Gas filter elements, filter devices, and methods of use
Patent Information
- Authority / Receiving Office
- JP · JP
- Patent Type
- Applications
- Current Assignee / Owner
- Filing Date
- 2024-06-24
- Publication Date
- 2026-08-14
Smart Images
Figure 2026527517000001_ABST
Abstract
Description
Background Art
[0001] Background of the Invention For example, in order to combat climate change, there is increasing interest in gas filtering that may include capturing carbon from gases such as flue gas (e.g., by capturing carbon dioxide (CO2) emissions from power plants and industrial facilities). For example, in order to protect a carbon capture system, an improved filter is needed to remove solid contaminants from a fluid and / or to capture carbon in a gas.
[0002] The present invention provides improvements to at least some of the drawbacks of the prior art. These and other advantages of the present invention will become apparent from the description set forth below.
Summary of the Invention
Means for Solving the Problems
[0003] Brief Summary of the Invention One aspect of the present invention provides a gas filter element having a first end and a second end, the gas filter element having a plurality of inlet channels and a plurality of slotted outlet channels between the first end and the second end, in an alternating pattern, each of the plurality of inlet channels having an inlet channel opening at the first end and being closed at the second end, each of the plurality of slotted outlet channels having a slotted outlet channel opening at the second end and being closed at the first end, each of the plurality of inlet channels being surrounded by four slotted outlet channels, each of the plurality of inlet channels and each of the plurality of slotted outlet channels having an inner cross-sectional area, each of the plurality of inlet channels having an inner cross-sectional area that exceeds the inner cross-sectional area of each of the plurality of slotted outlet channels, and the plurality of inlet channels and the plurality of slotted outlet channels having a common porous wall.
[0004] According to another aspect of the present invention, the gas filter element comprises a first end and a second end, the gas filter element having a plurality of inlet channels and a plurality of slotted outlet channels between the first end and the second end, in an alternating pattern, each of the plurality of inlet channels having an inlet channel opening at the first end and closed at the second end, each of the plurality of slotted outlet channels having a slotted outlet channel opening at the second end and closed at the first end, each of the plurality of inlet channels being surrounded on two opposing sides by two slotted outlet channels, each of the plurality of inlet channels and each of the plurality of plurality of slotted outlet channels having an inner tapered cross-sectional area, the tapered inner cross-sectional area of each of the plurality of inlet channels decreasing from the first end to the second end, the tapered inner cross-sectional area of each of the plurality of slotted outlet channels decreasing from the second end to the first end, and the plurality of inlet channels and the plurality of slotted outlet channels having a common porous wall.
[0005] According to another aspect of the present invention, the gas filter element comprises a first end and a second end, the gas filter element having a plurality of inlet channels and a plurality of outlet channels between the first end and the second end, in an alternating pattern, each of the plurality of inlet channels having an inlet channel opening at the first end and closed at the second end, each of the plurality of outlet channels having an outlet channel closed at the first end and an opening at the second end, each outlet channel forming a gap between adjacent inlet channels, the gap extending to the second end, each of the plurality of inlet channels being surrounded by an outlet channel, each inlet channel surrounded by an outlet channel forming an individual channel unit, each individual channel unit being surrounded by a gap extending to the second end such that adjacent individual channel units do not come into contact with each other, and the plurality of inlet channels and a plurality of outlet channels within each individual channel unit having a common porous wall.
[0006] According to another aspect of the present invention, the gas filter element comprises a first end and a second end, the gas filter element having a plurality of inlet channels and a plurality of outlet channels between the first end and the second end, in an alternating pattern, each of the plurality of inlet channels having an inlet channel opening at the first end and closed at the second end, each of the plurality of outlet channels having an outlet channel closed at the first end and an opening at the second end, each outlet channel forming a gap between adjacent inlet channels along the partial length between the first end and the second end, each of the plurality of inlet channels being surrounded by an outlet channel, each inlet channel surrounded by an outlet channel forming an individual channel unit, each individual channel unit being surrounded by a gap along the partial length between the first end and the second end, adjacent individual channel units being held together by a support bracket, and the plurality of inlet channels and the plurality of outlet channels within each individual channel unit having a common porous wall.
[0007] In some embodiments of the gas filter element, the element has a ratio greater than 1:1 of the total inner cross-sectional areas of the multiple inlet channels to the total inner cross-sectional areas of the multiple slotted outlet channels.
[0008] Alternatively or additionally, in some embodiments of the gas filter element, each of the plurality of inlet channels and each of the plurality of outlet channels or slotted outlet channels has a tapered inner cross-sectional area, wherein the tapered inner cross-sectional area of each of the plurality of inlet channels decreases from a first end to a second end, and the tapered inner cross-sectional area of each of the plurality of slotted outlet channels decreases from a second end to a first end.
[0009] In another aspect of the present invention, a filter device is provided, which comprises one embodiment of a gas filter element mounted on a frame.
[0010] In yet another aspect of the present invention, a filter array is provided comprising at least one, preferably two or more, configurations of filter devices arranged within a housing.
[0011] In yet another aspect of the present invention, a filter system is provided comprising two or more configurations of filter arrays arranged adjacent to one another.
[0012] In another embodiment, a method for filtering a gas includes passing the gas through one embodiment of a gas filter element, the method including passing the gas so that it enters an inlet channel opening and the inlet channel, passes through a porous wall into an outlet channel, and passes through the outlet channel opening. Typically, the gas entering the inlet channel contains contaminants that cannot pass through the porous wall, thereby providing a gas that enters the outlet channel and passes through the outlet channel opening with reduced levels of contaminants, and is a "cleaner" gas than the gas entering the gas filter element. [Brief explanation of the drawing]
[0013] [Figure 1A] Figures 1A and 1B illustrate the flow of gas through an embodiment of a gas filter element according to an aspect of the present invention. Figure 1A shows a cross-sectional view through one embodiment of the gas filter element, where dirty gas enters the open end of the inlet channel at the first end of the element, is purified as it passes through a common porous wall between the inlet channel and the slotted outlet channel, and clean gas exits the gas filter element through the open end of the slotted outlet channel at the second end of the element. Figure 1B is an enlarged view of the dirty gas inlet portion of the gas filter element shown in Figure 1A, showing the flow paths of dirty and clean gas, the inlet channel separated from the slotted outlet channel (shown here as having a substantially rectangular shape) by a porous wall, and the inlet channel having an inner cross-sectional area exceeding the inner cross-sectional area of the slotted outlet channel, with the wall closing the slotted outlet channel at the first end of the element (the wall closing the inlet channel at the second end of the element is not shown). [Figure 1B] Figures 1A and 1B illustrate the flow of gas through an embodiment of a gas filter element according to an aspect of the present invention. Figure 1A shows a cross-sectional view through one embodiment of the gas filter element, where dirty gas enters the open end of the inlet channel at the first end of the element, is purified as it passes through a common porous wall between the inlet channel and the slotted outlet channel, and clean gas exits the gas filter element through the open end of the slotted outlet channel at the second end of the element. Figure 1B is an enlarged view of the dirty gas inlet portion of the gas filter element shown in Figure 1A, showing the flow paths of dirty and clean gas, the inlet channel separated from the slotted outlet channel (shown here as having a substantially rectangular shape) by a porous wall, and the inlet channel having an inner cross-sectional area exceeding the inner cross-sectional area of the slotted outlet channel, with the wall closing the slotted outlet channel at the first end of the element (the wall closing the inlet channel at the second end of the element is not shown).
