Systems and devices for increasing filter flow in a filter cartridge

Abstract

A filtration cartridge is provided. The filtration cartridge includes a housing having at least one sidewall and a bottom portion having at least one outlet opening, a lid including one or more openings, a wicking substrate, and filter media positioned in the housing. In certain embodiments, the wicking substrate is positioned in the housing between the lid and the filter media. A container and a method featuring the filtration cartridge are also provided.

Description

Attorney Docket No. 030.0029-WO00SYSTEMS AND DEVICES FOR INCREASING FILTER FLOW IN A FILTER CARTRIDGECROSS-REFERENCE TO RELATED APPLICATION(S) AND CLAIM OF PRIORITY

[0001] This application claims the benefit of priority of U.S. Patent Application No. 63 / 695,468 filed in the U.S. Patent & Trademark Office on September 17, 2024, the complete disclosure of which is incorporated herein by reference.FIELD

[0002] This technology relates to systems, devices, and methods of use of the devices to support the velocity and flow of fluids through a filter chamber of a filter cartridge. In certain exemplary embodiments, the technology relates to systems and devices for increasing filter flow and reducing flow obstructions in water filters.BACKGROUND

[0003] A water filtration system can be designed to remove impurities, contaminants, and particles from water. The filtration process can remove total dissolved solids (TDS) like metals, minerals, salts, and ions to improve the taste of the water and provide healthier and cleaner water.

[0004] Water filtration systems can include various configurations including pour-through pitcher systems, countertop systems, filtration cartridge systems, etc. Pour-through pitcher systems can include an upper reservoir for receiving unfiltered water, a lower reservoir for receiving and storing filtered water, and a filtration cartridge through which water flows from the upper reservoir, is filtered, and travels to the lower reservoir.

[0005] A countertop water filter system can be a standalone system that includes an upper tank for receiving unfiltered water, a lower tank for receiving filtered water, one or more filters designed to remove contaminants, and a spigot for dispensing filtered water into a glass or other container.

[0006] Pitcher and countertop systems leverage gravity to move the unfiltered water from the top reservoir through a water filtration cartridge and into the lower reservoir where the filtered water is stored until used.Attorney Docket No. 030.0029-WO00

[0007] Water filtration cartridges used in gravity flow systems can include a sieve system and a housing to encase the sieve system to support the overall functionality of the water filtration cartridge. The sieve system can include various types of filter media designed to remove specific contaminants from the water. The filter media can be granular and include activated carbon, ceramic, ion exchange resins, membranes, or sediment filters. The sieve system can be mounted within a cavity of the filter housing.

[0008] I n conventional gravity flow water filtration cartridges, when water is introduced, surface tensions can be created that prevent water from continuously flowing into the filter housing. Solutions to this problem require complex configurations that include additional features and materials to reduce surface tension and create better flow within the filter.SUMMARY

[0009] This Summary is provided to introduce a selection of representative concepts in a simplified form, which representative concepts are further described below in the Detailed Description. This Summary is not intended to identify key features or essential features of the claimed subject matter, nor is it or the objects and benefits described herein intended to be used to limit the scope of the claimed subject matter.

[0010] The devices and systems of some exemplary aspects and embodiments described herein provide improvements in filter performance and flow rate by implementing capillary action or wicking techniques within a water filter.

[0011] In a first aspect, a filtration cartridge is provided that includes a housing, a lid, filter media, and a wicking substrate. The housing includes at least one side wall, a bottom portion having at least one outlet opening, and an interior cavity. The filter media is positioned in the interior cavity. The lid is engageable with the housing, and includes at least an upper surface, a lower surface, and one or more openings. When the lid is engaged with the housing, the upper surface faces away from the interior cavity, the lower surface faces towards the interior cavity, and the one or more lid openings provide fluid communication between the interior cavity and atmosphere outside the interior cavity. In one or more exemplary embodiments, the wicking substrate is positioned in association with the one or more openings, e.g., to receive liquid passing through the one or more lid openings.

[0012] According to a second aspect, a liquid container is provided. The liquid container comprises a first reservoir, a second reservoir, and a filtration cartridge. The filtration cartridge includes at least a housing,Attorney Docket No. 030.0029-WO00 a lid, filter media, and a wicking substrate. The housing includes at least one side wall, a bottom portion having at least one outlet opening, and an interior cavity. The filter media is positioned in the interior cavity. The lid is engageable with the housing, and includes at least an upper surface, a lower surface, and one or more openings. When the lid is engaged with the housing, the upper surface faces away from the interior cavity, the lower surface faces towards the interior cavity, the one or more lid openings provide fluid communication between the interior cavity and the first reservoir, and the outlet opening provides fluid communication between the interior cavity and the second reservoir. In one or more exemplary embodiments, the wicking substrate is positioned in association with the one or more openings, e.g., to receive liquid passing through the one or more lid openings.

[0013] In a third aspect, a filtration method is provided. The filtration method includes providing a filtration cartridge that includes a housing, a lid, filter media, and a wicking substrate. The housing includes at least one side wall, a bottom portion having at least one outlet opening, and an interior cavity. The filter media is positioned in the interior cavity. The lid is engaged with the housing, and includes at least an upper surface, a lower surface, and one or more openings. The upper surface faces away from the interior cavity, the lower surface faces towards the interior cavity, and the one or more lid openings provide fluid communication between the interior cavity and atmosphere outside the interior cavity. In one or more exemplary embodiments, the wicking substrate is positioned in association with the one or more openings, e.g., to receive liquid passing through the one or more lid openings. A liquid is introduced to the filtration cartridge, passes through the one or more openings of the lid to the wicking substrate and to the filter media for filtering.

[0014] In one or more exemplary embodiments of the above aspects, the wicking substrate is positioned in the interior cavity, and in one or more exemplary embodiments the wicking substrate is positioned between the lid and the filter media.

