• 专利附录
  • 专利说明
  • 权利要求
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    • 专利摘要:
    two-stage, coalescing and separating fluid filters a particulate material filter and water separator with a first stage or external stage configured to coalesce water from the fluid such as fuel and a second stage or internal stage configured to separate the coalesced water from the fluid and also remove minute solid contaminants from the fluid. the coalescence stage includes a pleated cylinder of polymeric media. the pleated cylinder has pleat valleys and pleat tips downstream, and release locations defined on the pleat tips downstream. the separator stage includes a non-pleated cylinder of polymeric media surrounding and in contact with the outer pleated ends of a pleated multilayer cylinder.
    公开号:BR112012019395B1
    申请号:R112012019395-3
    申请日:2011-04-05
    公开日:2020-09-29
    发明作者:Mark T. Wieczorek；Terry Shults；William C. Haberkamp；Jonathan Sheumaker；Barry M. Verdegan；Christopher E. Holm；Brian W. Schwandt
    申请人:Cummins Filtration Ip Inc；
    IPC主号:
    专利说明:

    Field
    [0001] This disclosure refers to a fuel / water separator and particulate material filter designed to provide high water and particulate material removal efficiency. The disclosure of this Order refers in particular to the disclosures of United States Order 12 / 820,784, filed on June 22, 2010 and entitled “Two Stage Water Separator And Particulate Filter” and United States Order 12,820,791, filed on 22 of June 200 and entitled “Modular Filter Elements For Use in a Filter-In-Filter Cartridge”, for which this application claims the priority benefit and whose contents are incorporated herein in full by reference. Background
    [0002] Fluid filters are widely known and used in various filtration systems and applications, for example, where there is a need to separate particulate material and / or fluid from a working fluid in a protected system. As an example, engine fuel filtration systems are well known and can employ fluid filters that aim to separate water and particles from the fuel. The filter cartridges in some of these filters have a filter element with means configured to coalesce water and have another filter element that has means configured to additionally filter the fuel and separate the coalesced water from the fuel. In many cases, the filter elements are arranged in a concentric filter, within a filter configuration, where an external filter element surrounds an internal filter element. summary
    [0003] A filter having improved fuel / water separation over the life of the filter is described. The filter has a two-stage configuration, for example, a concentric filter within a filter configuration, with the first stage, or external stage, being configured mainly to coalesce water from the fuel, or from another fluid, with the which filter is used and the second stage or internal stage being configured to separate coalesced water from the fluid and also remove minute solid contaminants from the fluid. The filter is preferably configured for use with fuel, such as diesel with ultra low sulfur content (ULSB) or biodiesel, however the filter concepts described here could be used with any type of fluid requiring the separation of water from the fluid, for example, hydraulic fluid, oil or lubricating fluid, air, and the like. When used with ULSD, biodiesel or other fuels having low interfacial stresses (IFTs), for example, IFTs less than approximately 15 dynes / cm, improved fuel / water separation is achieved.
    [0004] In one embodiment, the filter can be made from all polymeric materials. For example, the two stages of the filter, including the means and end caps, can be made of thermoplastic material (s) to facilitate disposal of the filter such as by recycling or incineration. The use of layers of all polymeric media (for example, thermoplastic) allows better bonding of the layers of media adjacent to each other. In addition, polymeric media provides better chemical resistance / compatibility compared to media formed from another non-polymeric material. In addition, certain properties of the media, for example, pore size and pore size distribution, are best controlled using polymeric media.
    [0005] Although the filter is mainly described as a two-stage configuration, the first stage could be used alone in a single-stage configuration, used in combination with different second-stage models, or used in combination with two or more additional stages . Similarly, the second stage could be used alone in a single stage configuration, used in combination with different first stage models, or used in combination with two or more additional stages.
    [0006] In one embodiment, a coalescing fluid filter includes a pleated cylinder of polymeric media configured to coalesce the water in the fluid. The pleated cylinder of polymeric media has pleat valleys and pleat tips downstream, and release locations on the pleat tips downstream or adjacent to them.
    [0007] In one embodiment, the pleated media cylinder has opposite ends that are attached to the end caps, for example, using an adhesive, embedding the ends in the end caps that are preferably made of polymeric material (for example, thermoplastic) , using mechanical fasteners, or using other suitable fastening techniques. The pleated cylinder may have a single layer or several layers of media.
    [0008] The release sites may be located, for example, at the junction of the downstream pleat tips and a non-pleated cylinder, made of polymeric means (for example, thermoplastic); or located in the openings formed at the downstream pleat ends. When a non-pleated cylinder is used adjacent to the pleat tips, the distance between the inner tips of the pleated cylinder and the non-pleated cylinder is such that there is no significant gap or separation between the two. The pleat tips of the pleated cylinder can be attached or not attached to the outer surface of the un pleated cylinder. In addition, a support cylinder for supporting the means can be arranged between the pleated ends and the non-pleated cylinder, or arranged within the non-pleated cylinder and surrounded by it.
    [0009] In the case of a two-stage configuration, a first stage is arranged upstream of a second stage with a gap between them. For example, the first and second stages can be on a filter in the filter arrangement, with the first stage being an external stage and the second stage being an internal stage. The external stage includes a pleated cylinder of polymeric media (for example, thermoplastic) configured to coalesce water that is in a fluid. The pleated cylinder has pleat valleys and pleat tips downstream, and release locations on the pleat tips downstream. The internal stage includes a non-pleated cylinder of polymeric media (for example, thermoplastics) involving a pleated cylinder of multiple layers of polymeric media (for example, thermoplastics), and the internal stage is configured to separate coalesced water from the fluid and remove minute solid contaminants from the fluid.
