High-Pressure Filter Apparatus Having an Outer Sleeve and Associated Methods

Abstract

A high pressure filter apparatus is described that includes first and second pieces having a weld seam along the circumference of the body, and a sleeve disposed about and surrounding the weld seam.

Description

[Technical Field]

[0001] SUMMARY OF THE INVENTION The present disclosure relates to housings and devices useful for containing fluid flows under high pressure. [Background technology]

[0002] Across a wide range of industries and applications, various types of fluid containers and fluid processing vessels are designed to contain liquid or gaseous fluids at high pressures. Examples include isotactic press devices (see, e.g., U.S. Patent Application Publication No. 2007 / 0218160), pressurized flow control structures (see, e.g., U.S. Patent Application Publication No. 2013 / 0240062), and high-pressure filter devices (see, e.g., U.S. Patent Application Publication No. 2018 / 0193785).

[0003] A fluid container or vessel must be capable of containing a fluid at high pressure and for a sustained period, either in a static or flowing state. The container or vessel must be stable to the pressure and temperature conditions of the fluid, be chemically stable, and not be degraded by the contained fluid. The container or vessel is constructed from components that fit together to form a fluid-tight seal that prevents fluid from escaping from the interior of the container or vessel.

[0004] The need to treat high-pressure fluid flows spans many industries, including, as more specific examples, the chemical processing industry, the automotive and aerospace industries, and the semiconductor manufacturing industry. Depending on the application, the process using the fluid may often require the fluid to be largely free of impurities. As a result, many systems using high-pressure fluids include filter devices that remove impurities from the fluid while it is under pressure.

[0005] Semiconductor manufacturing operations require high-purity fluids for various processing steps. As an example, liquid tin is a type of molten metal used to expose the extreme ultraviolet (EUV) light used in the photolithography process. For use in the photolithography process, liquid tin must be free of impurities, contaminants, and particles that could disrupt the process. Filtering the molten metal to remove impurities requires that the molten metal be passed through a filter at high pressure and temperature.

[0006] The filter and liquid metal stream must be contained in a filtration system that is leak-proof at temperatures that may exceed 200 degrees Celsius and pressures that may exceed 5,000 pounds per square inch (psig) or even exceed 8,000 psig or more. Certain filtration system designs currently available may be useful at temperatures and pressures that approach or meet these ranges for filtering fluids under pressure. However, as with many commercial endeavors, the need for improved performance is constant. Current or previous designs of high-pressure filtration equipment must continually be improved to meet ever-higher performance requirements.

[0007] For processing fluids at high temperatures and pressures, there remains a need for filtration equipment that can be used to filter a variety of fluids, such as, for example, molten metals and other types of liquids and gases. Summary of the Invention

[0008] A high-pressure filter apparatus is described that can withstand very high pressures without leaking or otherwise failing. The filter apparatus can include a fluid inlet at an inlet end, a fluid outlet at an outlet end, a metal sidewall between the fluid inlet and the fluid outlet, a filter chamber defined by the metal sidewall, and a filter positioned within the filter chamber.

[0009] More specific examples may include multiple (at least two) housing pieces joined together by weld seams. These exemplary assemblies may include a housing body having a weld seam and an outer sleeve disposed over the housing body (optionally, but not necessarily, over the weld seam) to reinforce the body and enable the housing body to withstand higher internal pressures during operation compared to a body without the weld seam.

[0010] There are a variety of known filtration systems useful for filtering fluids at high pressures and temperatures. Some of these include filter housing structures made of metal formed by welding (including brazing). While welded structures are useful and can handle high internal pressures, weld seams within pressure vessels can create areas of reduced strength. For example, welding high-melting-point metals or alloys can cause as much as a 50% reduction in material strength due to recrystallization.

[0011] As described herein, the separate sleeve piece is applied to the exterior surface of the housing body by preparing the exterior surface to a smooth finish and then sliding the sleeve over the exterior surface of the housing body. The outer sleeve may be heated to expand the sleeve to fit the filter housing. As the sleeve cools, the sleeve, which may have an inner diameter smaller than the outer diameter of the housing body, may pre-strain the housing body at room temperature. During use, when the housing body is subjected to stress, the outer sleeve may reduce deformation of the weld seam under load, thus increasing its ultimate strength.

[0012] Because the sleeve reinforces the welded housing body, the material used to form the welded housing body can be selected for compatibility with fluids that contact the housing body during use. The sleeve can be formed of a different material than the housing body. While the material selected for the sleeve can be driven by stiffness and strength, the material selected for the housing body can be driven by other properties, such as weldability or material compatibility. The housing body can be prepared from a material that is compatible with the fluids that pass through the body during use. The sleeve can be prepared from a material that has desirable mechanical properties, such as high tensile strength, elastic modulus, and ductility, compared to the material of the wetted housing body.

[0013] According to one aspect, the present disclosure relates to a high-pressure filter apparatus. The apparatus includes a welded housing body including a multi-piece welded housing body having a fluid inlet, a fluid outlet, and a weld seam between the fluid inlet and the fluid outlet, a filter chamber, and a filter housed in the filter chamber. The apparatus further includes a sleeve surrounding the housing body and applying pressure to the housing body.