[0015] In one or more embodiments of the above aspects, the lid is concave, and in one or more embodiments the lid possesses an inverted dome shape. In one or more embodiments of the above aspects, the lid is configured to press the wicking substrate into the filtering media such that a portion of the lid is positioned within the filtering media, with the wicking material interposed therebetween, optionally to prevent the lid from making direct contact with the filtering media. In one or more embodiments, the wicking material is made of, for example, a woven or non-woven fabric or non-woven material that acts as an intermediary layer and facilitates capillary action within the filtration cartridge,Attorney Docket No. 030.0029-WO00 thereby resulting in improved filtration efficiency, higher flow rates, reduced risk of channeling, extended filter life, increased consistency in filtered water quality, and / or reduced maintenance or replacement.

[0016] For example, in one or more exemplary embodiments, filtration efficiency can be improved through enhanced contact time between the water (or other fluid) and the filtering media. Increasing the flow of water through the filter causes the water or other fluid to continuously flow through the filter media, allowing for consistent removal of contaminants. Reduced obstructions can prevent areas of stagnant water or other fluids where contaminants could accumulate. With fewer obstructions, water or other fluid can pass more uniformly through the entire filter media, maximizing filtration capacity and effectiveness.

[0017] In certain embodiments, increased flow also allows filtered water or other liquid to be available more quickly, which is particularly beneficial for high-demand situations such as large households or during peak usage times. Higher flow improves the user experience by reducing the waiting time for filtered water or other liquid, making the filtration system more convenient and user-friendly.

[0018] Using capillary action in accordance with certain exemplary embodiments can aid in reducing obstructions and help ensure that water or other fluid flows evenly through the filter media, minimizing the risk of channeling. This leads to more uniform and thorough filtration as all parts of the filter media are utilized. By reducing channeling, the filter can maintain consistent filtration quality over its lifespan, ensuring that water is effectively purified.

[0019] In certain exemplary embodiments, when water or other fluid flows smoothly and without obstructions, there is less mechanical stress on the filter media, which can extend the operational life of the filter. Increased flow and reduced obstructions help prevent the buildup of sediments and other particulates that can clog the filter, thereby prolonging the time between necessary maintenance or replacement.

[0020] With increased flow and fewer obstructions, the filtration system of exemplary embodiments can maintain stable performance, ensuring that the quality of filtered water or other liquid remains high and consistent over time. Minimizing obstructions helps prevent scenarios where water or other fluids might bypass the filter media ensuring that all water or other fluid is properly treated.Attorney Docket No. 030.0029-WO00

[0021] Filters with fewer obstructions are easier to keep clean and maintain, reducing the effort and time required for routine maintenance. Increased flow and reduced clogging allow for longer intervals between maintenance, improving the overall convenience and cost-effectiveness of the filtration system.

[0022] It should be understood that objects, functions, and improvements discussed above and otherwise herein are desirable and may be achieved by one or more embodiments, but are not necessarily applicable to all embodiments and are not limiting.BRIEF DESCRIPTION OF THE DRAWINGS

[0023] The drawings referenced herein form a part of the specification, and are incorporated herein by reference. Features shown in the drawings are meant as illustrative of only some embodiments, and not of all embodiments, unless otherwise explicitly indicated.

[0024] FIG. 1 shows a perspective front view of an example of a water filter cartridge in accordance with an embodiment disclosed herein.

[0025] FIG. 2 shows a transparent, perspective front view of a housing of a filter cartridge in accordance with an embodiment disclosed herein.

[0026] FIG. 3 shows a perspective front view of a lid of a filter cartridge in accordance with an embodiment disclosed herein.

[0027] FIG. 4 shows a cross-sectional side view of a filter cartridge in accordance with an embodiment disclosed herein.

[0028] FIG. 5 shows a cross-sectional side view of a filter cartridge in accordance with another embodiment disclosed herein.

[0029] FIG. 6 shows a plurality of example water containers and integrated water table retention filters in accordance with embodiments disclosed herein.

[0030] FIG. 7 shows a diagram of a side view of an example embodiment of the flow of liquid through a filter cartridge in accordance with an embodiment.Attorney Docket No. 030.0029-WO00DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS

[0031] The various embodiments are described in detail with reference to the accompanying drawings. Whenever possible, the same reference numbers are used throughout the drawings to refer to the same or like parts. References made to particular examples, details, and representative materials, methods, and implementations are for illustrative purposes only, and thus do not, and are not intended to, limit the scope of the various embodiments of the claims.

[0032] The following description with reference to the accompanying figures is provided to assist in a comprehensive understanding of various embodiments of the present disclosure as defined by the claims and their equivalents. It includes various specific details to assist in that understanding, but these are to be regarded as merely exemplary. Accordingly, those of ordinary skill in the art will recognize that various changes and modifications of the various embodiments described herein can be made without departing from the scope and spirit of the present disclosure. In addition, descriptions of well-known functions and constructions may be omitted for clarity and conciseness.

[0033] The terms and words used in the following description and claims are not limited to the bibliographical meanings, but are merely used to enable a clear and consistent understanding of the present disclosure. Accordingly, it should be apparent to those skilled in the art that the following description of various embodiments of the present disclosure is provided for illustration purposes only and not for the purpose of limiting the present disclosure as defined by the appended claims and their equivalents.

[0034] It is to be understood that the singular forms "a," "an," and "the" include plural referents unless the context clearly dictates otherwise. Thus, for example, reference to "a component surface" includes reference to one or more of such surfaces.

[0035] The terms "have", "may have", "can have," "include", "may include", "can include", "comprise", and the like used herein indicate the existence of a corresponding feature (e.g., a number, a function, an operation, or an element) and do not exclude the existence of an additional feature.

[0036] The terms "A or B", "at least one of A and / or B", or "one or more of A and / or B" may include all possible combinations of items listed together. For example, the terms "A or B", "at least one of A and B",Attorney Docket No. 030.0029-WO00 or "at least one of A or B" may indicate all the cases of (1) including at least one A, (2) including at least one B, or (3) including at least one A and at least one B.

[0037] The terms "first", "second", and the like used herein may modify various elements regardless of the order and / or priority thereof, and are used only for distinguishing one element from another element, without limiting the elements. For example, "a first element" and "a second element" may indicate different elements regardless of the order or priority.