[0014] [Figure 2A] Figures 2A to 2I show a gas filter element according to one embodiment of the present invention. Figures 2A and 2B show isometric views of the gas filter element at the first end (dirty gas inlet) and the second end (clean gas outlet), respectively. Figures 2C and 2D show the first end (dirty gas inlet) and the second end (clean gas outlet) of the gas filter element shown in Figures 2A and 2B, respectively, where the outlet channel is closed at the first end and the inlet channel is closed at the second end. [Figure 2B]Figures 2A to 2I show a gas filter element according to one embodiment of the present invention. Figures 2A and 2B show isometric views of the gas filter element at the first end (dirty gas inlet) and the second end (clean gas outlet), respectively. Figures 2C and 2D show the first end (dirty gas inlet) and the second end (clean gas outlet) of the gas filter element shown in Figures 2A and 2B, respectively, where the outlet channel is closed at the first end and the inlet channel is closed at the second end. [Figure 2C] Figures 2A to 2I show a gas filter element according to one embodiment of the present invention. Figures 2A and 2B show isometric views of the gas filter element at the first end (dirty gas inlet) and the second end (clean gas outlet), respectively. Figures 2C and 2D show the first end (dirty gas inlet) and the second end (clean gas outlet) of the gas filter element shown in Figures 2A and 2B, respectively, where the outlet channel is closed at the first end and the inlet channel is closed at the second end. [Figure 2D] Figures 2A to 2I show a gas filter element according to one embodiment of the present invention. Figures 2A and 2B show isometric views of the gas filter element at the first end (dirty gas inlet) and the second end (clean gas outlet), respectively. Figures 2C and 2D show the first end (dirty gas inlet) and the second end (clean gas outlet) of the gas filter element shown in Figures 2A and 2B, respectively, where the outlet channel is closed at the first end and the inlet channel is closed at the second end.
[0015] [Figure 2E]Figure 2E is a side view of the gas filter element shown in Figures 2A and 2B. Figure 2F is a horizontal cross-sectional view of the element along line 2F-2F in Figure 2E, and also shows a repeating pattern of the four sides of each inlet channel, the four slotted outlet channels adjacent to the four sides, and the support at the intersection of the slotted outlet channels. Figure 2G is a vertical cross-sectional view of the element along line 2G-2G in Figure 2E, Figure 2H is an enlarged view of detail 2H (open-end outlet channel) shown in Figure 2G, and Figure 2I is an enlarged view of detail 2I (closed-end outlet channel) shown in Figure 2G. [Figure 2F] Figure 2E is a side view of the gas filter element shown in Figures 2A and 2B. Figure 2F is a horizontal cross-sectional view of the element along line 2F-2F in Figure 2E, and also shows a repeating pattern of the four sides of each inlet channel, the four slotted outlet channels adjacent to the four sides, and the support at the intersection of the slotted outlet channels. Figure 2G is a vertical cross-sectional view of the element along line 2G-2G in Figure 2E, Figure 2H is an enlarged view of detail 2H (open-end outlet channel) shown in Figure 2G, and Figure 2I is an enlarged view of detail 2I (closed-end outlet channel) shown in Figure 2G. [Figure 2G] Figure 2E is a side view of the gas filter element shown in Figures 2A and 2B. Figure 2F is a horizontal cross-sectional view of the element along line 2F-2F in Figure 2E, and also shows a repeating pattern of the four sides of each inlet channel, the four slotted outlet channels adjacent to the four sides, and the support at the intersection of the slotted outlet channels. Figure 2G is a vertical cross-sectional view of the element along line 2G-2G in Figure 2E, Figure 2H is an enlarged view of detail 2H (open-end outlet channel) shown in Figure 2G, and Figure 2I is an enlarged view of detail 2I (closed-end outlet channel) shown in Figure 2G. [Figure 2H]Figure 2E is a side view of the gas filter element shown in Figures 2A and 2B. Figure 2F is a horizontal cross-sectional view of the element along line 2F-2F in Figure 2E, and also shows a repeating pattern of the four sides of each inlet channel, the four slotted outlet channels adjacent to the four sides, and the support at the intersection of the slotted outlet channels. Figure 2G is a vertical cross-sectional view of the element along line 2G-2G in Figure 2E, Figure 2H is an enlarged view of detail 2H (open-end outlet channel) shown in Figure 2G, and Figure 2I is an enlarged view of detail 2I (closed-end outlet channel) shown in Figure 2G. [Figure 2I] Figure 2E is a side view of the gas filter element shown in Figures 2A and 2B. Figure 2F is a horizontal cross-sectional view of the element along line 2F-2F in Figure 2E, and also shows a repeating pattern of the four sides of each inlet channel, the four slotted outlet channels adjacent to the four sides, and the support at the intersection of the slotted outlet channels. Figure 2G is a vertical cross-sectional view of the element along line 2G-2G in Figure 2E, Figure 2H is an enlarged view of detail 2H (open-end outlet channel) shown in Figure 2G, and Figure 2I is an enlarged view of detail 2I (closed-end outlet channel) shown in Figure 2G.
[0016] [Figure 3A] Figures 3A to 3I illustrate gas filter elements according to another embodiment of the present invention, the illustrated embodiment including tapered flow channels, each of the plurality of inlet channels and each of the plurality of slotted outlet channels having a tapered inner cross-sectional area, the tapered inner cross-sectional area of each of the plurality of inlet channels decreasing from a first end to a second end, and the tapered inner cross-sectional area of each of the plurality of slotted outlet channels decreasing from a second end to a first end.
[0017] Figures 3A and 3B are perspective views of a gas filter element at a first end (dirty gas inlet) and a second end (clean gas outlet), respectively. Figures 3C and 3D are views showing the first end (dirty gas inlet) and the second end (clean gas outlet) of the gas filter element shown in Figures 3A and 3B, respectively, where the outlet channel is closed at the first end and the inlet channel is closed at the second end. [Figure 3B] Figures 3A and 3B are perspective views of a gas filter element at a first end (dirty gas inlet) and a second end (clean gas outlet), respectively. Figures 3C and 3D are views showing the first end (dirty gas inlet) and the second end (clean gas outlet) of the gas filter element shown in Figures 3A and 3B, respectively, where the outlet channel is closed at the first end and the inlet channel is closed at the second end. [Figure 3C] Figures 3A and 3B are perspective views of a gas filter element at a first end (dirty gas inlet) and a second end (clean gas outlet), respectively. Figures 3C and 3D are views showing the first end (dirty gas inlet) and the second end (clean gas outlet) of the gas filter element shown in Figures 3A and 3B, respectively, where the outlet channel is closed at the first end and the inlet channel is closed at the second end. [Figure 3D] Figures 3A and 3B are perspective views of a gas filter element at a first end (dirty gas inlet) and a second end (clean gas outlet), respectively. Figures 3C and 3D are views showing the first end (dirty gas inlet) and the second end (clean gas outlet) of the gas filter element shown in Figures 3A and 3B, respectively, where the outlet channel is closed at the first end and the inlet channel is closed at the second end.