[0014] According to another aspect, the present specification relates to a method of forming a high-pressure filter product, the method including providing two or more housing pieces including a filter, a filter chamber, an inlet end, and an outlet end, securing the filter in position within the filter chamber, welding the two or more housing pieces to form a housing body including one or more weld seams, and disposing one or more sleeves around the housing body to surround the housing body. According to another aspect, the present disclosure relates to a high-pressure filter apparatus including a fluid inlet at an inlet end, a fluid outlet at an outlet end, a metal sidewall between the fluid inlet and the fluid outlet, a filter chamber defined by the metal sidewall, and a filter positioned within the filter chamber, the apparatus capable of containing a fluid within the filter chamber at a fluid pressure of at least 40,000 psig at 20 degrees Celsius without leaking. [Brief explanation of the drawings]

[0015] [Figure 1A] 1 shows an assembly view of the exemplary filter device described. [Figure 1B] 1 shows an assembly view of the exemplary filter device described. [Figure 1C] 1 shows an assembly view of the exemplary filter device described. [Figure 2A] 1 shows an assembly view of the exemplary filter device described. [Figure 2B] 1 shows an example of the assembly process described. DETAILED DESCRIPTION OF THE INVENTION

[0016] The drawings are intended as non-limiting examples and are schematic and not necessarily to scale.

[0017] A high-pressure filter apparatus is described that can withstand very high pressures without leaking or otherwise failing. An exemplary apparatus includes a multi-piece welded housing (also known as a "welded housing body") that includes two or more housing pieces, with at least one weld seam formed between two of the housing pieces. The weld is a known weak point in the welded housing body. To strengthen the welded housing body, the apparatus includes an external sleeve that is positioned around the body, optionally at the weld seam, covering the weld seam and applying pressure to the exterior of the housing body at the weld seam. A welded housing body reinforced by the sleeve can withstand higher internal pressures compared to a welded housing body without the sleeve.

[0018] The exemplary housing body described is made by assembling multiple individual, structurally distinct pieces ("housing pieces") into an assembled welded housing body by welding the separate pieces together at their ends to form weld seams at the ends of the pieces. Two or more housing pieces are welded together at adjacent ends around the periphery of the pieces, and the welded pieces form a continuous, high-pressure housing body that includes a filter chamber, an inlet connected to the filter chamber, and an outlet connected to the filter chamber. The welded housing body has one or more weld seams and can withstand significantly higher internal pressures without leaking or otherwise failing. Furthermore, in certain types of high-pressure filtration applications, even higher levels of internal pressure within the housing body may be useful or advantageous, including pressure levels that are too high to be safely used due to reduced strength at the weld seams.

[0019] The term "welding," as in "welded seam," refers to any method of structurally attaching two opposing ends of two abutting housing body pieces by heating metal above its melting point and allowing the metal to cool to form a united metal structure at the location of the seam to structurally attach the two abutting ends to one another. Welding processes include any form of welding, including brazing, friction welding, soldering, etc.

[0020] According to this specification, a reinforcing sleeve is placed over the outside of a welded housing body, surrounding and reinforcing the body, and optionally surrounding the weld seam, allowing the housing body to safely maintain a greater internal pressure than would be safely maintained by the welded housing body alone in the absence of the reinforcing sleeve. The sleeve can be placed directly over the weld seam. Alternatively, the sleeve may be placed on the body surface in a location that does not cover the seam and does not include the seam, while still providing the desired reinforcing effect that strengthens the housing body and increases the level of internal pressure the body can withstand without causing a leak or other failure at the weld seam.

[0021] The housing of the high-pressure filter apparatus can be designed and constructed from a range of metallic materials, with a particular housing body material being selected to meet a combination of objectives which may include material strength and compatibility of the material with the fluids used in the high-pressure filtration process, particularly the fluids which flow through and contact the interior of the housing body during use.

[0022] For filter devices designed to process liquid metals at high pressures and temperatures, useful or preferred housings and their component pieces can be made from refractory metals. Refractory metals can be thermally stable and chemically resistant. For example, molybdenum can withstand high temperatures (e.g., above the freezing point of tin) without significant expansion or softening.

[0023] However, a problem with using molybdenum and other refractory metals is that the strength of the refractory metal can be significantly reduced when welded; for example, welded molybdenum may exhibit less than 50% of the strength of unwelded molybdenum.

[0024] To compensate for the reduced strength of the weld seam, the exemplary filter device described uses a reinforcing sleeve on the exterior of the body. Because the sleeve is present to increase the strength of the housing body, the strength of the housing body is not emphasized as a factor in selecting the material used to form the housing body. The housing body material may advantageously be selected based on its compatibility with the fluid contained by the device during operation and need not be selected primarily to provide a particular level of mechanical strength. The housing body of the high-pressure filter device, including the described sleeve, may be prepared from a high-melting-point metal such as molybdenum and may include a weld seam, but is not limited by the reduced strength of the weld seam.

[0025] The external sleeve may be made from a non-welded material that applies pressure to the housing body such that the body deforms from high fluid pressures inside the housing during use. The external sleeve acts to reduce or prevent deformation of the body under load during use, for example at the weld seam, thus increasing the overall strength of the housing body and allowing the housing to safely accommodate increased internal pressures compared to safe internal pressures in the absence of the sleeve.