[0038] It will be understood that when a certain element (e.g., a first element) is referred to as being "operatively or communicatively coupled with / to" or "connected to" another element (e.g., a second element), the certain element may be coupled to the other element directly or via another element (e.g., a third element). However, when a certain element (e.g., a first element) is referred to as being "directly coupled" or "directly connected" to another element (e.g., a second element), there may be no intervening element (e.g., a third element) between the element and the other element.

[0039] The term "configured (or set) to" as used herein may be interchangeably used with the terms, for example, "suitable for", "having the capacity to", "designed to", "adapted to", "made to", or "capable of". The term "configured (or set) to" may not necessarily have the meaning of "specifically designed to". In some cases, the term "device configured to" may indicate that the device "may perform" together with other devices or components.

[0040] It will be understood by those with skill in the art that if a specific number of an introduced claim element is intended, such intent will be explicitly recited in the claim, and in the absence of such recitation no such limitation is present. For a non-limiting example, as an aid to understanding, the appended claims contain usage of the introductory phrases "at least one" and "one or more" to introduce claim elements. However, the use of such phrases should not be construed to imply that the introduction of a claim element by the indefinite articles "a" or "an" limits any particular claim containing such introduced claim element to embodiments containing only one such element, even when the same claim includes the introductory phrases "one or more" or "at least one" and indefinite articles such as "a" or "an"; the same holds true for the use in the claims of definite articles. As used herein, the term "and / or" means either or both (or any combination or all of the terms or expressed referred to), e.g., "A., B, and / or C" encompasses A alone, B alone, C alone, A and B, A and C, B and C, and A, B, and C.Attorney Docket No. 030.0029-WO00

[0041] The terminology herein is only used for describing specific embodiments and is not intended to limit the scope of other embodiments. The terms of a singular form may include plural forms unless otherwise specified. The terms used herein, including technical or scientific terms, have the same meanings as understood by those of ordinary skill in the art. Terms defined in general dictionaries, among the terms used herein, may be interpreted as having meanings that are the same as, or similar to, contextual meanings defined in the related art, and should not be interpreted in an idealized or overly formal sense unless otherwise defined explicitly. Depending on the case, even the terms defined herein should not be so interpreted as to exclude various embodiments of the present disclosure unless the context clearly dictates otherwise.

[0042] The word "exemplary" is used herein to mean "serving as an example, instance, or illustration." Any implementation described herein as "exemplary" is not necessarily to be construed as preferred or advantageous over other implementations.

[0043] The devices and systems in accordance with one or more embodiments of the disclosure enhance filter performance and flow rate by utilizing capillary action or wicking techniques within the water filter. In some embodiments this water filter includes a housing with a lid, filtering media, and a wicking substrate positioned between the lid (e.g., concave lid) and the filtering media. In some embodiments, the lid is designed to press into the filtering media indirectly via the wicking substrate, embedding at least a portion of the lid in the media, in one or more embodiments without the lid making direct contact with the filtering media due to, at least, the interposing of the wicking substrate therebetween. In some embodiments, the wicking substrate, e.g., woven or non-woven fabric or other non-woven material, serves as an intermediary layer, promoting capillary action within the water filter. This configuration can lead to improved filtration efficiency, higher flow rates, reduced risk of channeling, extended filter life, more consistent filtered water quality, and / or decreased maintenance or replacement needs.

[0044] In gravity flow cartridges, air can get trapped in the headspace of the cartridge housing between the filter media and the housing causing an air lock. The headspace or "ullage" is the empty space above the filter media within the filter housing.

[0045] In some embodiments, when water is first introduced into a gravity flow filter, the water initially fills the headspace before flowing through the filter media to begin the filtration process. The headspace is designed to help distribute water evenly across the entire surface of the filter media being used which results in more efficient filtration and can reduce channeling. However, common problems can occur withAttorney Docket No. 030.0029-WO00 this configuration including air lock, air binding, and / or channeling which can result in reductions or obstructions to the flow rate of the water through the filter.

[0046] When air gets trapped in the headspace of the gravity flow filter, back pressure can be created causing an air lock that inhibits the flow of water through the filter media and can reduce filtration efficiency. Air binding occurs when air pockets form within the filter media, preventing water from flowing through the media effectively. Channeling occurs when pathways or channels are formed in the media during previous filtering processes. When channeling is present, water flows through areas of the media with less resistance (e.g., the previously formed pathways or channels) rather than uniformly passing through the entire media.

[0047] In some exemplary embodiments shown in FIGS. 1-7, capillary action or wicking is leveraged to increase flow and reduce obstructions in a water filtration cartridge 100. When unfiltered water is added to a reservoir of a filter device such as a jug, pitcher, bottle, cooler, etc., the water is directed to a water filtration cartridge 100 for filtering. Unfiltered water passes through one or more openings 112 in a lid 102 of a housing 101 of the water filtration cartridge 100 and is distributed by a layer of wicking substrate 106 (FIGS. 4 and 5). The wicking substrate 106 is configured to leverage capillary action to spread the water evenly or substantially uniformly throughout an upper surface of a filter media 108 disposed in the housing 101 of the water filtration cartridge 100 before the water reaches and saturates the filter media 108. After the water impinges on the filter media 108, water is directed through the filter media 108 within the housing 101 of the water filtration cartridge 100. Filtered water exits the water filtration cartridge 100 via an outlet opening 110 formed in a bottom portion, such as a bottom surface 109 of the housing 101 and can be stored, consumed, transferred, etc. As additional unfiltered water passes through the openings 112 formed in the lid 102, the additional unfiltered water is wicked by the layer of wicking substrate 106 and then filtered through the filter media 108. In one or more exemplary embodiments, the lid 102 has a concave shape, and in certain embodiments an inverted dome shape. The concave shape of the lid 102 of one or more embodiments and the shape of the one or more openings 112 assist in preventing air from becoming trapped in the housing 101 of the water filtration cartridge 100. The trapped air can create air lock, air binding, or channeling. In this fashion, the flow rate of water passing through the filter media 108 and a flow rate of filtered water exiting the water filtration cartridge 100 can be improved while reducing flow obstructions within the housing 101.Attorney Docket No. 030.0029-WO00

[0048] A number of exemplary embodiments in accordance with the disclosure can be used to filter water (or other liquid) while increasing flow rates and reducing obstructions. While the fluid that is filtered through filtration cartridge 100 is referred to as water, any fluid or liquid may be introduced into filtration cartridge 100. Different fluids or liquids may implement the same or different filter media materials.