[0018] [Figure 3E]Figure 3E is a side view of the gas filter element shown in FIGS. 3A and 3B. Figure 3F shows a horizontal cross-sectional view of the element along line 3F-3F of Figure 3E, and also shows, in a repeating pattern, the two opposing side surfaces of each inlet channel, two slotted outlet channels adjacent to the two opposing side surfaces, and a support portion at the intersection of the slotted outlet channels. Figure 3G is a view showing a vertical cross-sectional view of the element along line 3G-3G of Figure 3E, Figure 3H is a view showing an enlarged view of detail 3H (open-end outlet channel) shown in Figure 3G, and Figure 3I is a view showing an enlarged view of detail 3I (closed-end outlet channel) shown in Figure 3G. [Figure 3F] Figure 3E is a side view of the gas filter element shown in FIGS. 3A and 3B. Figure 3F shows a horizontal cross-sectional view of the element along line 3F-3F of Figure 3E, and also shows, in a repeating pattern, the two opposing side surfaces of each inlet channel, two slotted outlet channels adjacent to the two opposing side surfaces, and a support portion at the intersection of the slotted outlet channels. Figure 3G is a view showing a vertical cross-sectional view of the element along line 3G-3G of Figure 3E, Figure 3H is a view showing an enlarged view of detail 3H (open-end outlet channel) shown in Figure 3G, and Figure 3I is a view showing an enlarged view of detail 3I (closed-end outlet channel) shown in Figure 3G. [Figure 3G] Figure 3E is a side view of the gas filter element shown in FIGS. 3A and 3B. Figure 3F shows a horizontal cross-sectional view of the element along line 3F-3F of Figure 3E, and also shows, in a repeating pattern, the two opposing side surfaces of each inlet channel, two slotted outlet channels adjacent to the two opposing side surfaces, and a support portion at the intersection of the slotted outlet channels. Figure 3G is a view showing a vertical cross-sectional view of the element along line 3G-3G of Figure 3E, Figure 3H is a view showing an enlarged view of detail 3H (open-end outlet channel) shown in Figure 3G, and Figure 3I is a view showing an enlarged view of detail 3I (closed-end outlet channel) shown in Figure 3G. [Figure 3H]Figure 3E is a side view of the gas filter element shown in Figures 3A and 3B. Figure 3F is a horizontal cross-sectional view of the element along line 3F-3F in Figure 3E, and also shows a repeating pattern of two opposing sides of each inlet channel, two slotted outlet channels adjacent to the two opposing sides, and the support portion at the intersection of the slotted outlet channels. Figure 3G is a vertical cross-sectional view of the element along line 3G-3G in Figure 3E, Figure 3H is an enlarged view of detail 3H (open-end outlet channel) shown in Figure 3G, and Figure 3I is an enlarged view of detail 3I (closed-end outlet channel) shown in Figure 3G. [Figure 3I] Figure 3E is a side view of the gas filter element shown in Figures 3A and 3B. Figure 3F is a horizontal cross-sectional view of the element along line 3F-3F in Figure 3E, and also shows a repeating pattern of two opposing sides of each inlet channel, two slotted outlet channels adjacent to the two opposing sides, and the support portion at the intersection of the slotted outlet channels. Figure 3G is a vertical cross-sectional view of the element along line 3G-3G in Figure 3E, Figure 3H is an enlarged view of detail 3H (open-end outlet channel) shown in Figure 3G, and Figure 3I is an enlarged view of detail 3I (closed-end outlet channel) shown in Figure 3G.
[0019] [Figure 4A] Figures 4A to 4I show a gas filter element according to another embodiment of the present invention, in which each inlet channel surrounded by an outlet channel forms an individual channel unit, and each individual channel unit is surrounded by a gap so that adjacent individual channel units do not come into contact with each other. Figures 4A and 4B show isometric views of the gas filter element at the first end (dirty gas inlet) and the second end (clean gas outlet), respectively. Figures 4C and 4D show the first end (dirty gas inlet) and the second end (clean gas outlet) of the gas filter element shown in Figures 4A and 4B, respectively, in which the outlet channel is closed at the first end and the inlet channel is closed at the second end. [Figure 4B]Figures 4A to 4I show a gas filter element according to another embodiment of the present invention, in which each inlet channel surrounded by an outlet channel forms an individual channel unit, and each individual channel unit is surrounded by a gap so that adjacent individual channel units do not come into contact with each other. Figures 4A and 4B show isometric views of the gas filter element at the first end (dirty gas inlet) and the second end (clean gas outlet), respectively. Figures 4C and 4D show the first end (dirty gas inlet) and the second end (clean gas outlet) of the gas filter element shown in Figures 4A and 4B, respectively, in which the outlet channel is closed at the first end and the inlet channel is closed at the second end. [Figure 4C] Figures 4A to 4I show a gas filter element according to another embodiment of the present invention, in which each inlet channel surrounded by an outlet channel forms an individual channel unit, and each individual channel unit is surrounded by a gap so that adjacent individual channel units do not come into contact with each other. Figures 4A and 4B show isometric views of the gas filter element at the first end (dirty gas inlet) and the second end (clean gas outlet), respectively. Figures 4C and 4D show the first end (dirty gas inlet) and the second end (clean gas outlet) of the gas filter element shown in Figures 4A and 4B, respectively, in which the outlet channel is closed at the first end and the inlet channel is closed at the second end. [Figure 4D]Figures 4A to 4I show a gas filter element according to another embodiment of the present invention, in which each inlet channel surrounded by an outlet channel forms an individual channel unit, and each individual channel unit is surrounded by a gap so that adjacent individual channel units do not come into contact with each other. Figures 4A and 4B show isometric views of the gas filter element at the first end (dirty gas inlet) and the second end (clean gas outlet), respectively. Figures 4C and 4D show the first end (dirty gas inlet) and the second end (clean gas outlet) of the gas filter element shown in Figures 4A and 4B, respectively, in which the outlet channel is closed at the first end and the inlet channel is closed at the second end.