[0026] The material of the non-welded sleeve may be selected based on mechanical properties such as high tensile strength, modulus of elasticity, and ductility, and the material does not need to be compatible with the fluid flowing inside the housing.

[0027] The housing pieces of the described multi-piece filter devices can be prepared from a wide range of metallic materials, including, inter alia, refractory metals (including alloys), alloys such as stainless steel, other metals such as nickel and nickel alloys, aluminum and aluminum alloys, cobalt and cobalt alloys, etc. Refractory metals include niobium, molybdenum, tantalum, tungsten, rhenium, and alloys containing one or more of these, such as: alloys containing molybdenum and rhenium (MoRe), alloys containing tungsten and rhenium (WRe), alloys containing molybdenum, hafnium, and carbon (MoHfC, or "MHC"), or alloys containing titanium, zirconium, and molybdenum (TiZrMo).

[0028] The particular material for any of the various pieces may be selected based on factors including the need for particular mechanical properties such as strength and ductility, ease of processing including the ability to form welds using the material, and chemical compatibility with the fluid contained by the filter device during operation.

[0029] Advantageously, the use of the described sleeve to reinforce the housing body can reduce the need for the housing body to be made from a high-strength material. Instead of emphasizing material strength, the housing body material can be selected to emphasize material compatibility with the fluids that flow through and contact the housing body during use. For filter devices designed to process liquid metals at high pressures and temperatures, useful or preferred housing bodies and their component pieces may be made from refractory metals, including alloys thereof.

[0030] The reinforcing sleeve may be of any construction and material that can be incorporated into the described high-pressure filter apparatus, optionally positioned around the housing body to reinforce the housing body at the location of the weld seam.

[0031] An example of a useful or preferred sleeve can be in the form of a solid tubular structure in a rigid tubular (e.g., cylindrical) form, since the sleeve exists separately from the weld housing. The sleeve can be sized and configured to allow the sleeve to be installed on the outer surface of the weld housing body by sliding or "pressing" the sleeve along the length of the weld housing body, optionally to the location of the weld seam, so that the inner surface of the sleeve contacts the outer surface of the weld housing body, optionally at the weld seam.

[0032] Exemplary sleeves may be tubular and may have dimensions of length, inner and outer diameters, and thickness of the tubular wall. One example of a tubular wall structure may include a monolithic metal structure extending along the entire circumference and length of the sleeve. By "monolithic" structure, it is meant that the tubular sleeve wall includes at least one continuous, uninterrupted path of solid metal extending around the entire circumference of the sleeve and at least one continuous, uninterrupted path of solid metal extending along the length of the tubular sleeve. Specifically, these exemplary sleeves are formed from a single mass of metal that is continuous along its length and circumference, and not from multiple, separate, segmented windings of one or more lengths of metal in the form of strands (wires or bands) wrapped around the exterior of the housing body.

[0033] Consistent with this, if desired, the sleeve may include optional openings or apertures formed through the tubular monolithic metal wall along its length and width, with an open, solid metal sleeve still being considered "monolithic" and including a continuous path of metal around the sleeve circumference and along its length. Alternatively, the device may include multiple (two or more) separate sleeves located at spaced locations on the exterior surface of the housing body along its length; for example, the housing body may include two weld seams, with two separate sleeves each positioned to surround one of the two weld seams. According to these or other examples, the device may include multiple sleeves in an overlapping arrangement, with two sleeves (one overlapping the other) located at the same location along the length of the exterior surface of the body.

[0034] The sleeve of the described filter device can be prepared from a wide range of metallic materials, including refractory metals (including alloys), alloys such as stainless steel, other metals such as nickel and nickel alloys, aluminum and aluminum alloys, and cobalt alloys, among others. Exemplary sleeves may be prepared from the same or different refractory metal as the housing body, which is made of refractory metal, for example, niobium, molybdenum, tantalum, tungsten, rhenium, and alloys containing one or more of these, such as an alloy containing molybdenum and rhenium (MRe), an alloy containing tungsten and rhenium (WRe), an alloy containing molybdenum, hafnium, and carbon (MoHfC, or "MHC"), or an alloy containing titanium, zirconium, and molybdenum (TiZrMo).

[0035] The sleeve of a particular filter device may be prepared from any of these exemplary materials, and in some instances the device may be selected to have a higher modulus of elasticity and a higher tensile strength than the housing body of the device; tungsten, molybdenum, and alloys thereof are examples of useful materials for the sleeve.

[0036] The sleeve may have a size and shape that allows it to be installed onto the outer surface of the weld housing body by sliding or "pressing" the sleeve along the length of the weld housing body to the location of the weld seam (optionally while the sleeve is heated).

[0037] In some exemplary arrangements, the sleeve can be sized to have an inner diameter slightly smaller than the outer diameter of the welded housing body surface. The slightly smaller inner diameter of the sleeve compared to the outer diameter of the welded housing body allows the installed sleeve to create a "pre-strained" state of the housing body when installed. The amount of interference between the housing outer surface and the sleeve inner surface can be small, such as on the scale of thousandths of an inch or tens of thousandths of an inch, and the desired or useful amount of interference between the two surfaces can be selected based on the properties of the sleeve and body, such as their sizes, materials, and their respective coefficients of thermal expansion.