[0049] In an exemplary embodiment, water (or other liquid) can be introduced to water filtration cartridge 100 through the lid 102. The lid 102, side walls 104, and the bottom surface 109 define the filter cavity that includes the filter media 108. Water (or other liquid) enters the water filtration cartridge 100 through the openings 112 of the lid 102 and contacts the wicking substrate 106. Upon contact with the wicking substrate 106, water is wicked to spread the water throughout the wicking substrate 106 before impinging the filter media 108. Water (or other liquid) then passes through the filter media 108 to filter impurities in the water (or other liquid) and exits water filtration cartridge 100 through the outlet opening 110.

[0050] In an exemplary embodiment, water filtration cartridge 100 can be removably coupled with a water container configured to accommodate unfiltered water (or other liquid before water (or other liquid) enters the water filtration cartridge. Alternatively, the water filtration cartridge 100 can be integral with the filter device including a way to access and replace the filter media 108 (e.g. removable lid, hinged bottom surface, etc.). By "unfiltered", it is understood that the water or other liquid may be subject to a preliminary filtering stage prior to introduction to the water filtration cartridge 100. "Unfiltered" refers to the water or other liquid prior to filtering with the filter media 108.

[0051] Housing

[0052] As shown in the FIGS. 1, 2, 4, and 5, the housing 101 includes the lid 102, the side walls 104, and the bottom surface 109. The housing 101 defines a cavity and the filter media 108 is disposed in the cavity of the housing 101. In one or more embodiments, unfiltered water enters the housing 101 through the openings 112 formed in the lid 102, the unfiltered water is wicked by the wicking substrate 106 to evenly spread the water throughout an upper surface of the filter media 108 before the unfiltered water reaches and saturates the filter media 108. The unfiltered water filters through the filter media 108 situated within the housing 101, and is discharged from the housing 101 through the outlet opening 110.

[0053] In an exemplary embodiment, the housing 101 can be made from polymers such as polypropylene. However, any material that can be molded, extruded, cast, or otherwise formed intoAttorney Docket No. 030.0029-WO00 various shapes and forms may be used. For example, the housing 101 can be manufactured from polypropylene.

[0054] The side walls 104 can be configured to direct water from the lid 102 to the outlet opening 110 formed in a bottom portion having the bottom surface 109. The side walls 104 can form an upper housing opening in which the lid 102 is mounted. The openings 112 of the lid 102 are in fluid communication with a cavity formed by the side walls 104. As illustrated in at least FIGS. 1, 2, 4, and 5, the upper housing opening formed by the side walls 104 at the top of the housing 101 can have a greater circumference than the circumference of the bottom surface 109 of the housing 101, thereby creating a tapering or narrowing through the height of the housing 101. The tapering can direct any trapped air in the housing 101 toward the top and water downwards through the filter media 108. However, in other embodiments the bottom surface 109 can have the same or greater circumference than the upper housing opening formed by the side walls 104 at the top of the housing 101.

[0055] As illustrated in FIG. 2, the side walls 104 create an elongated body that tapers toward the bottom surface 109. However, the side walls 104 can have other shapes or configurations. As further shown in FIG. 2, the side walls 104 can be a continuous side wall having a circular cross section.

[0056] The lid 102 can be designed to snap fit or fit securely within the upper housing opening at the upper surface of the side walls 104. In an exemplary embodiment, the lid 102 is aligned and held in place by the side walls 104.

[0057] In an exemplary embodiment, a seal such as a gasket or an O-ring can be provided between the side walls 104 and the lid 102 to create a water-tight connection within the housing 101. The seal can be disposed above or below the wicking substrate 106. That is, the seal can be coupled with the lid 102 such that the wicking substrate 106 contacts an outside surface of the seal when the lid 102 is secured within the housing 101. Alternatively, the seal can be coupled with the lid 102. For example, in some embodiments the wicking substrate 106 contacts a mounting structure 114 or a lip 116 of the lid 102 and an inner surface of the seal such that the seal secures the wicking substrate 106 in place with respect to the lid 102. In another exemplary embodiment, the lid 102 can be welded to the side walls 104 to create a water-tight connection.

[0058] The seal can ensure that unfiltered water remains contained within the housing 101 during the filtering process and prevents any water outside of the housing 101 from entering the housing 101Attorney Docket No. 030.0029-WO00 through any openings other than the openings 112 formed in the lid 102. The seal, positioned around the perimeter of the upper housing opening formed by the side walls 104, can provide a reliable barrier that maintains the integrity of a water-tight enclosure within the housing 101.

[0059] In an exemplary embodiment, an additional coupling may be provided to assist in mounting the water filtration cartridge 100 within an upper chamber of a water container or a water filtration system. For example, the additional coupling can be threading, a seal, or gasket, etc. The additional coupling can prevent misplacement or misalignment which could impede filter performance.

[0060] The outlet opening 110 is formed in the bottom portion, such as the bottom surface 109 of the housing 101 and in the illustrated embodiment is positioned proximate to a central axis of the water filtration cartridge 100. In some embodiments, the outlet opening 110 is positioned at the central axis. In other embodiments, the outlet opening 110 is positioned near or proximate to the central axis. In some embodiments, multiple outlet openings are positioned equidistant from the outer edges of the bottom surface 109 of the housing 101. In some embodiments, the outlet opening 110 can be a circular configuration. In some embodiments, the outlet opening 110 can have any shape that would facilitate the rate of flow of filtered water exiting the water filtration cartridge 100.