    [00010] The external stage and the internal stage can be fixed on the end caps. The end caps can be separated so that the outer stage includes end caps fixed at their opposite ends and the inner stage includes end caps fixed at their opposite ends. In another embodiment, the external stage and the internal stage may share one, or both, end caps, whereby a single common end cap is attached to one end of each of the outer and inner stage and a single end cap. The common end is attached to the opposite end of each of the external and internal stages. Brief Description Of Drawings
    [00011] FIG. 1 is an exploded view of a two stage filter modality described here.
    [00012] FIG. 2 is a cross-sectional view of the two-stage filter of Figure 1 in an assembled state.
    [00013] FIG. 3 is an exploded view of another modality of a two-stage filter that can employ the concepts described here.
    [00014] FIG. 4 is an exploded view of the first stage or external stage of the two-stage filter of Figures 1 and 2.
    [00015] FIG. 5 is an exploded view of the second or internal stage of the two-stage filter of Figures 1 and 2.
    [00016] FIGS. 6A-6C show different configurations of the media layers of the first stage.
    [00017] FIG. 7 shows an exemplary configuration of the media layers of the second stage.
    [00018] FIG. 8 shows an example of an external stage with slits, holes or openings formed at the ends of pleats downstream to form release sites. Detailed Description
    [00019] A two-stage filter configuration is used with a first stage that is configured primarily to coalesce water from a fluid with which the filter is used and a second stage that is configured to separate coalesced water from the fluid and also remove tiny solid contaminants from the fluid. The fluid initially flows through the first stage followed by the flow through the second stage. Although the filter is mainly described as having a two stage configuration, the first stage could be used alone in a single stage configuration, used in combination with different second stage models than those described here, or used in combination with two or more additional stages. Similarly, the second stage could be used alone in a single stage configuration, used in combination with different first stage models than those described here, or used in combination with two or more additional stages.
    [00020] The filter is preferably configured for use with fuel, preferably diesel fuel such as ULSD, biodiesel or other fuels having low IFTs, to filter the fuel, before reaching an engine where the fuel is burned. However, the filter concepts described here could be employed with any type of fluid requiring separation of water from the fluid, for example, hydraulic fluid, oil or lubricating fluid, air and the like.
    [00021] Figures 1 and 2 illustrate an example of a two-stage filter 10 having a first stage upstream 12 which is configured primarily to coalesce water from the fluid and a second stage 14 downstream of the first stage 12 which is configured to separate coalesced water from the fluid and also remove minute solid contaminants from the fluid. In this example, filter 10 is a filter with a filter construction configured to flow from the outside in, with the first stage 12 being an external coalescence stage; and the second stage 14 being an internal separation stage, with the external stage surrounding the internal stage with a gap 16 between them. The filter 10 is configured to be disposed within a filter housing with the housing then being attached to a filter head. An example of this type of filter housing and head attachment employed with a single stage filter is described in United States Patent Application Publication 2007/0267338.
    [00022] An end cap 18 is connected to a first end, or upper end, of the first stage 12; and an end cap 20 is connected to a second end, or lower end, of the first stage. The end caps 18, 20 are made of polymeric material, for example, thermoplastic material, and the caps of the first stage means are properly attached to the end caps, for example, using an adhesive, embedding the ends of the media in the end caps. extremity, or other suitable fastening techniques. In another embodiment, end caps 18, 20 can be made of non-polymeric material, for example, metal with the ends of the media attached to the metal end caps using an encapsulating material known in the art.
    [00023] As shown in Figure 2, the end cap 18 includes a central opening 22 defined by a sleeve 23 that forms a fluid outlet passage for the fluid that has been filtered through the filter 10. An elastomeric gasket 25 surrounds the sleeve 23 for sealing engagement with the filter head when the filter and filter housing are installed. The end cap 20 includes an opening 24 that allows the insertion of the second stage 14 into the first stage 12 during the assembly of the filter.
    [00024] In addition, an end cap 26 is connected to a first end, or upper end, of the second stage 14; and an end cap 28 is connected to a second end or lower end of the second stage. The end caps 26, 28 are also made of polymeric material, for example, thermoplastic material, and the ends of the second stage means are properly attached to the end caps, for example, using an adhesive, by embedding the ends of the media in the caps or other suitable fastening techniques. In another embodiment, end caps 26, 28 are made of non-polymeric material, for example, metal with the ends of the media attached to the metal end caps using an encapsulating material known in the art.
    [00025] The end cap 26 includes a central opening 30 (see Figures 1, 2 and 5) that allows the end cap 26 to slide over and into a cylindrical tube 32 (see Figure 2) that extends downwards from the end cap 18 and forming a part of the central opening 22. The end cap 28 is generally closed to prevent the flow of fuel through the end cap 28.
    [00026] The first stage 12 and the second stage 14 can be connected together using any suitable connection technique. An example of a suitable connection technique is described in United States Patent Application Publication 2009/0065425. Using the technique described in Publication 2009/0065425, end caps 18, 26 can be connected via clamping ribs, while end caps 20, 28 can be connected using resilient arms 34 which connect with snap fit with end cap 20.
    [00027] Figures 1 and 2 illustrate that the end caps 18, 20 of the first stage 12 are separate from the end caps 26, 28 of the second stage 14. However, in another embodiment, the first stage 12 and the second stage 14 they can share common end caps, whereby a single common end cap is attached to the first or upper ends of the first stage and the second stage; and a single common end cap is attached to the second or lower ends of the first stage and the second stage. An example of a first stage and a second stage sharing common end caps can be found in United States Patent Application Publication 2007/0289915.