[0038] To create a smaller inner diameter for the sleeve and a relatively larger outer diameter for the housing body's outer surface, the sleeve's inner diameter may be curved or slightly "bulged" along its length, e.g., curved inward toward the housing body and exhibiting a minimum inner diameter at the center of its length. Alternatively, the housing body's outer surface may be curved or "bulged" along its length, e.g., curved outward toward the sleeve and exhibiting a maximum diameter at the center of its length. In either arrangement, the diameter of the housing body's outer surface is slightly larger than the diameter of the sleeve's inner surface. The housing body's outer surface interfaces with the sleeve's inner surface, and when the sleeve is placed on the housing body's outer surface, the smaller the sleeve's diameter, the more the sleeve will apply pressure to the housing body at ambient conditions (e.g., room temperature, 22 degrees Celsius) before the housing body's interior is pressurized during use. When the housing body's interior is pressurized, the housing body deforms and expands slightly to a state that offsets the housing body's pre-strained state, which is then transferred to the sleeve, which expands to a strained state during use.

[0039] Example filter devices constructed and assembled according to the present disclosure can perform at significantly higher pressures and temperatures, while the sleeve reinforces the housing body and prevents failure of the housing body, for example, at the weld seam. Exemplary high-pressure filter devices can be useful in filtration processes for filtering fluids, such as molten metals, at different temperature conditions, optionally at ambient temperature (20 degrees Celsius) or at temperatures reaching or exceeding 230 degrees Celsius, e.g., 250 or 300 degrees Celsius, and at pressures reaching or exceeding 5,000 pounds per square inch gauge (psig), or 10,000, 20,000 psig, 30,000 psig, or even 35,000, 40,000, 45,000, 50,000, 55,000, or 60,000 psig or more.

[0040] Filter devices can be measured for performance at high pressure and ambient (room) temperature, or at high pressure and operating temperature, to assess the maximum internal pressure the device can withstand without failure, where failure refers to the onset of any amount of leakage from the housing, such as at a weld seam. These tests are sometimes called "burst tests" and can be performed using water as the test fluid.

[0041] According to certain useful or preferred filter devices described, the devices may include an interior of at least 40,000 psig, or at least 45,000 psig, at least 50,000 psig, at least 55,000 psig, or at least 60,000 psig tested at 20 degrees C. Also, according to certain useful or preferred filter devices described, the devices may accommodate internal pressures of at least 40,000 psig, or at least 45,000 psig, at least 50,000 psig, at least 55,000 psig, or at least 60,000 psig tested at elevated (operating) temperatures, e.g., temperatures of 200 degrees C. or higher, or 230 degrees C. or higher, or 300 degrees C. or higher.

[0042] An example of a useful or preferred sleeve may be in the form of a solid tubular structure, in that the sleeve is separate from the weld housing and is of tubular rigidity. According to one useful method, the tubular sleeve may be installed onto the exterior surface of the weld housing body by sliding or "pressing" the sleeve along the length of the weld housing body, e.g., to the location of the weld seam.

[0043] According to the process for preparing the described device, a welded housing body is prepared from two housing pieces by forming a weld between them. In a housing body including two pieces (see FIGS. 1A, 1B, and 1C), the housing body is made from two pieces welded together to form a single weld seam. Each piece includes an end including a flow opening and a second end, a "weld end," that engages and is welded to the other piece. To form the housing body, the end of the first piece is welded to the end of the second piece to form a body portion formed by the welded pieces, having a first fluid opening (e.g., an inlet) at one end and a second fluid opening (e.g., an outlet) at the second end, including a weld seam, and including a filter chamber and a filter contained in the filter chamber.

[0044] After forming the welded housing body, the outer surface is prepared to allow the sleeve to be installed on the outer surface of the housing body with substantially uniform contact between the inner surface of the sleeve and the outer surface of the welded housing body. Typically, the weld seam is processed by machining, grinding, polishing, lathing, grinding, etc. to remove weld material to form a smooth outer surface of the welded seam. The outer surface of the welded housing body, including the location of the weld seam, can be formed into a smooth tubular (e.g., cylindrical) shape.

[0045] After the exterior surface of the welded housing body is appropriately smoothed, including any weld seams, the sleeve can be placed on the exterior surface. One method facilitates placement of the sleeve on the housing body by expanding the sleeve relative to the housing body and sliding the sleeve over the exterior surface of the housing body. To expand the sleeve relative to the housing body, the sleeve can be heated, the housing body can be cooled, or both. After the heated sleeve is placed (e.g., "pressed") onto the welded housing body, the temperature of the housing body and the temperature of the sleeve can be allowed to equilibrate.

[0046] A welded housing (or "welded housing body") includes a fluid inlet at one end and a fluid outlet at a second end, and is made from multiple (at least two) housing pieces welded together at adjacent ends (called "welded ends") to form one or more weld seams along the length of the housing body.

[0047] In certain exemplary welded housing bodies, the housing body is made from two housing pieces. Each housing piece includes a tubular (e.g., cylindrical) portion to form the body, a fluid opening (inlet or outlet) at one end, and a second end called the "weld end." The housing body can be made by assembling and welding the two housing pieces together, attaching the weld end of the first housing piece to the weld end of the second housing piece and forming a weld seam around the housing body that runs along the length of the housing body. The fluid inlets and outlets of the two housing pieces are located at opposite ends of the housing body.

