WO2024167574A1

WO2024167574A1 - Reverse osmosis pre-filter with scale reduction

Info

Publication number: WO2024167574A1
Application number: PCT/US2023/084257
Authority: WO
Inventors: Joshua Drew WALES
Original assignee: Delta Faucet Company
Priority date: 2023-02-10
Filing date: 2023-12-15
Publication date: 2024-08-15

Abstract

The present invention relates generally to a water treatment system and, more particularly, to a water treatment system including a reverse osmosis device and an upstream pre-filter to reduce the buildup of hard water scale. Water treatment systems including reverse osmosis devices are known in the art. There is a desire to protect such reverse osmosis devices from hard water scale buildup, specifically calcium carbonate scale which may be difficult to remove and be a limiting factor on the life and/or efficiency of such reverse osmosis devices. Additionally, there is a desire to deter biological growth (e.g., biofilm) in reverse osmosis devices which presents another potential for undesired clogging.

Description

REVERSE OSMOSIS PRE-FILTER WITH SCALE REDUCTION

Cross-Reference to Related Application

[0001] The present application claims priority to U.S. Provisional Patent Application Serial No. 63/484,478, filed February 10, 2023, the disclosure of which is expressly incorporated herein by reference.

Background and Summary⁷ of the Disclosure

[0002] The present invention relates generally to a water treatment system and. more particularly, to a water treatment system including a reverse osmosis device and an upstream pre-filter to reduce the buildup of hard water scale.

[0003] Water treatment systems including reverse osmosis devices are known in the art. There is a desire to protect such reverse osmosis devices from hard w ater scale buildup, specifically calcium carbonate scale which may be difficult to remove and be a limiting factor on the life and/or efficiency of such reverse osmosis devices. Additionally, there is a desire to deter biological growth (e.g., biofilm) in reverse osmosis devices which presents another potential for undesired clogging.

[0004] According to an illustrative embodiment of the present disclosure, a water treatment system includes a reverse osmosis device, and a pre-filter fluidly coupled to the reverse osmosis device. The pre-filter includes a filter housing and process media received within the filter housing. The process media illustratively includes copper zinc redox media.

[0005] According to another illustrative embodiment of the present disclosure, a water treatment system includes a reverse osmosis device, and a pre-filter fluidly coupled to the reverse osmosis device. The pre-filter includes a filter housing, a copper zinc redox media received within the filter housing, and a carbon media received within the filter housing in fluid communication with the copper zinc redox media. The copper zinc redox media illustratively comprises a kinetic degradation fluxion process media.

[0006] According to a further illustrative embodiment of the present disclosure, a water treatment system includes a filter housing, a reverse osmosis device received within the filter housing, and a pre-filter received within the filter housing and fluidly coupled to the reverse osmosis device. The pre-filter includes a copper zinc redox media, and a carbon media received in fluid communication with the copper zinc redox media.

[0007] According to another illustrative embodiment of the present disclosure, a prefilter for a reverse osmosis water treatment system includes a filter housing defining a chamber, and a copper zinc redox media received within the chamber of the filter housing. An inlet and an outlet in fluid communication with the filter housing, the copper zinc redoz media positioned intermediate the inlet and the outlet. An inlet flow deflector is positioned intermediate the inlet and the copper zinc redox media.

[0008] Additional features and advantages of the present invention will become apparent of those skilled in the art upon consideration of the following detailed description of the illustrative embodiment exemplifying the best mode of carrying out the invention as presently perceived.

Brief Description of the Drawings

[0009] The detailed description of the drawings particularly refers to the accompanying figures in which:

[0010] FIG. 1 is a diagrammatic view of an illustrative water treatment system of the present disclosure;

[0011] FIG. 2 is a side elevational view, with partial cut-aways, of an illustrative prefilter of the water treatment system of FIG. 1;

[0012] FIG. 3 is a diagrammatic view of another illustrative water treatment system of the present disclosure;

[0013] FIG. 4 is a schematic view of an illustrative filter of the water treatment system of FIG. 3;

[0014] FIG. 5 is a side elevational view of an further illustrative pre-filter of the water treatment system of FIG. 1, with the pre-filter shown in a shipment mode;

[0015] FIG. 6 is an exploded perspective view of the pre-filter of FIG. 5;

[0016] FIG. 7 is a cross-sectional view taken along line 7-7 of FIG. 5; and

[0017] FIG. 8 is a cross-sectional view similar to FIG. 7, with the pre-filter shown in an operating mode. Detailed Description of the Draw ings

[0018] For the purposes of promoting and understanding the principles of the present disclosure, reference will now be made to the embodiments illustrated in the drawings, which are described herein. The embodiments disclosed herein are not intended to be exhaustive or to limit the invention to the precise form disclosed. Rather, the embodiments are chosen and described so that others skilled in the art may utilize their teachings. Therefore, no limitation of the scope of the claimed invention is thereby intended. The present invention includes any alterations and further modifications of the illustrated devices and described methods and further applications of principles in the invention which would normally occur to one skilled in the art to which the invention relates.

[0019] With reference initially to FIGS. 1 and 2, an illustrative water treatment system 10 includes a w ater source 12 in fluid communication with an inlet 14 of an anti-scale pre-filter 16. The water source 12 may be a conventional tap water source, such as a cold water valve stop. An outlet 18 of the pre-filter 16 is fluidly coupled to an inlet 20 of a reverse osmosis (RO) device 22. The reverse osmosis device 22 may be of conventional design and is configured to provide treated water from a treated water outlet 24 to a fluid delivery device, such as a conventional faucet 26 including a dispensing outlet 28.