    [00028] Figure 3 is an exploded view of another embodiment of a two-stage filter 40 configured as a filter in the construction of a filter for outward-inward flow, which can employ the inventive concepts described here, with a first stage 42 being an external coalescence stage and a second stage 44 being an internal separation stage; with the second stage surrounding the internal stage with a gap between them. The first stage filter means 42 and the second stage filter means 44 are connected to the end caps 46, 48 and 51, 53, respectively, in the same manner as described above for the end caps 18, 20, 26, 28, although a common end cap can also be used at each end. The filter 40 is configured to be installed on a vertical tube inside a filter housing. Additional details of this general type of two-stage filter construction are disclosed in United States Patent Application Publication 2009/0065425.
    [00029] Figures 4 and 5 illustrate details of the first coalescence stage or external coalescence stage 12 and the second separation stage or internal separation stage 14 of the filter 10, respectively. Stages 42, 44 of filter 40 are configured substantially identical to stages 12, 14, except for the end caps, and will not be described separately.
    [00030] As shown in Figures 2 and 4, the first coalescence stage or external coalescence stage 12 includes a pleated cylinder 50 of polymeric means which when assembled surrounds an un pleated cylinder 52 of polymeric means. As shown in Figures 2 and 5, the second separation stage or separation stage 14 includes a non-pleated cylinder 54 of polymeric means which when assembled surrounds a pleated cylinder 56 of polymeric means.
    [00031] Turning to Figures 2 and 4, the pleated means 50 include internal pleat tips (i.e., downstream) 60 which in use are positioned closely adjacent to the outer surface of the cylinder 52 such that there is no gap or significant separation between the two. In one embodiment, the inner pleat tips 60 are in intimate contact with the outer surface of the cylinder 52. The inner pleat tips 60 may or may not be attached or attached to the outer surface of the cylinder 52, but are positioned closely adjacent, for example , in contact with the cylinder.
    [00032] Figure 6A shows a cross-sectional view of a first stage 12 modality with the thickness of the layers being exaggerated for clarity. In Figure 6A, the pleat ends 60 downstream of the pleated means 50 are in direct, intimate contact with the outer surface of the non pleated means 52, with the tips 60 being optionally attached or not attached to the outer surface. Thus, the embodiment in Figure 6A does not use a central tube, screen, cage or other support structure for the first stage 12 media. In this case, the non-pleated media 52 and / or the pleated media 50 would be sufficiently rigid to act as its own support structure.
    [00033] Figure 6B shows another embodiment of the first stage, where a central tube, screen, cage, spring or other support cylinder structure 70 for the first stage 12 means is located downstream of the non-pleated media cylinder 52 and adjacent to it. The support structure 70, if used, can be formed of a polymeric material, for example, thermoplastic material, and is provided with openings to allow the fluid to flow through the first stage to the second stage. Optional support structure 70 is used to prevent internal non-pleated means 52 from sagging under fluid flow and pressure drop. Ideally, however, the pleated means 50 and the non-pleated means 52 together provide sufficient strength and strength making the use of the support structure 70 unnecessary. In the embodiment in Figure 6B, the non-pleated means 52 can be attached to the support structure 70 only on the end caps because there is no need to connect them elsewhere due to fluid pressure during use. However, the non-pleated means 52 can be attached to the support structure 70 in any location that is considered suitable.
    [00034] Figure 6C shows another embodiment of the first stage, where the support structure 70 is located between or adjacent and contacts both the pleated means upstream 50 and the non-pleated means downstream 52. In Figure 6C, the support structure 70 provides support for the pleated means 50, whose inner pleat tips 60 are in intimate contact with them, while the non-pleated means 52 are located inside and downstream of the support structure 70 and in intimate contact therewith. Non-pleated means 52 can be thermally welded or injection molded with the polymeric support structure 70 to secure them to the support structure.
    [00035] In Figures 6A-6C, numerals 1-5 indicate, in order from upstream to downstream in the direction of the fluid flow, the different media layers of an example of pleated media 50. In the examples described here , the media layers of the pleated media 50 are made of polymeric materials, for example, thermoplastic materials.
    [00036] In one embodiment, the pleated media 50 may include three layers of polymeric fibrous filter media (1-3), a layer of polymeric nanofiber media (4) and a final layer (5) of polymeric fibrous media. In this example, the non-pleated media 52 is a single layer of polymeric fibrous media formed like a tube and placed within the pleated media 50 with its upstream face in direct contact with the pleated media via pleat ends 60, or in indirect contact with the pleated means 50 through the intermediate support structure 70.
    [00037] Typically, the axial lengths Li (see Figure 2) of the layers of the pleated media 50, the non-pleated media 52 and the support structure (if used) are identical, with the ends of each embedded in the end caps 18, 20 or encapsulated in an adhesive, for example, polyurethane, or otherwise attached to the end caps in a manner to prevent the unfiltered fluid from shifting around the media.
    [00038] Although Figures 6A-6C show five layers for pleated media 50 and one layer for non-pleated media 52, more or less layers can be used for pleated media 50 and non-pleated media 52 depending, for example, on application requirements and the coalescence medium model.
    [00039] The function and design limitations for each layer of the first coalescence stage 12 and when they are used, will now be described. For illustration purposes, examples of each layer are described in Table 1 for three different combinations of media, referred to as Coalescence Medium X, Y and Z. It is worth noting that these three media combinations reflect design options based on recognition that in low interfacial tension fuels, such as ULSD and biodiesel, there is relatively little thermodynamic drive for coalescence and coalescence kinetics tends to be slow. The examples described here are designed to physically slow the speed of water droplets passing through the media and increase their concentration locally within the coalescence medium.