[0048] In an alternative embodiment of the welded housing body, the housing body is made from three housing pieces. The first housing piece, which may be referred to as the "end housing piece," is a tubular piece including a fluid opening (inlet or outlet) at one end and a second end, referred to as the weld end. The second housing piece, which may be referred to as the "end housing piece," is a tubular piece including a second fluid opening (inlet or outlet) at one end and a second end, referred to as the weld end. The third housing piece, which may be referred to as the "middle piece," is a tubular piece including a first weld end and a second weld end. The housing body includes the first end housing piece welded to the weld end of the third piece (middle piece) with a weld seam located along the length of the housing body, and the second end housing piece welded to the second weld end of the third piece (middle piece) to form a second weld seam located along the length of the housing body. The fluid opening of the first end piece is located at one end of the weld housing body, and the fluid opening of the second end piece is located at a second end of the weld housing body.

[0049] 1A, a cross-sectional view of an exemplary high-pressure filter apparatus 100 is shown. The apparatus 100 includes a housing 112 including a first housing piece 102, a second housing piece 104, a filter 106, a weld seam 108, and a sleeve 110. The sleeve 110 covers a portion of the exterior surface of the housing piece 102 and the end piece 104, including the weld seam 108, and applies pressure to the weld seam, a portion of the exterior surface of the housing piece 102, and a portion of the exterior surface of the end piece 104. The weld seam 108 is formed between an end of the piece 102 (the "weld end") and an adjacent end of the piece 104 (the "weld end"), and may be a weld formed by heating metal to cause the metal to coalesce as the weld seam secures the end of the piece 102 to the end of the piece 104 and forms a fluid-tight seal at the interface between the ends of the two pieces. The welded seam can be a seam formed by any welding technique, including friction welding, brazing, soldering, and the like.

[0050] As shown, device 100 may be referred to as having a "forward" end oriented toward piece 104 and a "rearward" end oriented toward piece 102. The terms "forward" and "rearward" are for convenience in referring to features of device 100 and do not refer to structural requirements or methods of use of device 100, such as the direction of fluid flow through device 100, which may be in any direction between the front and rear of device 100.

[0051] Housing piece 102 includes a filter chamber 120 extending longitudinally within housing piece 102, defined by the inner surface of the cylindrical sidewall of housing piece 102. At one end (the "rear" end) of housing piece 102 is a first fluid flow opening 130 that leads to filter chamber 120. At the opposite end (the "front" end) of housing piece 102, housing piece 102 connects to the end of housing piece 102 (the "rear" end) with weld 108, which extends around the periphery of housing pieces 102 and 104 to form a circular weld seam. At the front end of housing piece 102 is a fluid flow opening 140 that also leads to filter chamber 120.

[0052] Filter 106 is adapted to fit within filter chamber 120 such that fluid flowing in either direction between fluid flow openings 130 and 140 must pass through filter 106 .

[0053] The sleeve 110 is a solid, monolithic piece of metal, meaning that the sleeve is made from a single, integral, connected mass of metal and is not formed from multiple strands of metal wire or material wound to form a cylinder.

[0054] 1B, a cross-sectional view of another exemplary high-pressure filter apparatus 100 is shown. The apparatus 100 includes a housing 112 including a first housing piece 102, a second housing piece 104, a filter 106, a weld seam 108, and a sleeve 110. The weld seam 108 is formed between an end ("weld end") of piece 102 and an adjacent end ("weld end") of piece 104. The sleeve 110 covers a portion of the outer surface of the housing piece 102 that does not include the weld seam 108 and applies pressure against the portion of the outer surface of the housing piece 102. Although the sleeve 110 does not cover the weld seam 108, the sleeve still acts to reinforce and strengthen the housing 112 of the apparatus 100, allowing the housing 112 to withstand greater internal pressures than would be withstood in the absence of the sleeve 110.

[0055] Referring to FIG. 1C, a cross-sectional view of another alternative exemplary high-pressure filter apparatus 100 is shown. The apparatus 100 includes a housing 112, which includes a first housing piece 102, a second housing piece 104, a filter 106, a weld seam 108, and a sleeve 110. As shown in FIG. 1C, the weld 108 formed from the welded ends of the two housing pieces can be located at any desired location along the length of the housing, including the central location of the housing as shown. Depending on the overall design and materials, a weld seam at the central location of the housing body length, as in FIG. 1C, may be weaker than a weld seam located near the end of the body, as in FIG. 1A. A sleeve located at or near the central weld seam, as in FIG. 1C, can provide a relatively large increase in the strength of the housing body.

[0056] 2A, a cross-sectional view of the described alternative exemplary high-pressure filter apparatus 200 is shown. Apparatus 200 includes a housing 212 including a first housing piece 202 (the "end piece"), a second housing piece 204 (the second "end piece"), a third housing piece (the "middle" piece) 214, a filter 206, weld seams 208a and 208b, and a sleeve 210. As shown, sleeve 210 covers weld seams 208a and 208b, a portion of end piece 202, and a portion of end piece 204, and applies pressure against the outer surfaces of end piece 202, end piece 204, middle piece 214, and weld seams 208a and 208b. In an alternative arrangement, sleeve 110 need not cover both weld seams 208a and 208b, but may cover or apply pressure to only a portion of intermediate piece 214, or only a portion of intermediate piece 214 and one of weld seams 208a and 208b.

