Composite filter element

Abstract

A combination filter element comprising a bundle of hollow microporous fibers housed within an extruded carbon block, wherein the carbon block is fabricated to balance particle retention capacity against absorption capacity to provide a composite filter with desirable pressure drop, filter life, and particulate and chemical contamination reduction, and a filtration device, in which combination filter element may be employed, having a base portion including a sump which has an inlet and an outlet and a base which has a reception port for receiving the filter element.

What is claimed is:  
     
         1 . A compound filter cartridge for filtering fluids comprising: 
 a) carbonaceous filter block element surrounding a void, said carbonaceous filter element having a fluid entry port located proximal to an outer portion of said carbonaceous filter element;    b) a selectively permeable fiber bundle positioned in said carbonaceous filter element void for receiving fluid passing through said carbonaceous filter element into said carbonaceous filter element void, said fiber bundle comprising a plurality of hollow, microporous fibers each having a first open end and a second open end, wherein said first and second open-end are potted in a sealing compound such that said first open end and said second open end of each of said hollow fibers are exposed on an outer end face of said sealing compound body permitting fluid entering said hollow, microporous fibers to exit through said outer end face of said sealing compound body; and    wherein less than about 60% of the selectively permeable fiber bundle is sheathed from radial flow.    
     
     
         2 . A compound filter cartridge as recited in  claim 1  wherein the pores of said hollow, microporous fibers have a maximum dimension of about 0.20 microns or less.  
     
     
         3 . A compound filter cartridge as recited in  claim 1  wherein the pores in the hollow, microporous fibers form tortuous, interconnected channels leading from one surface of the fiber to the other.  
     
     
         4 . A compound filter cartridge as recited in  claim 1  wherein the pores permit the flow of fluids but block passage of bacteria and sub-micron particles and solutes.  
     
     
         5 . A compound filter cartridge as recited in  claim 1  wherein the sealing compound body is selected from the group constituting of polyurethane, epoxy, polyethylene and polypropylene.  
     
     
         6 . A compound filter cartridge as recited in  claim 1 , wherein said carbonaceous filter block element is defined at least in part by an extruded carbon block.  
     
     
         7 . A compound filter cartridge as recited in  claim 1 , wherein more than about 40% of the surface area of said selectively permeable fiber bundle is in radial-flow contact with fluid when said carbonaceous filter element void is filled with fluid.  
     
     
         8 . A compound filter cartridge as recited in  claim 1 , wherein more than about 50% of the surface area of said selectively permeable fiber bundle is in radial-flow contact with fluid when said carbonaceous filter element void is filled with fluid.  
     
     
         9 . A compound filter cartridge as recited in  claim 1 , wherein more than about 75% of the surface area of said selectively permeable fiber bundle is in radial-flow contact with fluid when said carbonaceous filter element void is filled with fluid.  
     
     
         10 . A compound filter cartridge as recited in  claim 1 , wherein the carbonaceous filter block element has a k-value of between 0.01 to about 0.10.  
     
     
         11 . A compound filter cartridge as recited in  claim 1 , wherein the carbonaceous filter block element has a k-value of between about 0.02 to about 0.07.  
     
     
         12 . A compound filter cartridge as recited in  claim 1 , wherein the carbonaceous filter block element has a k-value of between about 0.03 to about 0.05.  
     
     
         13 . A compound filter cartridge as recited in  claim 7 , further comprising a cage positioned within said carbonaceous filter element void and surrounding said selectively permeable fiber bundle.  
     
     
         14 . A compound filter cartridge for filtering fluids comprising: 
 a) carbonaceous filter element surrounding a void, said carbonaceous filter element having a fluid entry port located proximal to an outer portion of said carbonaceous filter element;    b) a cage positioned in said carbonaceous filter element void;    c) a selectively permeable fiber bundle positioned in said cage for receiving fluid passing through said carbonaceous filter element into said carbonaceous filter element void, said fiber bundle comprising a plurality of hollow, microporous fibers each having a first open end and a second open end, at least said first open-end being potted in a sealing compound, anterior to said cage and said carbonaceous filter element, such that said first open end is exposed on an outer end face of said sealing compound body permitting fluid entering said hollow, microporous fibers to exit through said outer end face of said sealing compound body; and    wherein said cage has sufficient openwork such that more than about  40 % of the surface area of said selectively permeable fiber bundle is in direct contact with fluid when fluid fills said carbonaceous filter element void.    
     