    [00040] The combinations of media, materials and properties listed in Table 1 are exemplary only and reflect combinations, materials and properties that the inventors believed, at the time of filing this order, that would provide adequate performance results with respect to fuel systems common high-pressure injection diesel running on ULSD or biodiesel. Further research may reveal appropriate combinations of media, materials and material properties other than those listed in Table 1, both with respect to common high-pressure injection diesel fuel systems running on ULSD or biodiesel and with respect to other types of fluids in other types of systems.
    [00041] Therefore, although Table 1 lists several specific thermoplastic materials, such as polyamide, polybutylene terephthalate and polyethylene terephthalate, the layers of media are not limited to those specific thermoplastic materials. Other thermoplastic materials could be used. In addition, the layers of media are not limited to thermoplastic materials. Other polymeric materials could be used for the media layers including, but not limited to, thermal consolidation plastics.



    [00042] In Table 1 (and Table 2 below): g / m2 is defined as grams per square meter and cfm is defined as cubic feet per minute; thickness is measured from upstream to downstream in relation to the main direction of fluid flow through the layers of means. Coalescer X
    [00043] The example of Coalescence X media includes at least 6 layers of media, and an optional support structure can be used. Layers 1-5 form the pleated media 50 and layer 6 forms the non-pleated cylinder 52. Coalescence X medium can be referred to as a speed-changing coalescence medium (see, for example, PCT Publication No. WO 2010 / 042706) for use in a filter-on-filter model.
    [00044] Layer 1 works as a pre-filter and reduces the pressure drop across external stage 12. Layer 1 is more open (for example, it has a higher porosity, larger pore size, larger average fiber diameter, higher Frasier permeability, and / or lower contaminant removal efficiency) than Layer 2.
    [00045] Layer 2 works to capture fine emulsified droplets, for example, water droplets in ULSD fuel. Layer 2 is tighter (for example, having lower porosity, smaller pore size, smaller average fiber diameter, lower Frasier permeability, and / or higher contaminant removal efficiency) than Layer 3.
    [00046] Layer 3 works to reduce the speed of the fluid within the layer and provides space for drainage, accumulation and coalescence of the droplets captured in Layer 2. The physical properties of Layer 3 are such that the speed of the fluid in that layer is less than at Layer 4. Layer 3 is more open (for example, has higher porosity, larger pore size, larger average fiber diameter, higher Frasier permeability, and / or lower contaminant removal efficiency) than Layer 4.
    [00047] Layer 4 works to capture droplets that were not captured by the previous layers, especially the smallest droplets, and to serve as a semipermeable barrier to the passage of captured droplets. The semi-permeable barrier function causes the droplets to concentrate and accumulate in Layer 3, providing them with more time and greater probability for the occurrence of coalescence. Layer 4 also provides increased localized fluid velocity and a transient increase in drop surface area, which further increases coalescence. The fluid speed at Layer 4 is higher than at Layer 5. Layer 4 is tighter (for example, it has lower porosity, smaller pore size, smaller average fiber diameter, lower Frasier permeability, and / or efficiency of contaminant removal) than Layer 5.
    [00048] Layer 4 can be, for example, of thermoplastic nano-fiber filter media with fibers having a diameter of less than approximately 1 gm, which helps to achieve very high water removal efficiency requirements for systems common high-pressure injection diesel fuel running on ULSD or biodiesel. Layer 4 can be formed using an electro-blowing process, but it can be formed using other suitable processes. In addition to the properties listed in Table 1, for Layer 4, Layer 4 also has a maximum / medium pore size ratio of less than approximately 3, and more preferably less than approximately 2.
    [00049] Layer 5 works to create a lower speed environment for coalesced drops formed in the previous layers to be collected and drained before release. Layer 5 is more open (for example, has higher porosity, larger pore size, larger average fiber diameter, higher Frasier permeability, and / or lower contaminant removal efficiency) than Layer 4.
    [00050] Layer 6 (ie, the non-pleated cylinder 52) works to provide release sites for coalesced drops. As such, Layer 6 is more open (for example, it has higher porosity, larger pore size, larger average fiber diameter, higher Frasier permeability, and / or lower contaminant removal efficiency) than Layer 5. In In one embodiment, Layer 6 also provides structural support for the first stage 12 as discussed above for Figure 6A, eliminating the need for a separate support structure. Coalescer Y
    [00051] In the example of the Coalescence Y medium, two to three layers of media are used with or without an optional support structure. Coalescence medium Y can be referred to as a single layer surface coalescence medium (see United States Patent Application Serial No. 61 / 178,738 filed May 15, 2009 and United States Patent Application No. Series 12 / 780,392 deposited on May 14, 2010) for use in a filter-on-filter model.
    [00052] The first layer, Layer 4, works to provide a semipermeable barrier to the passage of small emulsified droplets, forcing them to concentrate on their upstream surface. In this way, the droplets have time and an adequate environment for coalescence and the development of gout to occur. Layer 4 is a relatively tight layer with characteristics comparable to Layer 4 in the Coalescence X medium or even tighter. Layer 4 relies on filtration to prevent fine droplets from passing through, and in this example can be a thermoplastic nano fiber filter media; with the fibers having a diameter of less than approximately 1 pm, an average pore size less than the average droplet size of the influencing droplets, and can have a maximum / average pore size ratio of less than approximately 3, and preferably less than approximately 2. Layer 4 can be formed using an electro-blowing process, but it can be formed using other suitable processes.
    [00053] Layer 5 is optional and provides structural support for Layer 4, if required, and serves as a drainage path for the coalesced drops forced through Layer 4. Layer 5 also connects Layer 4 to release layer 6 (ie, non-pleated cylinder 52). Layer 5 creates a lower velocity environment for coalesced drops to be collected and drained through prior to release. Layer 5 (if used) is more open than Layer 4 and is structurally stronger, to provide support for Layer 4 and facilitate the processing of filter media.