[0061] Lid

[0062] The lid 102 is configured to allow unfiltered water to enter the housing 101 of the water filtration cartridge 100. The contour of the lid 102 and / or the variables of the openings 112 in the lid 102 can be configured to guide the unfiltered water (or other liquid) toward the filter media 108 to increase the flow rate through the water filtration cartridge 100, reduce obstacles that impact the flow of water (or other liquid) through the housing 101, and route air bubbles up and away from the filter media 108. The lid 102 can be further configured to maintain filter media 108 within the water filtration cartridge 100.

[0063] Referring to FIG. 3, the lid 102 can include the mounting structure 114, the lip 116, and a contoured water guiding structure 118 including the openings 112.

[0064] The mounting structure 114 can be configured to support, secure, and / or position the water filtration cartridge 100 within the water container or other vessel, such as those shown in FIG. 6. The mounting structure 114 can include one or more of a tab, a protrusion, threads, a channel, a slot, a snap- fit connector, an interference fit, a clip, a clamp, or any other mechanical connector. The mountingAttorney Docket No. 030.0029-WO00 structure 114 can include one type of connector structure or a combination of connector structures. The mounting structure 114 can be positioned on an inner or outer surface of the lip 116 and can be utilized to create a permanent, semi-permanent, temporary, or removable connection with the water container. Some examples of connection methods can include adhesive bonding, welding, rivets, solvent welding, snap-fit connectors, clips, clamps, threads, quick-release mechanisms, tabs, slots, adhesive tape, force fit, etc.

[0065] The contoured water guiding structure 118 is shown with an upper surface 118a configured to face away from the interior cavity, a lower surface 118b configured to face towards the interior cavity The contoured water guiding structure 118 can be configured to guide unfiltered water towards the filter media 108 within the housing 101. In an exemplary embodiment, the contoured water guiding structure 118 can have a shape such that the center point of the lower surface 118b protrudes downward the furthest. The lower surface 118b of the contoured water guiding structure 118 can have any shape including being rounded, concave, domed, conical, truncated cone, V-shaped, angled, sloped, irregular, undulated or wavy, stepped, faceted, grooved, channeled, tapered, or textured. The contour can be embodied in both the upper and lower surfaces 118a and 118b of the contoured water guiding structure 118 or a different shape can be created in the lower surface 118b such that the upper surface 118a and the lower surface 118b of the contoured water guiding structure 118 have different contours.

[0066] In an exemplary embodiment, when the lid 102 is secured to the housing 101, a portion of the contoured water guiding structure 118, such as part of the lower surface 118b, can be embedded in or pressed into the filter media 108. For example, in an exemplary embodiment the depth (or lowest point) of the contoured water guiding structure 118, such as the center of the lower surface 118b of the contoured water guiding structure 118, is situated below the highest level of the filter media 108.

[0067] In exemplary embodiments, the contoured water guiding structure 118 does not directly contact the filter media 108. Instead, the wicking substrate 106 is provided between the lower surface 118b of the contoured water guiding structure 118 and the filter media 108 such that the wicking substrate 106 directly contacts an upper surface of the filter media 108 and the lower surface 118b of the contoured water guiding structure 118. It is contemplated that in one or more exemplary embodiments 30-50% of the surface area associated with the lower surface 118b of the contoured water guiding structure 118 can be below the highest level of the filter media 108.Attorney Docket No. 030.0029-WO00

[0068] Water can pass through the lid 102 via the openings 112 formed in the contoured water guiding portion 118. By "formed in / ' it is meant that the openings 112 are embodied in the lid 102. The formation of the openings 112 may occur as part of the production of the lid 102 or subsequent to production of the lid 102. The openings 112 in the contoured water guiding structure 118 can have various sizes, shapes, configurations, or arrangements to facilitate improved flow rates.

[0069] For example, larger-sized openings 112 can allow for a greater flow rate, while smaller openings 112 can restrict the flow rate to create more controlled and gradual filtration. Smaller openings 112 can increase surface tension which can impact the pressure at which water (or other liquid) enters the filter media 108 and can enhance penetration through finer media as well as reduce introducing bubbles as the water (or other liquid) flows through.

[0070] The shape of the openings 112 can influence the dynamics of water flow. For example, circular openings 112 can promote even flow while slotted openings 112 can channel water (or other liquid) in a more directional manner. Various shapes can be selected for the openings 112 including circular, square, slotted, rounded, etc. In addition, a single shape can be used for all the openings 112 or a combination of shapes can be used. In one or more embodiments, a single opening 112 is present.

[0071] Referring to FIGS. 1-4, an exemplary embodiment of the arrangement of the openings 112 is illustrated. For example, the lid 102 illustrated in FIGS. 1-4 includes two different shapes of the openings 112 - petal-shaped openings 112a and round (or circular) openings 112b. The petal-shaped openings 112a can be rounded, have a slightly elongated form with curved edges. Any number of petal-shaped openings 112a can be used. For instance, six petal shaped openings 112a are illustrated in FIGS. 1, 2, and 4. The petal-shaped openings 112a can be arranged in a symmetrical manner and can taper such that the portion having the smallest width of each petal-shaped opening 112a is closest to the center point of the contoured water-guiding structure 118. The round-shaped openings 112b can be arranged between the petal-shaped openings 112a near the wider radially outer portion of the petal-shaped openings 112a. The petal-shape openings 112a can direct unfiltered water (or other liquid) throughout the circumference of the filter media 108 and the round openings 112b can be configured to direct unfiltered water (or other liquid) to an outer circumference of the filter media 108. Any number of petal-shaped openings 112a and round openings 112b can be included in the lid 102.

[0072] Referring to FIG. 5, another exemplary embodiment of the arrangement of the inner openings 112c and outer openings 112d is illustrated. For example, as illustrated in FIG. 5, there are two rows ofAttorney Docket No. 030.0029-WO00 the openings 112c and 112d, such that each row has a different shape. Inner openings 112c closest to the center point are substantially triangular, i.e., tapering inwardly towards the center point. The outer openings 112d closest to the lip 116 have a different shape (e.g., trapezoidal) and a larger area than the inner openings 112c. Due to different surface tensions between the center point and the outer circumference, the difference in shape and size of the openings 112c and 112d allows the water (or other liquid) to pass substantially uniformly throughout the circumference of the lid 102. It is noted that while all of the openings 112c and 112d are illustrated as having a particular size, the size could be the same width or one or more strips can be wider. For example, the inner openings 112c can be wider or of larger overall dimension than the outer openings 112d.

