 , a graph showing the effect of core diameter on several properties is shown according to an embodiment. The graph illustrates that as the core diameter increases, the pressure drop and channel losses increase, the membrane surface area increases, and the dielectric losses remain approximately constant.

[0251] refer to Fig.30 , a graph showing the effect of spacer screen thickness on several properties is shown according to an embodiment. The graph illustrates that as the spacer screen thickness increases, the membrane surface area and channel loss decrease, while the pressure drop and dielectric loss increase.

[0252] It should be noted that, as used in this specification and the appended claims, the singular forms "a", "an", and "the" include plural referents unless the content clearly dictates otherwise. It should also be noted that the term "or" is generally used in its sense, including "and / or", unless the content clearly dictates otherwise.

[0253] It should also be noted that, as used in this specification and the appended claims, the phrase "configured to" describes a system, device, or other structure that is constructed or configured to perform a particular task or adopt a particular configuration. The phrase "configured to" may be used interchangeably with other similar phrases, such as arranged and configured, constructed and arranged, constructed, manufactured, and arranged, etc.

[0254] All publications and patent applications in this specification are indicative of the common technical level in the field to which the invention belongs. All publications and patent applications are incorporated herein by reference to the same extent as if each individual publication or patent application was specifically and individually indicated to be incorporated herein by reference.

[0255] As used herein, the recitations of numerical ranges by endpoints are intended to include all numbers within that range (eg, 2 to 8 includes 2.1, 2.8, 5.3, 7, etc.).

[0256] The headings used herein are intended to be consistent with the recommendations under 37 CFR 1.77 or to provide organizational cues. These headings should not be considered to limit or characterize the invention or inventions described in any claims that may issue from this disclosure. For example, although a heading refers to the "Field," such claims should not be limited by the language selected under this heading to describe the alleged technical field. In addition, the description of a technology in the "Background" is not an admission that the technology is prior art to any one or more inventions in the content of this disclosure. The "Summary of the Invention" should also not be considered to characterize the invention or inventions described in the issued claims.

[0257] The embodiments described herein are not intended to be exhaustive or to limit the invention to the precise forms disclosed in the following detailed description. Instead, the embodiments are selected and described so that those skilled in the art can appreciate and understand the principles and practices. Therefore, various aspects have been described with reference to various specific and preferred embodiments and techniques. However, it should be understood that many variations and modifications may be made while maintaining the spirit and scope of this article.

Claims

1. A filtering device, comprising: A first vortex spirally wound filter element, the first vortex spirally wound filter element comprising: one or more spacer layers; one or more membrane layers, the one or more membrane layers being disposed between the one or more spacer layers; and a plurality of spacer elements; Wherein, the aspect ratio of the height to the width of the first vortex spirally wound filter element is less than 8:

1.

2. The filter device according to any one of claims 1 and 3-13, further comprising a second vortex spirally wound filter element, a third vortex spirally wound filter element and a fourth vortex spirally wound filter element, wherein: The second, third and fourth vortex spirally wound filter elements each include: one or more spacer layers; one or more membrane layers, the one or more membrane layers being disposed between the one or more spacer layers; and a plurality of spacer elements; Wherein, the aspect ratio of the height to the width of the second vortex spirally wound filter element, the third vortex spirally wound filter element and the fourth vortex spirally wound filter element is less than 8:

1.

3. The filter device of any one of claims 2 and 4-13, further comprising a fifth vortex spirally wound filter element, a sixth vortex spirally wound filter element, a seventh vortex spirally wound filter element, and an eighth vortex spirally wound filter element, wherein: The fifth, sixth, seventh and eighth vortex spirally wound filter elements each comprise: one or more spacer layers; one or more membrane layers, the one or more membrane layers being disposed between the one or more spacer layers; and a plurality of spacer elements; Wherein, the aspect ratio of the height to the width of the fifth vortex spirally wound filter element, the sixth vortex spirally wound filter element, the seventh vortex spirally wound filter element and the eighth vortex spirally wound filter element is less than 8:

1.

4. The filter device of any one of claims 2-3 and 5-13, further comprising a first stack comprising the first, second, third, and fourth vortex spirally wound filter elements placed in parallel.

5. The filtering device according to any one of claims 3-4 and 6-13, further comprising a first stack, wherein the first stack comprises the first vortex spirally wound filter element, the second vortex spirally wound filter element, the third vortex spirally wound filter element and the fourth vortex spirally wound filter element placed in parallel, and further comprising a second stack, wherein the second stack comprises the fifth vortex spirally wound filter element, the sixth vortex spirally wound filter element, the seventh vortex spirally wound filter element and the eighth vortex spirally wound filter element placed in parallel.

6. The filtering device according to any one of claims 3-5 and 7-13, wherein: The first stack and the second stack are placed in series.

7. The filter device of any one of claims 1-6 and 8-13 having a height between two and ten inches.

8. The filter device of any one of claims 1-7 and 9-13 having a diameter between 5 and 40 inches.

9. The filtration device according to any one of claims 1-8 and 10-13, further comprising one or more support layers disposed between the one or more membrane layers and the one or more spacer layers.

10. The filtering device according to any one of claims 1 to 9 and 11 to 13, wherein: The plurality of spacer elements include various shapes including one or more of an airfoil, a triangle, a rhombus, a parallelogram, a trapezoid, a kite, a trapezoid, a pentagon, a heptagon, an octagon, a hexagon, a circle, an oval, a square, a rectangle, and a teardrop.

11. The filtering device according to any one of claims 1 to 10 and 12 to 13, wherein: The plurality of spacer elements include an airfoil shape.

12. The filtering device according to any one of claims 1 to 11 and 13, wherein: The plurality of spacer elements are arranged in a size gradient.

13. The filtering device according to any one of claims 1 to 12, wherein: The plurality of spacer elements are distributed asymmetrically.

14. A filtering device comprising: A vortex spirally wound filter element, the vortex spirally wound filter element comprising: one or more spacer screens having flow direction fibers and cross-flow direction fibers, wherein the flow direction fibers are oriented approximately in the direction of flow of a fluid entering the vortex spiral wound filter element; and One or more membrane layers are disposed between the one or more spacer screens.

15. The filter device of any one of claims 14 and 16-20, having an aspect ratio of height to width of less than 8:

1.

16. The filtering device according to any one of claims 14-15 and 17-20, wherein: The flow direction fibers and the cross flow direction fibers include various shapes, including one or more of the following: circular, polygonal, elliptical, lima bean, triangular, trilobal, lobular, mushroom, dog bone, ribbon, star and tubular.

17. The filtering device according to any one of claims 14 to 16 and 18 to 20, wherein: The flow direction fibers are 100 to 500 microns in size.

18. The filtering device according to any one of claims 14-17 and 19-20, wherein: The cross-flow direction fibers are 50 to 300 microns in size.

19. The filtering device according to any one of claims 14 to 18 and 20, wherein: The flow direction fibers are larger than the cross flow direction fibers.

20. The filtering device according to any one of claims 14 to 19, wherein: The one or more spaced screens may have an open area between 10 and 90 percent.

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