    [00054] The Coalescence Y medium has an additional non-pleated Layer 6 (ie, non-pleated cylinder 52) downstream of Layer 4 and optional Layer 5 that provides release of locations for coalesced drops. Layer 6 is more open than the optional Layer 5. Coalescer Z
    [00055] In the example of the Coalescence Z medium, three or more layers of media with an optional support structure are used (see United States Patent Application Serial No. 61 / 179,170, filed May 18, 2009; Order United States Patent No. Serial 61 / 179,939 filed on May 20, 2009, and United States Patent Application Serial No. 12 / 780,392 filed on May 14, 2010. A Coalescence means Z is a means Surface Coalescence method more complex than Coalescence Y medium for use in a filter-in-filter model.
    [00056] Layer 3 works to reduce the pressure drop through the coalescence medium and serves as a pre-filter of particulate matter for the coalescence medium and to increase its service life. Layer 3 is more open than Layer 4 and has higher capillary pressure (that is, more positive capillary pressure) than Layer 4.
    [00057] The functions and properties of Layer 4, Layer 5 (optional) and Layer 6 are as described for the Coalescence Y medium.
    [00058] In all three Coalescers X, Y and Z, the nature of the transition from Layer 5 to Layer 6 is of interest. In the illustrated and described modalities, Layers 1-5 are pleated. As such, a fluid flow profile within the folds and dragging on the captured droplets causes them to accumulate in the valleys 62 (downstream direction) of the folds. This results in droplets concentrating in this localized region, increasing coalescence by providing increased time for the drops to coalesce before they are released. The inventors observed that coalesced droplets tend to be released from the same active regions or areas on the downstream face of the Coalescers, while little droplet release occurs elsewhere. This suggests that when a drainage path through the media is created, it is used repeatedly.
    [00059] In the first stage described, preferred drainage paths ending in larger pores are created by the intimate contact of the inner pleat tips of Layer 4 (for Coalescers Y and Z) or Layer 5 (for Coalescers X, as well as Coalescers Y and Z if Layer 5 is included) with the surface upstream of the non-pleated layer 6. At the point of contact between the pleated media and the non-pleated media, there is a localized breakdown of the pore structure of the media that provide these pathways. drainage, preferred. The result is larger drops that are released. In addition, these drainage paths occur at the bottom 64 of pleat valleys 62 (see Figures 6A, 6B and 6C) where coalesced drops tend to concentrate and the effect is greatest. The contact between Layers 4 or 5 and Layer 6 need not be direct. Instead, the same benefits can be obtained indirectly by having the inner pleat tips or downstream 60 of the pleated media 50 in direct contact with the porous support structure 70, which in turn is in direct contact with the Layer 6 (ie, non-pleated cylinder 52) on its downstream side, as shown in Figure 6C.
    [00060] In an additional embodiment, the pleated means 50 could be as described in the exemplary Coalescers X, Y or Z described above, except that Layer 6, that is, the non-pleated cylinder 52, would be absent. This additional modality achieves the same fluid flow profile within the pleat and drag drop capture effects as Coalescers X, Y or Z, to cause coalesced droplets and droplets to concentrate in the pleat valleys 62 to perfect the coalescence. However, instead of coalesced droplets being drained to Layer 6, the droplets are released from small slits or holes (ie openings) in the inner pleat tips 60. These openings could be produced by needle drilling or other means and can be on the order of 30-300 pm in size. The openings serve as release points for the coalesced drops.
    [00061] Figure 8 illustrates an example of openings 80 formed in the inner pleat ends of the pleated means 50. An optional layer 82 with a relatively large pore size (in comparison with the means 50), which can be equivalent to the cylinder not pleated 52 or support structure 70, may also be present. As shown in Figure 8, during the flow, the emulsion containing water droplets flows into the pleat at (1). In (2), water droplets unable to penetrate the barrier formed by the media flow along the surface of the media to the valley of the pleat. In (3), the water droplets gather in the valley and coalesce in drops. In (4), the pressure drop forces the coalesced drops through an opening 80 in the pleat tip. In (5), the release of drops through layer 82 is present. In (6), the coalesced water droplets settle and / or are loaded downstream to the external un pleated cylinder 54 of the second stage 14 where they are separated and drained.
    [00062] Figure 7 and Table 2 provide an exemplary configuration of the second separation stage 14 or internal separation stage 14. The second stage 14 serves to separate the coalesced water droplets from the fluid and to remove minute solid contaminants from from the fluid. The second stage 14 includes the outer non-pleated cylinder 54 in close contact with the outer pleated ends of the multilayer internal pleated cylinder 56.
    [00063] As shown in Figure 2, the axial lengths L2 of the non-pleated cylinder 54 and pleated cylinder 56 are substantially identical, with the ends of the cylinders embedded in the end caps 26, 28 or encapsulated in an adhesive, for example, polyurethane , or otherwise attached to the end caps in a manner to prevent the unfiltered fluid from shifting around the means.
    [00064] The combinations of media, materials and properties listed in Figure 2 are only exemplary and reflect combinations, materials and properties that the inventors believe, at the time of filing this order, that would provide adequate performance results with respect to diesel fuel systems common high pressure injection in ULSD or biodiesel. Further research may reveal suitable combinations of media, materials and material properties other than those listed in Table 2, both with respect to common high-pressure injection diesel fuel systems operating on ULSD or biodiesel and with respect to other types of fluids or other types of systems.