[0073] FIG. 7 illustrates an embodiment including arrows showing the flow of water towards the center of the lid 102, converging along the upper surface 118a to establish a concentration of force at 120. The concentration of force at the center in contact with the filter media 108 allows for better water flow through.

[0074] Wicking Substrate

[0075] The wicking substrate 106, best shown in FIG. 4, is configured to facilitate capillary action to wick unfiltered water (or other liquid) substantially horizontally along the surfaces of the wicking substrate 106 as well as vertically through fibers towards the filter media 108. In an exemplary embodiment, the wicking substrate 106 can be a non-woven, porous material that includes a fine network of fibers and pores (that is, a fibrous material) created without weaving, knitting, or using bonded fibers. In another embodiment, the wicking substrate 106 can be a woven or non-woven fabric.

[0076] The pores or tiny openings formed in the wicking substrate 106 can absorb water (or other liquid) and transport the absorbed water (or other liquid) through the interconnected pores. In some embodiments, the wicking substrate 106 has pores of approximately 1 / 32 inch (0.312 inch) or less, although this disclosure and the accompanying claims are not so limited. The wicking substrate 106 can be made from any suitable type of material including paper, plastics, polyester, polypropylene, wood pulp, resins, fiberglass, and / or others. In some exemplary embodiments, the wicking substrate 106 can be a polypropylene sheet.

[0077] In some exemplary embodiments, the thickness and weight (e.g., threads per inch) of the wicking substrate 106 is configured to wick water (or other liquid) while preventing the filtering media 108 fromAttorney Docket No. 030.0029-WO00 exiting the water filtration cartridge 100. In exemplary embodiments, the wicking substrate 106 is a single layer that communicates with all the openings 112 in the lid 102. No further structures other than the wicking substrate 106 are necessary (e.g., mesh screen, etc.) for wicking, although they are not necessarily precluded from the scope of this disclosure.

[0078] Using one ( / .e., a single) sheet of the wicking substrate 106 for all the openings 112 in the lid 102 can allow for more unform saturation as well as ease of manufacturing. For example, the size of the sheet may be selected to be greater than the circumference of the lid such that excess portions of the wicking substrate 106 that extend beyond the housing 101 can be trimmed after the lid 102 is secured to the housing 101 of the water filtration cartridge 100.

[0079] In one or more exemplary embodiments, the wicking substrate 106 is attached to the bottom surface 118b of the lid 102 to possess the same shape as the bottom surface 118b of the lid 102. In one or more exemplary embodiments, the wicking substrate 106 is associated with the one or more openings 112 to extend continuously across the one or more openings 112 of the lid 102 to intercept all water or other liquid passing through the one or more openings 112 associated with the wicking substrate 106.

[0080] In one or more exemplary embodiments, the bottom surface 118b of the lid 102 and the wicking substrate 106 attached thereto have an inverted conical or dome shape so the lid 102 and the wicking substrate 106 extend farthest downward near the center of the cavity of the housing 101, such as shown in FIGS. 5 and 7, for example. In exemplary embodiments, the lid 102 and portions of the wicking substrate 106 extending farthest downward apply a downward force on the filter media 108, as shown in at least FIGS. 5 and 7. In one or more exemplary embodiments, the shape of the lid 102 presses the wicking substrate 106 against the filter media 108. In one or more exemplary embodiments, the lid 102 presses the wicking substrate 106 against the filter media 108 to compress the filter media 108.

[0081] In one or more embodiments, such as the embodiment illustrated in FIGS. 5 and 7, a portion of the wicking substrate 106 that corresponds to the center point or area of the lower surface 118b of the contoured water guiding structure 118 can directly contact the filter media 108 while the portions closest to the lip 116 of the lid 102 can be spaced apart from the filter media 108. The contact between the wicking substrate 106 and the filter media 108 can reduce the surface tension and increase the flow rate of unfiltered water reaching the filter media 108. Focusing the water near the center in accordance with this embodiment increases the chances of breaking pressure barriers that might otherwise slow the passage of water. Additionally, the described structure of this embodiment can allow the unfiltered waterAttorney Docket No. 030.0029-WO00(or other liquid) to more easily enter the housing 101 no matter if the filter media 108 is dry or moist before unfiltered water (or other liquid) is added to the upper reservoir. In addition, unfiltered water (or other liquid) can pass through the wicking substrate 106 at the portions closest to the lip 116 of the lid 102 such that the unfiltered water (or other liquid) drops onto the filter media 108 from a predetermined height rather than being absorbed at the portions that directly contact the filter media 108 adjacent to the center point.

[0082] The wicking substrate 106 can serve one or more of multiple functions. For example, the wicking substrate 106 can be utilized as a substrate to focus water pressure near the center where contact is made with the filter media. In another embodiment, the wicking substrate 106 can evenly distribute water (or other liquid) prior to reaching the filter media 108. The wicking substrate 106 can act as a primary filter for the unfiltered water (or other liquid) as well as keeping the filter media 108 in the water filtration cartridge 100. In some embodiments, the multi-functional wicking substrate 106 results in the water filtration cartridge 100 having a reduced number of elements from other conventional filters. The simplified design with a reduced number of components facilitates easier and more efficient manufacturing. For example, the water filtration cartridge 100 of exemplary embodiments is easier to assemble with less meticulous alignment necessary which reduces assembly times, labor costs, the need for specialized equipment or highly skilled workers, and which can result in fewer mistakes during assembly.