[0020] [Figure 4E] Figure 4E is a side view of the gas filter element shown in Figures 4A and 4B. Figure 4F is a horizontal cross-sectional view of the element along line 4F-4F in Figure 4E, and also shows the outlet channel surrounding the inlet channel, where the inlet channel surrounded by the outlet channel forms individual channel units in a repeating pattern, and each individual channel unit is surrounded by a gap so that adjacent individual channel units do not come into contact with each other. Figure 4G is a vertical cross-sectional view of the element along line 4G-4G in Figure 4E, Figure 4H is a magnified view of detail 4H (open-end outlet channel) shown in Figure 4G, and Figure 4I is a magnified view of detail 4I (closed-end outlet channel) shown in Figure 4G. [Figure 4F]Figure 4E is a side view of the gas filter element shown in Figures 4A and 4B. Figure 4F is a horizontal cross-sectional view of the element along line 4F-4F in Figure 4E, and also shows the outlet channel surrounding the inlet channel, where the inlet channel surrounded by the outlet channel forms individual channel units in a repeating pattern, and each individual channel unit is surrounded by a gap so that adjacent individual channel units do not come into contact with each other. Figure 4G is a vertical cross-sectional view of the element along line 4G-4G in Figure 4E, Figure 4H is a magnified view of detail 4H (open-end outlet channel) shown in Figure 4G, and Figure 4I is a magnified view of detail 4I (closed-end outlet channel) shown in Figure 4G. [Figure 4G] Figure 4E is a side view of the gas filter element shown in Figures 4A and 4B. Figure 4F is a horizontal cross-sectional view of the element along line 4F-4F in Figure 4E, and also shows the outlet channel surrounding the inlet channel, where the inlet channel surrounded by the outlet channel forms individual channel units in a repeating pattern, and each individual channel unit is surrounded by a gap so that adjacent individual channel units do not come into contact with each other. Figure 4G is a vertical cross-sectional view of the element along line 4G-4G in Figure 4E, Figure 4H is a magnified view of detail 4H (open-end outlet channel) shown in Figure 4G, and Figure 4I is a magnified view of detail 4I (closed-end outlet channel) shown in Figure 4G. [Figure 4H]Figure 4E is a side view of the gas filter element shown in Figures 4A and 4B. Figure 4F is a horizontal cross-sectional view of the element along line 4F-4F in Figure 4E, and also shows the outlet channel surrounding the inlet channel, where the inlet channel surrounded by the outlet channel forms individual channel units in a repeating pattern, and each individual channel unit is surrounded by a gap so that adjacent individual channel units do not come into contact with each other. Figure 4G is a vertical cross-sectional view of the element along line 4G-4G in Figure 4E, Figure 4H is a magnified view of detail 4H (open-end outlet channel) shown in Figure 4G, and Figure 4I is a magnified view of detail 4I (closed-end outlet channel) shown in Figure 4G. [Figure 4I] Figure 4E is a side view of the gas filter element shown in Figures 4A and 4B. Figure 4F is a horizontal cross-sectional view of the element along line 4F-4F in Figure 4E, and also shows the outlet channel surrounding the inlet channel, where the inlet channel surrounded by the outlet channel forms individual channel units in a repeating pattern, and each individual channel unit is surrounded by a gap so that adjacent individual channel units do not come into contact with each other. Figure 4G is a vertical cross-sectional view of the element along line 4G-4G in Figure 4E, Figure 4H is a magnified view of detail 4H (open-end outlet channel) shown in Figure 4G, and Figure 4I is a magnified view of detail 4I (closed-end outlet channel) shown in Figure 4G.
[0021] [Figure 5A] Figures 5A to 5I illustrate a gas filter element according to yet another embodiment of the present invention, wherein each inlet channel surrounded by an outlet channel forms an individual channel unit, each individual channel unit is surrounded by a gap along a partial length from a first end to a second end, and adjacent individual channel units are in contact with each other by at least one support bracket between the first and second ends of the element.
[0022] Figures 5A and 5B show isometric views of the gas filter element at the first end (dirty gas inlet) and the second end (clean gas outlet), respectively. Figures 5C and 5D show the first end (dirty gas inlet) and the second end (clean gas outlet) of the gas filter element shown in Figures 5A and 5B, respectively, with the outlet channel closed at the first end and the inlet channel closed at the second end. [Figure 5B] Figures 5A and 5B show isometric views of the gas filter element at the first end (dirty gas inlet) and the second end (clean gas outlet), respectively. Figures 5C and 5D show the first end (dirty gas inlet) and the second end (clean gas outlet) of the gas filter element shown in Figures 5A and 5B, respectively, with the outlet channel closed at the first end and the inlet channel closed at the second end. [Figure 5C] Figures 5A and 5B show isometric views of the gas filter element at the first end (dirty gas inlet) and the second end (clean gas outlet), respectively. Figures 5C and 5D show the first end (dirty gas inlet) and the second end (clean gas outlet) of the gas filter element shown in Figures 5A and 5B, respectively, with the outlet channel closed at the first end and the inlet channel closed at the second end. [Figure 5D] Figures 5A and 5B show isometric views of the gas filter element at the first end (dirty gas inlet) and the second end (clean gas outlet), respectively. Figures 5C and 5D show the first end (dirty gas inlet) and the second end (clean gas outlet) of the gas filter element shown in Figures 5A and 5B, respectively, with the outlet channel closed at the first end and the inlet channel closed at the second end.
[0023] [Figure 5E]Figure 5E is a side view of the gas filter element shown in Figures 5A and 5B. Figure 5F shows a horizontal cross-sectional view of the element along line 5F-5F in Figure 5E, passing through support brackets that connect individual channel units, and also shows the outlet channel surrounding the inlet channel and adjacent to the inlet channel, the inlet channel surrounded by the outlet channel forming individual channel units in a repeating pattern, with gaps along a partial length from the first end to the second end (above and / or below the support brackets). [Figure 5F] Figure 5E is a side view of the gas filter element shown in Figures 5A and 5B. Figure 5F shows a horizontal cross-sectional view of the element along line 5F-5F in Figure 5E, passing through support brackets that connect individual channel units, and also shows the outlet channel surrounding the inlet channel and adjacent to the inlet channel, the inlet channel surrounded by the outlet channel forming individual channel units in a repeating pattern, with gaps along a partial length from the first end to the second end (above and / or below the support brackets).
[0024] [Figure 5G] Figure 5G shows a vertical cross-sectional view of an element along line 5G-5G in Figure 5E, and also shows three vertically arranged support brackets. Figure 5H shows an enlarged view of detail 5H (open-end outlet channel) shown in Figure 5G, and Figure 5I shows an enlarged view of detail F (closed-end outlet channel) shown in Figure 5I. [Figure 5H] Figure 5G shows a vertical cross-sectional view of an element along line 5G-5G in Figure 5E, and also shows three vertically arranged support brackets. Figure 5H shows an enlarged view of detail 5H (open-end outlet channel) shown in Figure 5G, and Figure 5I shows an enlarged view of detail F (closed-end outlet channel) shown in Figure 5I. [Figure 5I]Figure 5G shows a vertical cross-sectional view of an element along line 5G-5G in Figure 5E, and also shows three vertically arranged support brackets. Figure 5H shows an enlarged view of detail 5H (open-end outlet channel) shown in Figure 5G, and Figure 5I shows an enlarged view of detail F (closed-end outlet channel) shown in Figure 5I.