    [00065] Therefore, although Table 2 lists several specific thermoplastic materials such as polyamide, polybutylene terephthalate and polyethylene terephthalate, the layers of media are not limited to those specific thermoplastic materials. Other thermoplastic materials could be used. In addition, the layers of media are not limited to thermoplastic materials. Other polymeric materials could be used for the media layers including, but not limited to, thermal consolidation plastics.
    * Average nominal fiber diameter for Layer A is currently believed to be irrelevant to functionality.
    [00066] In the example illustrated in Figure 7 and Figure 2 above, the second stage includes at least five layers. Layer A (i.e., the non-pleated cylinder 54) works to separate coalesced water droplets from the fuel. Layer A can be, for example, a polymeric mesh woven in the form of a tube that repels coalesced drops of water and allows them to drain freely from the surface. Layer A is outside the outer pleat tips 90 and in close contact with the outer pleat tips 90 of the multilayer pleated cylinder, inner 56. The inventors currently believe that the mesh opening of Layer A should be less than 100 pm and preferably less than 50 pm for ULSD and biodiesel applications. However, further research may reveal other suitable mesh opening sizes.
    [00067] The pleated layers (Layers B-E, that is, pleated cylinder 56) work to capture solid contaminants and drops not removed by the upstream layers. The first of these pleated layers, Layers B and C in Figure 7 and Table 2, are transitory layers that reduce pressure drop, provide additional removal of droplets and droplets, and reduce the gathering of solids in the next nanofiber filtration layer, Layer D. Layer B and C have similar properties to Layer 1 and 2 in external stage 12. Layer B also facilitates manufacturing and processing.
    [00068] The next pleated layer, Layer D, works as a high efficiency filter for fine particles, 4 pm (c) and smaller. For common high pressure injection applications, very high removal efficiencies for particles as small as 4 gm (c) are required to protect the fuel injectors. The layers upstream of Layer D work primarily to remove and separate water droplets. Layer D works to protect a downstream system, such as a common high pressure injection fuel injection system, from the solid mines. Layer D also removes drops that may have passed through the preceding layers. Preferably, Layer D is tighter than any of the other layers of the outer stage 12 or the inner stage 14 and, in an exemplary embodiment, comprises nano-fiber filter media with fibers having a diameter of less than 1 gm. At a minimum, Layer D should be as tight as Layer 4 of external stage 12.
    [00069] The final layer, Layer E, works to provide support for the preceding layers without significantly increasing the pressure drop. Layer E consists of relatively open media with sufficient strength and hardness to support the layers upstream of the internal stage 14 under conditions of use and to improve the processing capacity of the media of the internal stage 14.
    [00070] The examples in Tables 1 and 2 above list the various layers of media as being made from specific thermoplastic materials. The end caps and the support structure 70 are also described as being made of thermoplastic materials. However, the performance advantages of the filter described here can be obtained if some of the components are not thermoplastic, but are made of other polymeric materials or in some circumstances non-polymeric materials. For example, one or more of the media layers of the outer stage 12 and / or the inner stage 14 can be made of polymeric materials except thermoplastic materials. In another embodiment, the end caps may be formed of material except the thermoplastic material, for example, metal or other polymeric material such as thermally consolidating plastic. In addition, the support structure 70 can be made of materials except the thermoplastic material, for example, other polymeric materials, metal or other materials known in the art.
    [00071] Suitable polymeric materials that can be used for the various filter elements described herein may include, but are not limited to, polyamide material, polyalkylene terephthalate material (e.g. polyethylene terephthalate material or polybutylene terephthalate material ); other polyester material, halocarbon material (eg, ethylene chlorotrifluoroethylene (ECTFE) from the Halar® brand), and polyurethane material.
    [00072] Pleated media 50 and pleated media 56 can be formed using any suitable techniques known in the art, including, but not limited to blowing molten material from two different layers of media on top of each other, through a process of wet settlement, electro-centrifugation, electro-blowing, molten material centrifugation, ultrasonic bonding, combined pleating; or otherwise chemically or physically linking two or more different layers together; or using other techniques or combinations of techniques.
    [00073] The invention can be incorporated into other forms without departing from the essence or novel characteristics of it. The modalities revealed in this application must be considered in all aspects as illustrative and not limiting. The scope of the invention is indicated by the appended claims more properly than by the preceding description; and all changes covered within the meaning and equivalence range of the claims must be covered by them.
    权利要求:
    Claims (21)
    [0001]
    1 - Two Stage Fluid Filter, comprising: an external coalescence medium stage (12) surrounding an internal separation stage (14) with a gap between them, the external coalescence medium stage (12) including a cylinder pleated (50) of polymeric media configured to coalesce water that is in a fluid, the pleated cylinder (50) of polymeric media having pleat valleys (62) and downstream pleat tips (60), and release locations located in pleat ends downstream (60) or adjacent to them; the pleated cylinder (50) of polymeric media from the external coalescence medium stage (12) having opposite ends that are attached to the end caps (18, 20); the internal separation stage (14) including a non-pleated cylinder (54) of polymeric media surrounding the multilayer pleated cylinder (56) of polymeric media, and the internal separation stage (14) is configured to separate coalesced water from from the fluid and remove minute solid contaminants from the fluid; and the non-pleated cylinder (54) of polymeric media and the pleated multilayer cylinder (56) of polymeric media of the internal separation stage (14) have individually opposite ends that are fixed on the end caps (26, 28), in that the two-stage fluid filter is characterized in that the pleated cylinder (50) of polymeric media of the external coalescence medium stage (12) comprises from upstream to at least the following layers: an upper layer (1) comprising a polymeric nonwoven, the upper layer (1) having an average fiber diameter greater than 10 pm, the upper layer (1) having greater porosity, greater pore size, greater average fiber diameter, greater Frasier permeability and less contaminant removal efficiency than a layer immediately downstream of the top layer (1); a nanofiber layer (4) comprising a polymeric nonwoven, the nanofiber layer (4) having an average fiber diameter of 0.1-1.0 pm, the nanofiber layer (4) having a lower porosity, a smaller pore size, smaller medium fiber diameter, lower Frasier permeability or higher contaminant removal efficiency than a support layer (6) immediately downstream of the nanofiber layer (4); and the support layer (6) comprising a polymeric nonwoven, the support layer (6) having an average fiber diameter greater than 20 pm, the support layer (6) with greater porosity, greater pore size, greater diameter medium fiber, greater Frasier permeability and less efficiency in removing contaminants than the nanofiber layer (4) immediately upstream of the support layer (6).