[0057] In the assembled configuration, the intermediate piece 214 defines a filter chamber 220 between the first end piece 202 and the second end piece 204. The forward end of the end piece 202 is welded to the aft end of the intermediate piece 214, forming weld seam 208b. The aft end of the end piece 204 is welded to the forward end of the intermediate piece 214, forming weld seam 208a.

[0058] Midpiece 214 includes a longitudinally extending filter chamber 220. At one end of device 200 (the "rear" end) is a first fluid flow opening 230 that leads to filter chamber 220. At the opposite end of device 200 (the "front" end) is a fluid flow opening 240 that also leads to filter chamber 220. Filter 206 is adapted to fit within filter chamber 220 such that fluid flowing in either direction between fluid flow openings 230 and 240 must pass through filter 206.

[0059] Sleeve 210 is a solid, monolithic piece of metal, meaning that the sleeve is made from a single, integral, connected mass of metal and is not formed from multiple strands of metal wire or material wound to form a cylinder.

[0060] 2B illustrates an example process for assembling a high-pressure filter apparatus. As shown, a filter apparatus housing 212 is assembled from a first housing piece 202 (the "end piece"), a second housing piece 204 (the second "end piece"), a third housing piece (the "middle" piece) 214, and a filter 206 by forming a first weld seam 208a at adjacent ends of the end piece 204 and the middle piece and a second weld seam 208b at adjacent ends of the end piece 202 and the middle piece 214. After forming the housing 212, the sleeve 210 is placed on the exterior surface of the housing 212 by sliding, e.g., pressing, the sleeve 110 over the exterior surface along the length of the exterior surface to a desired position.

[0061] The "filter membrane" or (also known as "filter element") that may be retained within the described filter device to remove contaminants from the fluid stream passing therethrough may be any useful filter membrane, including filter membranes of the type known to process fluids at high temperatures, pressures, or both.

[0062] The filter membrane may be, for example, a sintered porous filter element known to be useful for filtering liquid metals and gases at high pressures or temperatures.

[0063] Useful filter membranes may have pore sizes ranging from about 0.1 to about 5 microns, e.g., from about 0.5 to about 1.5 microns, as measured by bubble point according to ASTM E 128. Exemplary filter membranes may be made from materials including titanium, tungsten, tantalum, molybdenum, niobium, alumina, titanium oxide, titanium nitride, and silicon carbide.

[0064] The filter elements of the present disclosure can be used to filter a variety of liquid metals and gases. For example, the filter elements of the present disclosure can be used to filter gases ranging from inert gases such as argon to corrosive gases such as hydrogen bromide. Gases that can be filtered include, for example, argon, nitrogen, carbon dioxide, hydrogen bromide, and hydrogen chloride, as well as hydrides. The filter elements of the present disclosure can also be used to filter supercritical fluids, such as carbon dioxide in its supercritical state.

[0065] The described filter device can be used to filter gases and liquids, including molten metals ("liquid metals"). Metals that can be filtered include tin, lead, sodium, cadmium, selenium, mercury, and generally materials that melt below about 400 degrees Celsius. Gases that can be processed at high temperatures and pressures include, by way of non-limiting example, argon, nitrogen (N), hydrogen bromide (HBr), hydrogen chloride (HCl), and carbon dioxide (CO).

[0066] The following are apparatus and methods that are aspects of the present specification.

[0067] Aspect 1. A high-pressure filter device, comprising: A welded housing body, a multi-piece welded housing body including a fluid inlet, a fluid outlet, and a weld seam between the fluid inlet and the fluid outlet; a filter chamber and a filter housed in the filter chamber; a welded housing body including: a sleeve that surrounds the housing body and applies pressure to the housing body; A high-pressure filter device comprising:

[0068] Embodiment 2. The filter device of embodiment 1, wherein the sleeve surrounds the weld seam.

[0069] Aspect 3. A first housing piece including a welded end at a fluid inlet and a welded seam; a second housing piece including a fluid outlet and a welded end at the weld seam; 3. The filter device of embodiment 1 or 2, comprising:

[0070] Embodiment 4. A first housing piece including a welded end at a fluid inlet and a first weld seam; a second housing piece including a welded end at the fluid outlet and a second weld seam; and 3. The filtering apparatus of any one of embodiments 1 to 2, comprising a third housing piece including a first welded end at the first welded seam and a second welded end at the second welded seam.

[0071] Aspect 5. The filter device of any one of Aspects 1 to 4, wherein the welded housing body comprises a high melting point metal.

[0072] Embodiment 6. The filter device of any of embodiments 1 to 5, wherein the welded housing body comprises niobium, molybdenum, tantalum, tungsten, rhenium, or alloys thereof.

[0073] Embodiment 7. The filter device of any of embodiments 1 to 6, wherein the sleeve comprises a metal band.

[0074] Embodiment 8. The filter device of embodiment 7, wherein the sleeve comprises a refractory metal, tungsten, molybdenum, stainless steel, nickel, cobalt, or an alloy thereof.