[0025] [Figure 6A] Figures 6A to 6E show embodiments of a gas filter device comprising a gas filter element mounted on a frame, embodiments of a filter array comprising a plurality of gas filter devices arranged within a housing, and embodiments of a gas filter system comprising a filter array, the system including a blowback duct associated with the housing. Figure 6A is a top view of the gas filter system with the top wall of the housing removed, Figure 6B is a view along the cross section 6B-6B of the system shown in Figure 6A, Figure 6C is a view along the cross section 6C-6C of the system shown in Figure 6A, Figure 6D is a magnified view of detail 6D of the system shown in Figure 6C, and Figure 6E is a top view of the gas filter system shown in Figure 6A with the top wall of the housing present. [Figure 6B] Figures 6A to 6E show embodiments of a gas filter device comprising a gas filter element mounted on a frame, embodiments of a filter array comprising a plurality of gas filter devices arranged within a housing, and embodiments of a gas filter system comprising a filter array, the system including a blowback duct associated with the housing. Figure 6A is a top view of the gas filter system with the top wall of the housing removed, Figure 6B is a view along the cross section 6B-6B of the system shown in Figure 6A, Figure 6C is a view along the cross section 6C-6C of the system shown in Figure 6A, Figure 6D is a magnified view of detail 6D of the system shown in Figure 6C, and Figure 6E is a top view of the gas filter system shown in Figure 6A with the top wall of the housing present. [Figure 6C]Figures 6A to 6E show embodiments of a gas filter device comprising a gas filter element mounted on a frame, embodiments of a filter array comprising a plurality of gas filter devices arranged within a housing, and embodiments of a gas filter system comprising a filter array, the system including a blowback duct associated with the housing. Figure 6A is a top view of the gas filter system with the top wall of the housing removed, Figure 6B is a view along the cross section 6B-6B of the system shown in Figure 6A, Figure 6C is a view along the cross section 6C-6C of the system shown in Figure 6A, Figure 6D is a magnified view of detail 6D of the system shown in Figure 6C, and Figure 6E is a top view of the gas filter system shown in Figure 6A with the top wall of the housing present. [Figure 6D] Figures 6A to 6E show embodiments of a gas filter device comprising a gas filter element mounted on a frame, embodiments of a filter array comprising a plurality of gas filter devices arranged within a housing, and embodiments of a gas filter system comprising a filter array, the system including a blowback duct associated with the housing. Figure 6A is a top view of the gas filter system with the top wall of the housing removed, Figure 6B is a view along the cross section 6B-6B of the system shown in Figure 6A, Figure 6C is a view along the cross section 6C-6C of the system shown in Figure 6A, Figure 6D is a magnified view of detail 6D of the system shown in Figure 6C, and Figure 6E is a top view of the gas filter system shown in Figure 6A with the top wall of the housing present. [Figure 6E]Figures 6A to 6E show embodiments of a gas filter device comprising a gas filter element mounted on a frame, embodiments of a filter array comprising a plurality of gas filter devices arranged within a housing, and embodiments of a gas filter system comprising a filter array, the system including a blowback duct associated with the housing. Figure 6A is a top view of the gas filter system with the top wall of the housing removed, Figure 6B is a view along the cross section 6B-6B of the system shown in Figure 6A, Figure 6C is a view along the cross section 6C-6C of the system shown in Figure 6A, Figure 6D is a magnified view of detail 6D of the system shown in Figure 6C, and Figure 6E is a top view of the gas filter system shown in Figure 6A with the top wall of the housing present. [Modes for carrying out the invention]
[0026] Detailed description of the invention One aspect of the present invention provides a gas filter element having a first end and a second end, the gas filter element having a plurality of inlet channels and a plurality of slotted outlet channels between the first end and the second end, wherein in an alternating pattern, each of the plurality of inlet channels has an inlet channel opening at the first end and is closed at the second end, each of the plurality of slotted outlet channels has a slotted outlet channel opening at the second end and is closed at the first end, each of the plurality of inlet channels is surrounded by four slotted outlet channels, each of the plurality of inlet channels and each of the plurality of plurality of slotted outlet channels has an internal cross-sectional area, each of the plurality of inlet channels has an internal cross-sectional area exceeding the internal cross-sectional area of each of the plurality of slotted outlet channels, and the plurality of inlet channels and plurality of slotted outlet channels have a common porous wall.
[0027] According to another aspect of the present invention, the gas filter element comprises a first end and a second end, the gas filter element having a plurality of inlet channels and a plurality of slotted outlet channels between the first end and the second end, in an alternating pattern, each of the plurality of inlet channels having an inlet channel opening at the first end and closed at the second end, each of the plurality of slotted outlet channels having a slotted outlet channel opening at the second end and closed at the first end, each of the plurality of inlet channels being surrounded on two opposing sides by two slotted outlet channels, each of the plurality of inlet channels and each of the plurality of plurality of slotted outlet channels having an inner tapered cross-sectional area, the tapered inner cross-sectional area of each of the plurality of inlet channels decreasing from the first end to the second end, the tapered inner cross-sectional area of each of the plurality of slotted outlet channels decreasing from the second end to the first end, and the plurality of inlet channels and the plurality of slotted outlet channels having a common porous wall.
[0028] According to another aspect of the present invention, the gas filter element comprises a first end and a second end, the gas filter element having a plurality of inlet channels and a plurality of outlet channels between the first end and the second end, in an alternating pattern, each of the plurality of inlet channels having an inlet channel opening at the first end and closed at the second end, each of the plurality of outlet channels having an outlet channel closed at the first end and an opening at the second end, each outlet channel forming a gap between adjacent inlet channels, the gap extending to the second end, each of the plurality of inlet channels being surrounded by an outlet channel, each inlet channel surrounded by an outlet channel forming an individual channel unit, each individual channel unit being surrounded by a gap extending to the second end such that adjacent individual channel units do not come into contact with each other, and the plurality of inlet channels and a plurality of outlet channels within each individual channel unit having a common porous wall.
[0029] According to another aspect of the present invention, the gas filter element comprises a first end and a second end, the gas filter element having a plurality of inlet channels and a plurality of outlet channels between the first end and the second end, in an alternating pattern, each of the plurality of inlet channels having an inlet channel opening at the first end and closed at the second end, each of the plurality of outlet channels having an outlet channel closed at the first end and an opening at the second end, each outlet channel forming a gap between adjacent inlet channels along a partial length between the first end and the second end, each of the plurality of inlet channels being surrounded by an outlet channel, each inlet channel surrounded by an outlet channel forming an individual channel unit, each individual channel unit being surrounded by a gap along a partial length between the first end and the second end, adjacent individual channel units being held together by a support bracket, and the plurality of inlet channels and the plurality of outlet channels within each individual channel unit having a common porous wall.