    [0002]
    2 - Two Stage Fluid Filter, according to Claim 1, characterized by the fact that the fluid is combustible and the external coalescence medium stage (12) and the internal separation stage (14) are configured to function as fuel.
    [0003]
    3 - Two-Stage Fluid Filter according to Claim 1, characterized by the fact that the nanofiber layer (4), an average pore size less than 8.0 pm, a maximum pore size between 5, 0 to 15.0 pm, a permeability of between 5 to 20 cfm, a thickness of between 0.1 to 0.25 mm, and a base weight greater than 20 gsm.
    [0004]
    4 - Two-Stage Fluid Filter according to Claim 3, characterized by the fact that the external coalescence medium stage (12) optionally includes one or more of the following layers upstream of the nanofiber layer (4): one second layer (2) comprising a polymeric nonwoven, the second layer having less porosity, smaller pore size, smaller average fiber diameter, less Frasier permeability or greater contaminant removal efficiency than a third layer (3) immediately after downstream of the second layer (2); a third layer (3) comprising a polymeric nonwoven, the third layer (3) having greater porosity, greater pore size, greater average fiber diameter, greater Frasier permeability or less contaminant removal efficiency than a fourth layer ( 4) immediately downstream of the third layer (3); the fourth layer (4) comprising a polymeric nonwoven, the fourth layer (4) having less porosity, smaller pore size, smaller average fiber diameter, less Frasier permeability or greater efficiency in removing contaminants than a fifth layer ( 5) downstream of the fourth layer (4); and the external coalescence medium stage (12) includes at least one of the following layers downstream of the nanofiber layer (4): a fifth layer (5) comprising a polymeric nonwoven, the fifth layer (5) having a greater porosity , larger pore size, larger average fiber diameter, higher Frasier permeability or less efficiency in removing contaminants than the nanofiber layer (4) immediately upstream of the fifth layer (5).
    [0005]
    5 - Two Stage Fluid Filter according to Claim 4, characterized by the fact that the polymeric nonwovens of the first (1), second (2), third (3), fourth (4), fifth (5) and support layers (6) comprise thermoplastic material.
    [0006]
    6 - Two Stage Fluid Filter according to Claim 5, characterized in that the thermoplastic material of the first layer (1) comprises a polyamide; and the thermoplastic material of the second (2), third (3), fourth (4), fifth (5) and support layers (6) comprise polyester.
    [0007]
    7 - Two Stage Fluid Filter, according to Claim 4, characterized by the fact that the support layer (6) is not pleated and the first (1), second (2), third (3), fourth ( 4) and fifth (5) layers form the pleated cylinder (50) of polymeric media from the external coalescence medium stage (12).
    [0008]
    8 - Two-Stage Fluid Filter according to Claim 1, characterized by the fact that the internal separation stage (14) includes: a first layer (A) comprising a polymeric woven fabric having a base weight of 37 + 10 gsm; and a second layer (D) downstream of the first layer (A) comprising a polymeric nonwoven having a nominal average fiber diameter between 0.1 to 0.8 pm and a basis weight greater than 20 gsm.
    [0009]
    9 - Two-Stage Fluid Filter according to Claim 8, characterized by the fact that the internal separation stage (14) further includes: a third layer (B) comprising a polymeric nonwoven between the first layer (A) and the second layer (D), with the third layer (B) having less porosity, smaller pore size, smaller average fiber diameter, less Frasier permeability or greater efficiency in removing contaminants than a fourth layer (C) immediately after downstream of the third layer (B); the fourth layer (C) comprising a polymeric nonwoven between the third layer (B) and the second layer (D), the fourth layer (C) having a greater porosity, greater pore size, greater average fiber diameter, greater permeability Frasier or less efficient removal of contaminants than the second layer (D) immediately downstream of the fourth layer (C); and a fifth layer (E) comprising a polymeric nonwoven downstream of the second layer (D), with the fifth layer (E) having a greater porosity, greater pore size, greater average fiber diameter, greater Frasier permeability and less efficiency contaminant removal than the second layer (D) immediately upstream of the fifth layer (E).
    [0010]
    10 - Two Stage Fluid Filter, according to Claim 9, characterized by the fact that the polymeric woven fabric of the first layer (A) and the polymeric nonwovens of the second (D), third (B), fourth (C ) and fifth (E) layers comprise a thermoplastic material.
    [0011]
    11 - Two Stage Fluid Filter according to Claim 10, characterized in that the thermoplastic material of the first (A) and the fifth (E) layer comprises polyester; the thermoplastic material of the second layer (D) comprises a polyamide, and the thermoplastic material of the second (D) and third (B) layers comprises polyester.
    [0012]
    12 - Two Stage Fluid Filter according to Claim 5, characterized by the fact that the first layer (1) is the non-pleated cylinder (54) of polymeric media and the second (2), third (3), fourth (4) and fifth (5) layers form the pleated multilayer cylinder (56).