     
         15 . A compound filter cartridge as recited in  claim 14  wherein the pores of said hollow, microporous fibers have a maximum dimension of about 0.2 microns or less.  
     
     
         16 . A compound filter cartridge as recited in  claim 14  wherein the pores in the fibers form tortuous, interconnected channels leading from one surface of the fiber to the other.  
     
     
         17 . A compound filter cartridge as recited in  claim 14  wherein the pores permit the flow of gases and vapors but block passage of bacteria and sub-micron particles and solutes.  
     
     
         18 . A compound filter cartridge as recited in  claim 14  wherein the sealing compound body is selected from the group consisting of epoxy, polyurethane, polyethylene and polypropylene.  
     
     
         19 . A compound filter cartridge as recited in  claim 14 , wherein said carbonaceous filter block element is defined at least in part by an extruded or molded carbon block.  
     
     
         20 . A compound filter cartridge as recited in  claim 14 , wherein more than about 40% of the surface area of said selectively permeable fiber bundle is in radial-flow contact with fluid when said carbonaceous filter element void is filled with fluid.  
     
     
         21 . A compound filter cartridge as recited in  claim 14 , wherein more than about 50% of the surface area of said selectively permeable fiber bundle is in radial-flow contact with fluid when said carbonaceous filter element void is filled with fluid.  
     
     
         22 . A compound filter cartridge as recited in  claim 14 , wherein more than about 75% of the surface area of said selectively permeable fiber bundle is in radial-flow contact with fluid when said carbonaceous filter element void is filled with fluid.  
     
     
         23 . A compound filter cartridge as recited in  claim 14 , wherein the carbonaceous filter block element has a k-value of between 0.01 to about 0.10.  
     
     
         24 . A compound filter cartridge as recited in  claim 14 , wherein the carbonaceous filter block element has a k-value of between about 0.02 to about 0.07.  
     
     
         25 . A compound filter cartridge as recited in  claim 14 , wherein the carbonaceous filter block element has a k-value of between about 0.03 to about 0.05.  
     
     
         26 . A compound filter cartridge as recited in  claim 14 , further comprising a cage positioned within said carbonaceous filter element void and surrounding said selectively permeable fiber bundle.  
     
     
         27 . A compound filter cartridge as recited in  claim 14 , further comprising a pre-filter layer covering the outer surface of said carbonaceous filter element.  
     
     
         28 . A compound filter cartridge for filtering fluids comprising: 
 a) carbonaceous filter element surrounding a void approximately concentric with a central axis of said carbonaceous filter element, said carbonaceous filter element having a fluid entry port located proximal to an outer portion of said carbonaceous filter element;    b) a perforated jacket positioned in said carbonaceous filter element void in a manner approximately con centric with s aid central axis of said carbonaceous filter element;    c) a selectively permeable fiber bundle positioned in said perforated jacket for receiving fluid passing through said carbonaceous filter element into said carbonaceous filter element void, said fiber bundle comprising a plurality of hollow, microporous fibers each having a first open end and a second open end, at least said first open-end being potted in a sealing compound such that said first open end is exposed on an outer end face of said sealing compound body permitting fluid entering said hollow, microporous fibers to exit through said outer end face of said sealing compound body; and    wherein said perforated jacket has sufficient perforations such that more than about 40% of the surface area of said selectively permeable fiber bundle is in direct contact with fluid when fluid fills said carbonaceous filter element void. A filtration device as recited in  claim 25 , wherein said filter element is defined at least in part by an extruded carbon block.    
     
     
         29 . A compound filter cartridge as recited in  claim 28 , wherein the carbonaceous filter block element has a k-value of between 0.01 to about 0.10.  
     
     
         30 . A compound filter cartridge as recited in  claim 28 , wherein the carbonaceous filter block element has a k-value of between about 0.02 to about 0.07.  
     
     
         31 . A compound filter cartridge as recited in  claim 28 , wherein the carbonaceous filter block element has a k-value of between about 0.03 to about 0.05.  
     
     
         32 . A compound filter cartridge as recited in  claim 28 , wherein more than about 50% of the surface area of said selectively permeable fiber bundle is in radial-flow contact with fluid when said carbonaceous filter element void is filled with fluid.  
     