[0030] In a typical embodiment of a gas filter element, each of the multiple inlet channels and each of the multiple outlet channels has an internal cross-sectional area, and each of the multiple inlet channels has an internal cross-sectional area greater than the internal cross-sectional area of each of the multiple outlet channels. However, in some embodiments, each of the multiple inlet channels has an internal cross-sectional area equal to the internal cross-sectional area of each of the multiple outlet channels.
[0031] In some embodiments of the gas filter element, the element has a ratio greater than 1:1 of the total inner cross-sectional areas of the multiple inlet channels to the total inner cross-sectional areas of the multiple slotted outlet channels, for example, 1.4:1, 5:1, 10:1, or 14:1. However, in some other embodiments, the element has a ratio of 1:1 of the total inner cross-sectional areas of the multiple inlet channels to the total inner cross-sectional areas of the multiple slotted outlet channels.
[0032] Alternatively or additionally, in some embodiments of the gas filter element, each of the plurality of inlet channels and each of the plurality of plurality of slotted outlet channels has a tapered inner cross-sectional area, wherein the tapered inner cross-sectional area of each of the plurality of inlet channels decreases from a first end to a second end, and the tapered inner cross-sectional area of each of the plurality of slotted outlet channels decreases from a second end to a first end.
[0033] In another aspect of the present invention, a filter device is provided, which comprises one embodiment of a gas filter element mounted on a frame.
[0034] In yet another aspect of the present invention, a filter array is provided comprising at least one, preferably two or more, configurations of filter devices arranged within a housing.
[0035] In yet another aspect of the present invention, a filter system is provided comprising two or more configurations of filter arrays arranged adjacent to one another.
[0036] In another embodiment, a method for filtering a gas includes passing the gas through one embodiment of a gas filter element, the method including passing the gas so that it enters an inlet channel opening and the inlet channel, passes through a porous wall into an outlet channel, and passes through the outlet channel opening. Typically, the gas entering the inlet channel contains contaminants that cannot pass through the porous wall, thereby providing a gas that enters the outlet channel and passes through the outlet channel opening with reduced levels of contaminants, and is a "cleaner" gas than the gas entering the gas filter element.
[0037] Advantageously, since outlet channels and slotted outlet channels are generally narrower (e.g., have a smaller cross-sectional area) than inlet channels (e.g., have a larger cross-sectional area), a higher pressure difference is provided, resulting in greater separation between the gas and the contaminants. In their embodiments having tapered channels, an even greater desired pressure difference can be provided.
[0038] If desired, the gas filter element is suitable for backflow cleaning, and the gas is allowed to pass through the outlet channel opening at the second end, through the porous wall, and through the inlet channel opening at the first end, thereby removing the filter cake accumulated on the porous wall of the inlet channel.
[0039] In particular for industrial applications, the gas filter elements possess excellent mechanical strength and have been tested in laboratory tests for over 20,000 blowback cycles and over 200,000 fatigue cycles.
[0040] In some embodiments, individual channel units can be slightly flexed under pressure, which advantageously provides improved cleaning during backflow by loosening a portion of the accumulated filter cake.
[0041] The components of the present invention will be described in more detail below, with similar components having the same reference numeral.
[0042] According to an embodiment of the gas filter according to the present invention, dirty gas enters the open end of the inlet channel at a first end of the element, the gas is purified as it passes through a common porous wall between the inlet channel and the outlet channel, and the clean gas exits the gas filter element through the open end of the outlet channel at a second end of the element.
[0043] In the illustrated embodiments shown in Figures 1A and 1B, dirty gas enters the open end 111A of the inlet channel 111 at the first end 101 of the gas filter element 500, the gas is purified as it passes through a common porous wall 130 between the inlet channel 111 and the outlet channel 112, and the clean gas exits the gas filter element through the open end 122A of the outlet channel at the second end 102 of the gas filter element. In the embodiment shown in Figure 1B, each of the multiple inlet channels has an internal cross-sectional area 115, and each of the multiple slotted outlet channels has an internal cross-sectional area 125.
[0044] In the illustrated embodiments shown in Figures 2A to 2I, the gas filter element 500 comprises a first end 101 and a second end 102, and the gas filter element 500 has a plurality of inlet channels 111 and a plurality of slotted outlet channels 122 between the first end and the second end, and in an alternating pattern, each of the plurality of inlet channels 111 has an inlet channel opening 111A at the first end and is closed at the second end 111B, and each of the plurality of slotted outlet channels 122 has a slotted outlet channel opening 122A (shown as having a substantially rectangular slot opening) at the second end and is closed at the first end 122B Each of the multiple inlet channels is surrounded by four slotted outlet channels (see, for example, Figure 2F), each of the multiple inlet channels has an internal cross-sectional area (115), each of the multiple slotted outlet channels has an internal cross-sectional area (125), each of the multiple inlet channels has an internal cross-sectional area greater than the internal cross-sectional area of each of the multiple slotted outlet channels, the element has a ratio greater than 1 of the total internal cross-sectional areas of the multiple inlet channels to the total internal cross-sectional areas of the multiple slotted outlet channels, and the multiple inlet channels and the multiple slotted outlet channels have a common porous wall 130. For example, in the embodiment shown in Figure 2F, a support 150 is present along the intersection of the slotted outlet channels.
[0045] For example, in the embodiments shown in Figures 2B to 2D, both the slotted outlet channel 122 of the first end 101 (shown as having a substantially rectangular channel; see also Figure 1B) and the inlet channel 111 of the second end 102 are blocked at 122B and 111B. These blocked ends are structurally similar to, or identical in structure to, the porous wall 130, but due to lower resistance, the gas flows through the open ends along the inlet and outlet channels rather than through the blocked ends.
[0046] In the illustrated embodiment (see, for example, Figures 2C and 2D), all openings 111A (inlet channel openings) at the first end 101 are the same or larger in size, and all openings 122A (slotted channel openings) at the second end 102 are the same or smaller in size.
[0047] In some embodiments, the first end 101 includes a lip 101A for mounting to a frame, for example, to provide a filter device.
[0048] In some embodiments of any gas filter element, using the gas filter element shown in Figure 2A for general reference, the gas filter element may include one or more optional spacers 190 (shown as two spacers on each of the four sides of the gas filter element near the second end 102).
[0049] In the illustrated embodiments shown in Figures 3A to 3I, the gas filter element 600 comprises a first end 201 and a second end 202, and the gas filter element 600 has a plurality of inlet channels 211 and a plurality of slotted outlet channels 222 between the first end and the second end, and in an alternating pattern, each of the plurality of tapered inlet channels 211 has an inlet channel opening 211A at the first end and is closed at the second end 211B, and each of the plurality of slotted outlet channels 222 has a slotted outlet channel opening 222A (shown as having a substantially rectangular slot opening) at the second end and is closed at the first end Furthermore, each of the multiple inlet channels is surrounded on two opposing sides by two slotted outlet channels (see, for example, Figure 3F), each of the multiple inlet channels has a tapered inner cross-sectional area (215), and each of the multiple slotted outlet channels has a tapered inner cross-sectional area (225), the tapered inner cross-sectional area of each of the multiple inlet channels decreases from the first end to the second end, and the tapered inner cross-sectional area of each of the multiple slotted outlet channels decreases from the second end to the first end, and the multiple inlet channels and the multiple slotted outlet channels have a common porous wall 230. For example, in the embodiment shown in Figure 3F, a support portion 250 is present along the intersection of the slotted outlet channels.