[0083] Filter Media

[0084] The filter media 108 can be configured to remove particulates, absorb contaminants, improve fluid quality, and regulate flow rate. Material for the filter media can be chosen based on the requirements of the water purification quality. In exemplary embodiments, the filter media 108 is made of a different material and / or has a different configuration than those of the wicking substrate 106. The filter media 108 can be chosen from one or more of sorption media (e.g., activated carbon, synthetic zeolite, schungite, and the like); ion exchange media (e.g., ion exchange resins and the like), porous media (e.g., polypropylene, porous glass beads or frits, filter paper, and the like), catalytic media (e.g., KDF and the like), a disinfecting resin (e.g., iodine resin and the like) and mixed media combining properties of media of different compositions. The filter media 108 can be selected and used to remove impurities such as bacteria, heavy metals, chlorine, organic impurities, inorganic impurities, radiological impurities, and the like. The filter media 108 can have any form including beads, powders, and / or granules, and can be formedAttorney Docket No. 030.0029-WO00 between porous membranes or other forms. Examples of such filter media 108 are described in U.S. Patent Numbers 10,099,942; 8,252,185; 7,413,663; 7,276,161; 7,153,420; 6,752,768; and 5,635,063; all of which are incorporated herein by reference in their entirety. The filter media 108 can be separated into individual layers or mixed together as a whole or with different combinations of filter media included as different layers. The filters of embodiments of the disclosure can include more than one layer of a particular filter media or filter media mixture.

[0085] Though the discussion below refers to certain filter media for exemplary embodiments, any filter media (media known for purification and treatment of water) or combinations of filter media known in the art can be used in accordance with embodiments of the disclosure.

[0086] In some embodiments, the filter media 108 can be arranged like the water table retention in U.S. Patent Number 10,099,942. In U.S. Patent Number 10,099,942, the top-down filter media construction is a micron filter, a mixed bed ion exchange, a separator, and a redox alloy and carbon screen. In some embodiments, the filter media 108 can be arranged in layers or mixed. In some embodiments, the carbon screen layer is the last layer of the filter media 108 that the filtered water or other liquid passes through before the water or other liquid leaves the housing. In some embodiments, the carbon screen layer is the first layer of the filter media 108 when the water or other liquid enters the filter media 108.

[0087] As best shown in FIGS. 4 and 5, the filter media 108 is contained in the housing 101 of the water filtration cartridge 100. An activated carbon layer can be incorporated in the water filtration cartridge 100 as a beginning filter stage at or near the very beginning of the filtering process. In an exemplary embodiment, the filter media 108 can include one or more of an activated carbon layer, a redox alloy layer, a mixed bed ion layer, and / or other discrete layers of filter media. In one example of this disclosure, an activated carbon layer can be designed and manufactured to remove organic elements from the unfiltered water or other liquid. The activated carbon layer can be a powdered, granular, and / or carbon block material. The activated carbon filter medium may also simply be mixed into the rest of the filter media for varied water (or other liquid) filtering results. In some embodiments the activated carbon filter medium is at or near the beginning of the filtering process. After the carbon layer of the filter media, any number of combinations, mixed or layered, of the filter media below may be used.

[0088] A redox alloy layer may also be incorporated in the water filtration cartridge 100. The redox alloy layer can be positioned immediately below the carbon layer, or it could be mixed into the carbon layer. The redox alloy layer is designed and manufactured to prevent the growth of mold, mildew, and bacteriaAttorney Docket No. 030.0029-WO00 in the water, in the filter cartridge, and in the filter materials. One example of the redox alloy layer includes a KDF (kinetic degradation fluxion) alloy, or other high purity alloys of copper and zinc. One example of the redox alloy layer includes flaked or granulated particulates.

[0089] A mixed bed ion exchange resin can also be included in the water filtration cartridge 100. The mixed bed ion exchange resin is designed and manufactured to eliminate inorganic elements among other things. One example of the mixed bed ion resin includes porous beads or other porous structures with large surface area per volume characteristics. One example of a mixed bed ion resin in accordance with embodiments of the disclosure includes approximately one-half anions and one-half cations. The mixed bed ion resin includes a highly developed structure of pores. On the surface of the pores, there are sites with easily trapped and released ions. The trapping of ions takes place with simultaneous releasing of other ions. That is the ion-exchange. Cations can be replaced with hydrogen ions, and anions can be replaced with hydroxyls. The hydrogen ions and the hydroxyls can recombine producing water molecules.

[0090] Additionally, in an exemplary embodiment, dividers can be added between the filter layers to further eliminate inter-mixing of filter media and to further promote the even flow of water through the filter. An even flow of water (or other liquid) through the filter prevents channeling within the filter media.

[0091] The water filters of exemplary embodiments disclosed herein can be integrated into containers that house and store filtered water or other liquid to form water (or other liquid) treatment apparatuses. These water (or other liquid) containers can be in fluid communication with the water filtration cartridge to receive and collect the filtered water (or other liquid) from the water outlet on the filter. The filtered water (or other liquid) can be stored in the water (or other liquid) container for future use.

[0092] Referring to FIG. 6, some example water containers that can be integrated with the water filters of exemplary embodiments of the disclosure include pitchers 606, 616, 626, travel bottles 636, sports bottle, a water cooler 646, a water jug 656, and a water bottle 666. In some embodiments, the mounting structure 114 of the water filtration cartridge 100 mates with the water container. In some embodiments, the mounting structure 114 of the water filtration cartridge 100 reversibly mates with the water containers to allow removal of the water filtration cartridges. As shown in the water containers of FIG. 6, water is introduced into a first reservoir of the water containers and fees into the water filtration cartridge 100. After filter water is filtered by and exits the water filtration cartridge 100 through the outlet opening 110 of the bottom surface 109, the water enters into a second reservoir of the water container. The waterAttorney Docket No. 030.0029-WO00 in the second reservoir may then be poured or otherwise discharged through an opening of the water container, such as by tilting the water containers into a pouring position.

[0093] One or more embodiments of the systems, devices, and methods of filtering liquids described herein prevent clogging of filters due to airlocks, provide filter cartridges with improved performance, provide improved taste of the filtered water, and / or make the use of the filter systems easier for customers.