     
         33 . A compound filter cartridge as recited in  claim 28 , wherein more than about 75% of the surface area of said selectively permeable fiber bundle is in radial-flow contact with fluid when said carbonaceous filter element void is filled with fluid.  
     
     
         34 . A compound filter cartridge for filtering fluids comprising: 
 a) a pre-filter element for filtering course particulates surrounding a void, said pre-filter element having a fluid entry port located proximal to an outer portion of said pre-filter element;    b) a carbonaceous filter element positioned in said pre-filter element void, said carbonaceous filter element surrounding a carbonaceous filter element void;    c) a selectively permeable fiber bundle positioned in said carbonaceous filter element void for receiving fluid passing through said carbonaceous filter element into said carbonaceous filter element void, said fiber bundle comprising a plurality of hollow, microporous fibers each having a first open end and a second open end, wherein said first and second open-end are potted in a sealing compound in such a manner that said first open end and said second open end of each of said hollow fibers are exposed on an outer end face of said sealing compound body permitting fluid entering said hollow, microporous fibers to exit through said outer end face of said sealing compound body.    
     
     
         35 . A compound filter cartridge as recited in  claim 34  further comprising a cage positioned within said carbonaceous filter element void and surrounding said selectively permeable fiber bundle.  
     
     
         36 . A compound filter cartridge for filtering fluids comprising: 
 a) carbonaceous filter block element surrounding a void, said carbonaceous filter element having a fluid entry port located proximal to an outer portion of said carbonaceous filter element;    b) a selectively permeable fiber bundle positioned in said carbonaceous filter element void for receiving fluid passing through said carbonaceous filter element into said carbonaceous filter element void, said fiber bundle comprising a plurality of hollow, microporous fibers each having a first open end and a second open end, wherein said first and second open-end are potted in a sealing compound such that said first open end and said second open end of each of said hollow fibers are exposed on an outer end face of said sealing compound body permitting fluid entering said hollow, microporous fibers to exit through said outer end face of said sealing compound body; and    wherein the k-value of the carbonaceous filter block element is between about 0.01 to 0.10.    
     
     
         37 . A compound filter cartridge as recited in  claim 36  wherein the pores of said hollow, microporous fibers have a maximum dimension of about 0.2 microns or less.  
     
     
         38 . A compound filter cartridge as recited in  claim 36  wherein the pores in the hollow, microporous fibers form tortuous, interconnected channels leading from one surface of the fiber to the other.  
     
     
         39 . A compound filter cartridge as recited in  claim 36  wherein the pores permit the flow of fluids but block passage of bacteria and sub-micron particles and solutes.  
     
     
         40 . A compound filter cartridge as recited in  claim 36  wherein the sealing compound body is comprised of epoxy.  
     
     
         41 . A compound filter cartridge as recited in  claim 36 , wherein said carbonaceous filter block element is defined at least in part by an extruded or molded carbon block.  
     
     
         42 . A compound filter cartridge as recited in  claim 36 , wherein said carbonaceous filter block element is defined at least in part by a wet-felted structure.  
     
     
         43 . A compound filter cartridge as recited in  claim 36 , wherein said carbonaceous filter block element is defined at least in part by a dry-felted structure.  
     
     
         44 . A compound filter cartridge as recited in  claim 36 , wherein more than about 40% of the surface area of said selectively permeable fiber bundle is in radial-flow contact with fluid when said carbonaceous filter element void is filled with fluid.  
     
     
         45 . A compound filter cartridge as recited in  claim 36 , wherein more than about 50% of the surface area of said selectively permeable fiber bundle is in radial-flow contact with fluid when said carbonaceous filter element void is filled with fluid.  
     
     
         46 . A compound filter cartridge as recited in  claim 36 , wherein more than about 75% of the surface area of said selectively permeable fiber bundle is in radial-flow contact with fluid when said carbonaceous filter element void is filled with fluid.  
     
     
         47 . A compound filter cartridge as recited in  claim 36 , wherein the carbonaceous filter block element has a k-value of between about 0.02 to about 0.07.  
     
     
         48 . A compound filter cartridge as recited in  claim 36 , wherein the carbonaceous filter block element has a k-value of between about 0.03 to about 0.05.  
     
     
         49 . A compound filter cartridge as recited in  claim 36 , further comprising a cage positioned within said carbonaceous filter element void and surrounding said selectively permeable fiber bundle.