[0050] In some embodiments of the gas filter element 600, each of the plurality of inlet channels and each of the plurality of outlet channels has an internal cross-sectional area, and each of the plurality of inlet channels has an internal cross-sectional area greater than the internal cross-sectional area of each of the plurality of outlet channels. However, in some other embodiments, each of the plurality of inlet channels has an internal cross-sectional area equal to the internal cross-sectional area of each of the plurality of outlet channels.
[0051] For example, in the embodiments shown in Figures 3B to 3D, both the slotted outlet channel 222 at the first end 201 and the inlet channel 211 at the second end 202 are blocked at 222B and 211B. These blocked ends are structurally similar to, or identical in structure to, the porous wall 230, but due to lower resistance, the gas flows through the open ends along the inlet and outlet channels rather than through the blocked ends.
[0052] In the illustrated embodiment (see, for example, Figures 3C and 3D), all openings 211A (inlet channel openings) at the first end 201 are the same or larger in size, and all openings 222A (slotted channel openings) at the second end 202 are the same or smaller in size.
[0053] In some embodiments, the first end 201 includes a lip 201A for mounting to a frame, for example, to provide a filter device.
[0054] In the illustrated embodiments shown in Figures 4A to 4I, the gas filter element 700 comprises a first end 301 and a second end 302, and the gas filter element 700 has a plurality of inlet channels 311 and a plurality of outlet channels 322 between the first end and the second end, in an alternating pattern, each of the plurality of inlet channels 311 has an inlet channel opening 311A at the first end and is closed at the second end 311B, each of the plurality of outlet channels 322 has an outlet channel opening 322A at the second end and is closed at the first end 322B, and each outlet channel 322 is between adjacent inlet channels 311 A gap 375 is formed, the gap extends to a second end, each of the multiple inlet channels is surrounded by an outlet channel, each inlet channel surrounded by an outlet channel forms an individual channel unit 390, each individual channel unit is surrounded by a gap 375 extending to a second end so that adjacent individual channel units do not come into contact with each other, each of the multiple inlet channels has an inner cross-sectional area (315), each of the multiple slotted outlet channels has an inner cross-sectional area (325), and the multiple inlet channels and multiple outlet channels have a common porous wall 330.
[0055] For example, in the embodiments shown in Figures 4B to 4D, both the outlet channel 322 at the first end 301 and the inlet channel 311 at the second end 302 are blocked by 322B and 311B. These blocked ends are structurally similar to, or identical in structure to, the porous wall 330, but due to lower resistance, the gas flows through the open ends along the inlet and outlet channels rather than through the blocked ends.
[0056] In some embodiments, the first end 301 includes a lip 301A for mounting to a frame, for example, to provide a filter device.
[0057] In the illustrated embodiments shown in Figures 5A to 5I, the gas filter element 800 comprises a first end 401 and a second end 402, and the gas filter element 800 has a plurality of inlet channels 411 and a plurality of outlet channels 422 between the first end and the second end, in an alternating pattern, each of the plurality of inlet channels 411 has an inlet channel opening 411A at the first end and is closed at the second end 411B, each of the plurality of outlet channels 422 has an outlet channel opening 422A at the second end and is closed at the first end 422B, and each outlet channel 422 has at least one gap 475 (shown as separate gaps above and / or below the support bracket 450) along the partial length between the second end and the second end (shown as gaps 475A, 475B, 475C, and 475D) between adjacent inlet channels 411, and the support bracket 450 is The inlet channels are formed by a gap (shown as a first support bracket 450A, a second support bracket 450B, a third support bracket 450C, and a fourth support bracket 450D), the gap is not continuous between the first end and the second end, each of the plurality of inlet channels is surrounded by an outlet channel, each inlet channel surrounded by an outlet channel forms an individual channel unit 490, each individual channel unit is surrounded by at least one gap along a partial length between the first end and the second end, adjacent individual channel units are held together by at least one support bracket, each of the plurality of inlet channels has an inner cross-sectional area (415), each of the plurality of plurality of slotted outlet channels has an inner cross-sectional area (425), and the plurality of inlet channels and plurality of outlet channels within each individual channel unit have a common porous wall 430.
[0058] For example, in the embodiments shown in Figures 5B to 5D, both the outlet channel 422 at the first end 401 and the inlet channel 411 at the second end 402 are blocked by 422B and 411B. These blocked ends are structurally similar to, or identical in structure to, the porous wall 430, but due to lower resistance, the gas flows through the open ends along the inlet and outlet channels rather than through the blocked ends.
[0059] In some embodiments, the first end 401 includes a lip 401A for mounting to a frame, for example, to provide a filter device.
[0060] The porous wall can be any suitable pore structure, for example, by bubble points, or by K as described in U.S. Patent No. 4,340,479. L The porous wall may have pore size (as demonstrated by or by capillary condensation flow porometry), mean flow pore (MFP) size (if characterized using a porometer, e.g., one available under the trademarks of Porvair Porometer (Porvair plc, Norfolk, UK), or POROLUX (Porometer.com; Belgium)), pore diameter (if characterized using a modified OSU F2 test, e.g., one described in U.S. Patent No. 4,925,572), or removal evaluation medium. In some embodiments, the porous wall may have a mixture of pore structures ranging, for example, 5 to 20 micrometers, or a pore structure of, for example, 10 micrometers.
[0061] Optionally, in some embodiments, the porous wall includes one or more catalysts for, for example, nitrous oxide reduction, sulfur removal, and / or sulfur oxide removal. Exemplary catalysts suitable for nitrous oxide reduction include, for example, MnOx, Mn-TiO2, and Cu / Al2O3; exemplary catalysts suitable for sulfur reduction include, for example, Ca(OH)2 and NaHCO3; and exemplary catalysts suitable for simultaneous reduction of nitrous oxide and sulfur oxide include, for example, Fe2O3.
[0062] The filter elements can be formed, for example, from ceramics, such as silica, and from stainless steel powders such as 316 low-carbon stainless steel and 310 stainless steel, by processes including sintering. Other suitable metal powders include, for example, alloys (e.g., HASTELLOY® X, HAYNES® HR-160® (Haynes International), and Inconel 600), nickel, chromium, tungsten, copper, bronze, aluminum, platinum, iron, magnesium, cobalt, or combinations thereof (including combinations of metals and metal alloys).
[0063] The filter elements according to embodiments of the present invention may be monolithic and can be manufactured, for example, by additive manufacturing (sometimes called “additive manufacturing” or “3D printing”). They are typically formed by the repeated deposition of metal powder bound to an activatable binder (e.g., binder jetting, sometimes called “drop-on powder”), and the powder is typically agglomerated by sintering, for example. If present, housing elements, extensions, and other components can be manufactured together by additive manufacturing in substantially simultaneous and continuous operation.