[0075] Embodiment 9. The filter device of embodiment 7 or 8, wherein the metal band has a higher modulus of elasticity than the welded housing body, a higher tensile strength than the welded housing body, or both.

[0076] Embodiment 10. The filter device of any of embodiments 1 to 9, wherein the filter comprises titanium, silicon carbide, tungsten, tantalum, molybdenum, niobium, alumina, titanium oxide, or titanium nitride.

[0077] Embodiment 11. The filter device of any of embodiments 1 to 10, wherein the sleeve has an inner diameter that is smaller than the outer diameter of the housing body.

[0078] Embodiment 12. The filter device of embodiment 11, wherein the sleeve has an inner diameter that varies along the length of the sleeve, including a minimum diameter at a location between the ends of the sleeve.

[0079] Embodiment 13. The filter device of embodiment 11 or 12, wherein the housing body has an outer diameter that varies along the length of the sleeve, including a maximum diameter at a location between the ends of the sleeve.

[0080] Embodiment 14. The filter device of any one of embodiments 1 to 13, wherein the filter has an average pore size in the range of 0.1 to 5 microns.

[0081] Embodiment 15. The filter apparatus of any of embodiments 1 to 14, wherein the filter apparatus is capable of containing fluid within the filter chamber at a fluid pressure of at least 40,000 psig without leakage.

[0082] Embodiment 16. The filter apparatus of any of embodiments 1 to 15, wherein the filter apparatus is capable of containing fluid within the filter chamber at a fluid pressure of at least 45,000 psig without leakage.

[0083] Embodiment 17. The filter device of embodiment 15 or 16, wherein the filter device is capable of containing a fluid within the filter chamber at a fluid temperature of at least 230 degrees Celsius without leakage.

[0084] Embodiment 18. The filter device of embodiment 15 or 16, wherein the filter device is capable of containing a fluid within the filter chamber at a fluid temperature of at least 230 degrees Celsius without leakage.

[0085] Embodiment 19. A method of filtering a fluid, comprising: providing a high-pressure filter product according to any one of aspects 1 to 18; Passing the impurity-containing fluid through a filter to remove the impurities from the fluid; A method comprising:

[0086] Embodiment 20. The method of embodiment 19, comprising passing the fluid through the filter chamber at a fluid pressure of at least 40,000 psig.

[0087] Embodiment 21. The method of embodiment 19 or 20, comprising passing the fluid through the filter chamber at a fluid temperature of at least 230 degrees Celsius.

[0088] Embodiment 22. A method of forming a high-pressure filter product, comprising: A filter, two or more housing pieces including a filter chamber, an inlet end, and an outlet end; and securing the filter in position within the filter chamber; welding two or more housing pieces together to form a housing body including one or more weld seams; disposing one or more sleeves around the housing body so as to surround the housing body; A method comprising:

[0089] Embodiment 23. The method of embodiment 22, comprising placing one or more sleeves over the one or more weld seams so as to surround the one or more weld seams.

[0090] Embodiment 24. The method of embodiment 22 or 23, comprising treating one or more weld seams to form a smooth weld seam surface.

[0091] Embodiment 25. The method of any of embodiments 22 to 24, comprising sliding one or more sleeves over the housing body.

[0092] Aspect 26. Placing a sleeve on the housing body heating the sleeve to expand the sleeve; Sliding the expanded sleeve over the housing body; allowing the expanded sleeve to cool and shrink on the housing body; 26. The method of any of embodiments 22 to 25, comprising:

[0093] Aspect 27. A high-pressure filter device, comprising: a fluid inlet at the inlet end; a fluid outlet at the outlet end; a metal sidewall between the fluid inlet and the fluid outlet; a filter chamber defined by a metal sidewall; and a filter located in a filter chamber; A high-pressure filter apparatus capable of containing fluid within a filter chamber at a fluid pressure of at least 40,000 psig without leakage.

[0094] Embodiment 28. The filter device of embodiment 25, which is capable of containing fluid within the filter chamber at a fluid pressure of at least 45,000 psig without leakage.

[0095] Embodiment 29. The filter device of embodiment 27 or 28, which is capable of containing fluid within the filter chamber at a fluid temperature of at least 230 degrees Celsius without leakage.

[0096] Embodiment 30. The filter device of any of embodiments 27 to 29, wherein the metal sidewall comprises a high melting point metal.

[0097] Embodiment 31. The filter device of any of embodiments 27 to 30, wherein the metal sidewall does not include a weld seam.

[0098] Embodiment 32. The filter device of any of embodiments 27 to 31, wherein the filter comprises titanium, silicon carbide, tungsten, tantalum, molybdenum, niobium, alumina, titanium oxide, or titanium nitride.

[0099] Embodiment 33. The filter device of any of embodiments 27 to 32, wherein the filter has an average pore size in the range of 0.1 to 5 microns.