    [0013]
    13 - Two Stage Fluid Filter according to Claim 1, characterized in that the pleated cylinder (50) of the external coalescence medium stage (12) includes one of the following: in a direction from upstream downstream, three layers of polymeric fibrous filter media, one layer of polymeric nanofiber media, and one layer of polymeric fibrous media; in a direction from upstream to downstream, a layer of polymeric nano fiber media and optionally a layer of polymeric fibrous media; or in a direction from upstream to downstream, a layer of polymeric fibrous filter media, a layer of polymeric nano fiber media and optionally a layer of polymeric fibrous media.
    [0014]
    14. Two Stage Fluid Filter according to Claim 13, characterized by the fact that the polymeric media comprises thermoplastic media.
    [0015]
    15 - Two Stage Fluid Filter, according to Claim 13, characterized by the fact that the external coalescence medium stage (12) further includes an un pleated cylinder (54) downstream of the pleated cylinder (50), the non-pleated cylinder (54) of the external coalescence medium stage (12) comprising a layer of polymeric fibrous media;
    [0016]
    16 - Two Stage Fluid Filter according to Claim 15, characterized in that the polymeric means of the non-pleated cylinder (54) of the external coalescence medium stage (12) comprise thermoplastic means.
    [0017]
    17 - Two Stage Fluid Filter, according to Claim 1, characterized by the fact that the external coalescence medium stage (12) includes in a direction from upstream to downstream: the upper layer (1) configured to function as a pre-filter and reduce the pressure drop through the external coalescence medium stage (12); a second layer (2) configured to capture fine droplets of emulsified water; a third layer (3) configured to reduce the speed of the fluid; the nanofiber layer (4) configured to capture droplets of water not captured by the first, second and third layers; a fifth layer (5) configured to slow the fluid; the support layer (6) configured to provide release locations for coalesced water droplets.
    [0018]
    18 - Two Stage Fluid Filter according to Claim 17, characterized by the fact that the internal separation stage (14) includes in a direction from upstream to downstream: the non-pleated cylinder (54) of polymeric means that is configured to separate coalesced water from the fluid; and the pleated multilayer cylinder (56) of polymeric means includes a first pleated layer (B) and a second pleated layer (C) each of which is configured to reduce the pressure drop; a third pleated layer (D) configured to act as a high efficiency filter for fine particles; and a fourth pleated layer (E) configured to support the non-pleated cylinder (54) of polymeric media and the first (B), second (C), third (D) and fourth (E) pleated layers.
    [0019]
    19 - Two-Stage Fluid Filter according to Claim 1, characterized by the fact that the external coalescence medium stage (12) includes a non-pleated cylinder (54) of polymeric media adjacent to the downstream pleat tips ( 60), or the downstream pleat ends (60) include openings formed there.
    [0020]
    20 - Two-Stage Fluid Filter according to Claim 19, characterized by the fact that it further comprises a support structure (70) disposed between the downstream pleat tips (60) and the un pleated cylinder (54) of polymeric means of the external coalescence medium stage (12), or the non-pleated cylinder of polymeric means of the external coalescence medium stage is disposed between the downstream pleat ends (60) and the support structure (70).
    [0021]
    21 - Two Stage Fluid Filter according to Claim 19, characterized in that the non-pleated cylinder (54) of polymeric media of the external coalescence medium stage (12) comprises thermoplastic material.
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    同族专利:
    公开号 | 公开日
    CN103025404A|2013-04-03|
    BR112012019395A8|2019-09-10|
    DE112011102095T5|2013-07-18|
    RU2654979C1|2018-05-23|
    RU2013102594A|2014-07-27|
    RU2013102593A|2014-07-27|
    CN102946966A|2013-02-27|
    CN102946966B|2016-01-27|
    DE112011102095B4|2022-02-17|
    BR112012019483B1|2020-12-22|
    BR112012019483A2|2018-03-27|
    CN105561650A|2016-05-11|
    RU2557613C2|2015-07-27|
    CN105561650B|2018-11-27|
    CN103025404B|2015-11-25|
    DE112011102094T5|2013-07-18|
    RU2561993C2|2015-09-10|
    BR112012019395A2|2018-03-20|
    WO2011162855A1|2011-12-29|
    WO2011162854A1|2011-12-29|
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    法律状态:
    2018-04-10| B06F| Objections, documents and/or translations needed after an examination request according [chapter 6.6 patent gazette]|
    2019-02-05| B06T| Formal requirements before examination [chapter 6.20 patent gazette]|
    2019-04-16| B06G| Technical and formal requirements: other requirements [chapter 6.7 patent gazette]|Free format text: CONFORME A IN INPI/DIRPA NO 03 DE 30/09/2016, O DEPOSITANTE DEVERA COMPLEMENTAR A RETRIBUICAO RELATIVA AO PEDIDO DE EXAME DO PRESENTE PEDIDO, DE ACORDO COM TABELA VIGENTE, REFERENTE A(S) GUIA(S) DE RECOLHIMENTO 0000221401480319 (PETICAO 020140009238, DE 28/02/2014). PUBLIQUE-SE A EXIGENCIA (6.7). |
    2019-12-10| B07A| Application suspended after technical examination (opinion) [chapter 7.1 patent gazette]|
    2020-05-05| B09A| Decision: intention to grant [chapter 9.1 patent gazette]|
    2020-09-29| B16A| Patent or certificate of addition of invention granted [chapter 16.1 patent gazette]|Free format text: PRAZO DE VALIDADE: 20 (VINTE) ANOS CONTADOS A PARTIR DE 05/04/2011, OBSERVADAS AS CONDICOES LEGAIS. |
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