[0094] Exemplary Embodiments:

[0095] El: Afiltration cartridge comprising: a housing comprising at least one sidewall, a bottom portion, and an interior cavity; a lid engageable with the housing, the lid including an upper surface configured to face away from the interior cavity, a lower surface configured to face towards the interior cavity, and one or more openings configured to provide fluid communication with the interior cavity when the lid is engaged with the housing; filter media positioned in the interior cavity of the housing; and a wicking substrate positioned in association with the one or more openings.

[0096] E2: The filtration cartridge of El, wherein the wicking substrate is positioned in association with the one or more openings to receive liquid passing through the one or more openings when liquid passes through the one or more openings.

[0097] E3: The filtration cartridge of El or E2, wherein the wicking substrate is positioned in the interior cavity of the housing.

[0098] E4: The filtration cartridge of any one of El to E3, wherein the wicking substrate is positioned between the lid and the filter media when the lid is engaged with the housing.

[0099] E5: The filtration cartridge of any one of El to E4, wherein the lid further includes a center area extending farther than other peripheral portions of the lid into the interior cavity of the housing when the lid is engaged with the housing to place the wicking substrate into contact with the filter media.

[0100] E6: The filtration cartridge of any one of El to E5, wherein the lid is configured to press a central portion of the wicking substrate downward into the filter media when the lid is engaged with the housing.

[0101] E7: The filtration cartridge of E6, wherein the lid is configured to press the central portion of the wicking substrate downward to compress the filter media when the lid is engaged with the housing.Attorney Docket No. 030.0029-WO00

[0102] E8: The filtration cartridge of any one of El to E7, wherein a portion of the lid extends downward to embed at least a portion of the wicking substrate within the filter media when the lid is engaged with the housing.

[0103] E9: The filtration cartridge of any one of El to E8, wherein a portion of the lid adjacent to the sidewalls of the housing is spaced apart from the filter media.

[0104] E10: The filtration cartridge of any one of El to E9, wherein the upper and lower surfaces of the lid have a concave or conical shape.

[0105] Ell: The filtration cartridge of any one of El to E10, wherein at least the lower surface of the lid is configured with a dome shape.

[0106] E12: The filtration cartridge of any one of El to Ell, wherein the wicking substrate extends across the one or more openings.

[0107] E13: The filtration cartridge of any one of El to E12, wherein the wicking substrate is a non-woven, porous material.

[0108] E14: The filtration cartridge of any one of El to E12, wherein the wicking substrate is a fabric.

[0109] E15: The filtration cartridge of any one of El to E14, wherein the wicking substrate is attached to the lower surface of the lid and extends across the one or more openings.

[0110] E16: A container comprising: a first reservoir; a second reservoir; and a filtration cartridge of any one of El to E15.

[0111] E17: A method of filtering a liquid, comprising providing a filtration cartridge of any one of El to E15, introducing liquid into the filtration cartridge; passing the liquid through the opening of the lid to the wicking substrate; and filtering the liquid with the filter media.

[0112] The foregoing detailed description of the certain exemplary embodiments has been provided for the purpose of explaining the principles of the invention and its practical application, thereby enabling others skilled in the art to understand the invention for various embodiments and with various modifications as are suited to the particular use contemplated. This description is not necessarily intended to be exhaustive or to limit the invention to the precise embodiments disclosed. The specificationAttorney Docket No. 030.0029-WO00 describes specific examples of accomplishing a more general goal that also may be accomplished in another way. Those skilled in the art will appreciate that the features described above can be combined in various ways to form multiple variations of the invention.

Claims

Attorney Docket No. 030.0029-WO00We claim:

1. A filtration cartridge, comprising: a housing comprising at least one sidewall, a bottom portion, and an interior cavity; a lid engageable with the housing, the lid including an upper surface configured to face away from the interior cavity, a lower surface configured to face towards the interior cavity, and one or more openings configured to provide fluid communication with the interior cavity when the lid is engaged with the housing; filter media positioned in the interior cavity of the housing; and a wicking substrate positioned in association with the one or more openings.

2. The filtration cartridge of claim 1, wherein the wicking substrate is positioned in association with the one or more openings to receive liquid passing through the one or more openings when liquid passes through the one or more openings.

3. The filtration cartridge of claim 1, wherein the wicking substrate is positioned in the interior cavity of the housing.

4. The filtration cartridge of claim 1, wherein the wicking substrate is positioned between the lid and the filter media when the lid is engaged with the housing.

5. The filtration cartridge of claim 1, wherein the lid further includes a center area extending farther than other peripheral portions of the lid into the interior cavity of the housing when the lid is engaged with the housing to place the wicking substrate into contact with the filter media.

6. The filtration cartridge of claim 1, wherein the lid is configured to press a central portion of the wicking substrate downward into the filter media when the lid is engaged with the housing.

7. The filtration cartridge of claim 6, wherein the lid is configured to press the central portion of the wicking substrate downward to compress the filter media when the lid is engaged with the housing.Attorney Docket No. 030.0029-WO008. The filtration cartridge of claim 1, wherein a portion of the lid extends downward to embed at least a portion of the wicking substrate within the filter media when the lid is engaged with the housing.

9. The filtration cartridge of claim 1, wherein a portion of the lid adjacent to the sidewalls of the housing is spaced apart from the filter media.

10. The filtration cartridge of claim 1, wherein the upper and lower surfaces of the lid have a concave or conical shape.

11. The filtration cartridge of claim 1, wherein at least the lower surface of the lid is configured with a dome shape.

12. The filtration cartridge of claim 1, wherein the wicking substrate extends across the one or more openings.

13. The filtration cartridge of claim 1, wherein the wicking substrate is a non-woven, porous material.

14. The filtration cartridge of claim 1, wherein the wicking substrate is a fabric.

15. The filtration cartridge of claim 1, wherein the wicking substrate is attached to the lower surface of the lid and extends across the one or more openings.

16. A container comprising: a first reservoir; a second reservoir; and a filtration cartridge of any one of claims 1 to 15.

17. A method of filtering a liquid, comprising: providing a filtration cartridge of any one of claims 1 to 15; introducing liquid to the filtration cartridge; passing the liquid through the openings of the lid to the wicking substrate; and filtering the liquid with the filter media.

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