Claims

1. A high-pressure filter device, comprising: A welded housing body, a multi-piece welded housing body including a fluid inlet, a fluid outlet, and a weld seam between the fluid inlet and the fluid outlet; A filter chamber and a filter housed in the filter chamber a welded housing body including: a sleeve that surrounds the housing body and applies pressure to the housing body; A high-pressure filter device comprising:

2. The filter device of claim 1 , wherein a sleeve surrounds the weld seam.

3. a first housing piece including a fluid inlet and a welded end at a weld seam; a second housing piece including a fluid outlet and a welded end at the weld seam; 3. The filter device of claim 1, comprising:

4. a first housing piece including a fluid inlet and a welded end at a first weld seam; a second housing piece including a fluid outlet and a welded end at a second weld seam; and a third housing piece including a first weld end at the first weld seam and a second weld end at the second weld seam; 3. The filter device of claim 1, comprising:

5. 5. The filter arrangement of claim 1, wherein the welded housing body comprises a high melting point metal.

6. 6. The filter apparatus of claim 1, wherein the welded housing body comprises niobium, molybdenum, tantalum, tungsten, rhenium, or alloys thereof.

7. 7. The filter device of claim 1, wherein the sleeve comprises a metal band.

8. 8. The filter device of claim 7, wherein the sleeve comprises a refractory metal, tungsten, molybdenum, stainless steel, nickel, cobalt, or alloys thereof.

9. 9. The filter arrangement of claim 7 or 8, wherein the metal band has a higher modulus of elasticity than the welded housing body, a higher tensile strength than the welded housing body, or both.

10. 10. The filtering device of any one of claims 1 to 9, wherein the filter comprises titanium, silicon carbide, tungsten, tantalum, molybdenum, niobium, alumina, titanium oxide, or titanium nitride.

11. 11. The filter device of claim 1, wherein the sleeve has an inner diameter that is smaller than the outer diameter of the housing body.

12. 12. The filter device of claim 11, wherein the sleeve has an inner diameter that varies along the length of the sleeve, including a minimum inner diameter at a location between the ends of the sleeve.

13. 13. The filter arrangement of claim 11 or 12, wherein the housing body has an outer diameter that varies along the length of the sleeve, including a maximum inner diameter at a location between the ends of the sleeve.

14. 14. The filter device of any one of claims 1 to 13, wherein the filter has an average pore size in the range of 0.1 to 5 microns.

15. 15. The filter apparatus of any one of claims 1 to 14, capable of containing fluid within the filter chamber at a fluid pressure of at least 40,000 psig at 20 degrees Celsius without leakage.

16. 16. The filter apparatus of any one of claims 1 to 15, capable of containing fluid within the filter chamber at a fluid pressure of at least 45,000 psig at 20 degrees Celsius without leakage.

17. 17. A filter device according to claim 15 or 16, capable of containing fluid within the filter chamber at a fluid temperature of at least 230 degrees Celsius without leakage.

18. 1. A method of filtering a fluid, comprising: Providing a high-pressure filter product according to any one of claims 1 to 18; Passing the impurity-containing fluid through a filter to remove the impurities from the fluid; A method comprising:

19. 20. The method of claim 18, comprising passing the fluid through the filter chamber at a fluid pressure of at least 40,000 psig at 20 degrees Celsius.

20. 20. The method of claim 18 or 19, comprising passing the fluid through the filter chamber at a fluid temperature of at least 230 degrees Celsius.

21. 1. A method of forming a high pressure filter product, comprising: A filter, two or more housing pieces including a filter chamber, an inlet end, and an outlet end; and securing the filter in position within the filter chamber; welding two or more housing pieces together to form a housing body including one or more weld seams; disposing one or more sleeves around the housing body so as to encircle the housing body; A method comprising:

22. The method of claim 21 , comprising placing one or more sleeves over the one or more weld seams to surround the one or more weld seams.

23. 23. The method of claim 21 or 22, comprising treating one or more weld seams to form a smooth weld seam surface.

24. 24. The method of any one of claims 21 to 23, comprising sliding one or more sleeves over the housing body.

25. Disposing a sleeve over the housing body; heating the sleeve to expand the sleeve; Sliding the expanded sleeve over the housing body; allowing the expanded sleeve to cool and shrink on the housing body; 25. The method of any one of claims 21 to 24, comprising:

26. A high-pressure filter device, comprising: a fluid inlet at the inlet end; a fluid outlet at the outlet end; a metal sidewall between the fluid inlet and the fluid outlet; a filter chamber defined by a metal sidewall; and a filter located in a filter chamber; A high-pressure filter apparatus capable of containing fluid within a filter chamber at a fluid pressure of at least 40,000 psig at 20 degrees Celsius without leaking.

27. 27. The filter apparatus of claim 26, wherein the filter chamber can accommodate a fluid pressure of at least 45,000 psig at 20 degrees Celsius without leaking.

28. 28. A filter apparatus according to claim 26 or 27, capable of containing fluid within the filter chamber at a fluid temperature of at least 230 degrees Celsius without leakage.

29. 29. The filter apparatus of any one of claims 26 to 28, wherein the metal sidewall comprises a refractory metal.

30. 30. The filter apparatus of any one of claims 26 to 29, wherein the metal sidewall does not include a weld seam.

31. 31. The filtering apparatus of any one of claims 26 to 30, wherein the filter comprises titanium, silicon carbide, tungsten, tantalum, molybdenum, niobium, alumina, titanium oxide, or titanium nitride.

32. 32. The filter device of any one of claims 26 to 31, wherein the filter has an average pore size in the range of 0.1 to 5 microns.

Images