[0064] Any suitable additive manufacturing equipment can be used, and various 3D printers are suitable and commercially available.
[0065] In another aspect of the present invention, a gas filter device is provided, the filter device comprising one aspect of a gas filter element mounted on a frame. For example, Figures 6A to 6D show a plurality of gas filter devices 900, each gas filter device comprising two or more aspects of a gas filter element mounted on a frame 950 (shown as gas filter elements 500, 600, 700, 800, and each illustrated gas filter device comprises nine gas filter elements; see Figure 6A), the frame comprising an opening for receiving the gas filter element, for example, a first end of a gas filter element (the first end may comprise a plate) comprising an outwardly extending lip (shown as 101A, 201A, 301A, 401A) that prevents the first end from passing through the opening in the frame. The lip may be positioned in direct contact with the edge of the opening and may be bonded thereto if desired, or a gasket may be positioned between the lip and the edge of the opening, for example.
[0066] In yet another aspect of the present invention, a gas filter array is provided comprising at least one, preferably two or more, configurations of filter devices arranged within a housing. For example, using Figures 6A–6D for reference, the illustrated gas filter array 1000 comprises two or more gas filter devices mounted on a frame 950 arranged within a housing 1015. In the configuration of the gas filter array shown in Figure 6B, each of the three gas filter arrays 1000 comprises seven gas filter devices 900, and each gas filter device comprises nine gas filter elements.
[0067] In yet another aspect of the present invention, using Figures 6A–6D for reference, a gas filter system 2000 is provided which includes at least one gas filter array 1000 including two or more embodiments of a gas filter device 900 (Figure 6E shows an external view of the system 2000, and since the rear of the system is usually open, the rear view is similar to that shown in Figure 6C), the filter devices are arranged adjacent to one another in a continuous manner, and preferably the filter system further comprises a blowback duct 2015.
[0068] Using the embodiment shown in Figure 6B for reference, the illustrated embodiment of the gas filter system 2000 comprises a filter array 1000 having two or more embodiments of filter devices 900 linearly arranged within a housing 1015, and a blowback duct 2015 located at one end of the housing, the blowback duct being arranged to operate at the second ends 102, 202, 302, 402 of the gas filter elements. Thus, the gas passing through the blowback duct passes through the outlet channel openings at the second ends of each gas filter device in the gas filter array, through the porous walls, and through the inlet channel openings at the first ends 101, 201, 301, 401, removing the filter cake accumulated on the porous walls of the inlet channels.
[0069] All references cited herein, including publications, patent applications, and patents, are incorporated herein by reference to the same extent as they are incorporated herein by reference, provided that each reference is indicated to be incorporated individually and specifically by reference.
[0070] In the context describing the present invention (in particular, in the context of the following claims), the terms “a,” “an,” “the,” and “at least one,” and similar references, should be interpreted as encompassing both singular and plural unless otherwise indicated herein or unless clearly inconsistent with the context. The use of the term “at least one,” followed by a list of one or more items (e.g., “at least one of A and B”), should be interpreted as meaning one item selected from the enumerated items (A or B) or any combination of two or more enumerated items (A and B), unless otherwise indicated herein or unless clearly inconsistent with the context. The terms “comprising,” “having,” “including,” and “containing” should be interpreted as non-restrictive terms (i.e., “including but not limited”) unless specifically stated otherwise. The enumeration of value ranges herein is intended solely as a convenient way to refer individually to each distinct value contained within the range, unless otherwise indicated herein, and each distinct value is incorporated herein as if it were individually enumerated herein. All methods described herein may be performed in any suitable order unless otherwise indicated herein or unless it is clearly inconsistent with the context. The use of any examples or exemplary language provided herein (e.g., "etc.") is intended solely to better illustrate the invention and, unless specifically requested, does not limit the scope of the invention. No language herein should be construed as indicating that an unclaimed element is essential for the practice of the invention.
[0071] Preferred embodiments of the Invention, including the best mode known to the inventors for carrying out the Invention, are described herein. Variations of these preferred embodiments may become apparent to those skilled in the art by reading the foregoing description. The inventors expect that those skilled in the art will appropriately use such variations, and the inventors intend that the Invention may be carried out in ways other than those specifically described herein. Accordingly, the Invention includes all modifications and equivalents of the subject matter enumerated in the appended claims, where permitted by applicable law. Furthermore, unless otherwise indicated herein, or unless clearly inconsistent with the context, any combination of the aforementioned elements in all possible variations thereof is incorporated into the Invention.
Claims
1. A gas filter element comprising a first end and a second end, The gas filter element has a plurality of inlet channels and a plurality of outlet channels between the first end and the second end, In an alternating pattern, each of the multiple inlet channels has an inlet channel opening at the first end and is closed at the second end, and each of the multiple outlet channels has an outlet channel closed at the first end and an opening at the second end, and each outlet channel forms a gap between adjacent inlet channels, the gap extending to the second end, Each of the plurality of inlet channels is surrounded by an outlet channel, and each inlet channel surrounded by an outlet channel forms an individual channel unit, and each individual channel unit is surrounded by the gap extending to the second end such that adjacent individual channel units do not come into contact with each other. A gas filter element in which the plurality of inlet channels and the plurality of outlet channels within each individual channel unit have a common porous wall.
2. A gas filter element comprising a first end and a second end, The gas filter element has a plurality of inlet channels and a plurality of outlet channels between the first end and the second end, In an alternating pattern, each of the plurality of inlet channels has an inlet channel opening at the first end and is closed at the second end, and each of the plurality of outlet channels has an outlet channel closed at the first end and an opening at the second end, and each outlet channel forms a gap between adjacent inlet channels along the partial length between the first end and the second end. Each of the plurality of inlet channels is surrounded by an outlet channel, and each inlet channel surrounded by an outlet channel forms a separate channel unit, each separate channel unit is surrounded by the gap along the partial length between the first end and the second end, and adjacent separate channel units are held together by a support bracket. A gas filter element in which the plurality of inlet channels and the plurality of outlet channels within each individual channel unit have a common porous wall.
3. The gas filter element according to claim 1 or 2, wherein the ratio of the total inner cross-sectional area of the plurality of inlet channels to the total inner cross-sectional area of the plurality of outlet channels is greater than 1:
1.
4. A method for filtering a gas, the method comprising passing the gas through a gas filter element according to any one of claims 1 to 3, the method comprising passing the gas so as to enter the inlet channel opening and the inlet channel, through the porous wall into the outlet channel, and through the outlet channel opening.
5. A gas filter device comprising a gas filter element according to any one of claims 1 to 3, mounted on a frame.
6. A gas filter array comprising at least one gas filter device according to claim 5, arranged within a housing.
7. A gas filter system comprising two or more gas filter arrays according to claim 6, arranged adjacent to each other.