[0020] Illustratively, the reverse osmosis device 22 includes a reverse osmosis (RO) filter membrane 30. As is known, the illustrative filter membrane 30 is received within a housing 32 and includes a feed or concentrate side 34 (sometimes called a dirty side) and a permeate or purified side 36 (sometimes called a clean side). The concentrate side 34 of the filter membrane 30 is fluidly coupled to a waste drain 38 via a wastewater outlet 40. A flow restrictor 42 may be fluidly coupled intermediate the wastewater outlet 40 of the reverse osmosis device 22 and the waste drain 38. In certain illustrative embodiments, the flow restrictor 42 may form part of the reverse osmosis device 22.

[0021] The filter membrane 30 of the reverse osmosis device 22 may be of conventional design and of the type commercially available. The reverse osmosis device 22 may be a high efficiency system (e.g., 1: 1 pure water to w aste water ratio or better), w hich due to its high efficiency multiplies the hard water concentration (e g., a 1: 1 system doubles the concentration, a 2: 1 system triples the concentration, etc.). Also, for tankless reverse osmosis devices, the impact on the user of decreased flow rate caused by calcium carbonate scale may be more dramatic because lack of a tank flow rate through the RO membrane is directly equal to flow rate out of the faucet 26 as experienced by the user at the outlet 28. An illustrative reverse osmosis device is detailed in PCT International Patent Application No. PCT/US23/26646, filed June 29. 2023, the disclosure of which is expressly incorporated herein by reference.

[0022] With reference to FIG. 2. the pre-filter 16 illustratively includes a filter housing 44 defining a chamber 46 extending between the inlet 14 and the outlet 18. Illustratively, a first fluid coupler 48 (e.g., a 3/8 inch quick connect coupler) may be received within the inlet 14, and a second fluid coupler 50 (e.g., a 3/8 inch quick connect coupler) may be received within the outlet 18. An anti-scale media 52 is illustratively received within the chamber 46 of the filter housing 44. Upstream and downstream filter membranes 54a and 54b may assist in retaining the media 52 within the filter housing 44. Illustratively, the filter membranes 54a and 54b may be a mesh formed of a polymer or a metal (e.g., stainless steel).

[0023] The anti-scale media 52 illustratively includes a copper zinc redox media. In one illustrative embodiment, the anti-scale media 52 is a kinetic degradation fluxion process media, such as kinetic degradation fluxion (KDF) 55 or equivalent. In such an illustrative embodiment, copper granules comprise between 48% and 52% of the media, and zine granules comprising between 48% to 52% of the media. In another illustrative embodiment, the anti-scale media 52 is a kinetic degradation fluxion process media, such as kinetic degradation fluxion (KDF) 85 or equivalent. In such an illustrative embodiment, copper granules comprise between 83% to 87% of the media, and zinc granules comprise between 13% to 17% of the media. A carbon media 56 may also be provided in fluid communication with the anti-scale media 52. Illustratively, the anti-scale media 52 may be positioned upstream from the carbon media 56 to protect it. In alternative embodiments, the anti-scale media 52 may be positioned downstream from the carbon media 56. However, in the illustrative embodiments the anti-scale media 52 and the carbon media 56 are positioned upstream from the reverse osmosis device 22. The carbon media 56 may be positioned within the filter housing 44 or in spaced relation thereto.

[0024] In an illustrative embodiment, approximately 200 grams of anti-scale media 52 may be received within the filter housing 44. The filter housing 44 illustratively has a diameter of 2 inches, and a length of 4 inches. The estimated life of the anti-scale media 52 is two years (illustratively at least as long as the RO filter membrane 30). In an illustrative embodiment, a carbon volatile organic compound (VOC) filter (not shown) may be positioned downstream from the reverse osmosis device 22. The VOC filter may be of conventional design.

[0025] With reference to FIGS. 3 and 4, a further illustrative embodiment water treatment system 110 is shown. The water treatment system 110 includes many similar elements as the water treatment system 10 detailed above, wherein similar elements are identified with like reference numbers.

[0026] The w ater treatment system 110 illustratively includes a filter system 112 having a filter housing 1 14. Illustratively, the filter housing 114 receives an annular antiscale pre-filter 116, an annular sediment filter layer 118, an annular carbon pre-filter 120 and a reverse osmosis (RO) device 122. The filter housing 114 illustratively includes a chamber 124 in fluid communication with an inlet 126 and an outlet 128. In the illustrative embodiment shown in FIG. 4. the inlet 126 and the outlet 128 are coaxially aligned. More particularly, the inlet 126 illustratively concentrically surrounds the outlet 128.

[0027] With further reference to FIG. 4, an outer portion 130 of the chamber 124 receives the anti-scale pre-filter 116 including the anti-scale media 52. The carbon pre-filter 120, including the carbon media 56, is positioned in the outer portion 130 of the chamber 124 downstream from the sediment filter layer 118. The anti-scale pre-filter 116 may be positioned upstream or downstream from the sediment filter layer 118 and the carbon prefilter 120. An inner portion 132 of the chamber 124 is illustratively position radially inwardly from the outer portion 130 of the chamber 124 and receives the reverse osmosis device 122. Illustratively, the reverse osmosis device 122 includes a spiral wound filter membrane 134. Water flow through the w ater treatment system 110 is illustratively shown by arrows 136 in FIG. 4.

[0028] The filter housing 114 illustratively has a diameter of 5 inches and a length of 12 inches. A handle (not shown) may be supported on one or both ends of the filter housing 114.

[0029] The anti-scale media 52 is known to remove chlorine which may increase biofilm formation on the carbon pre-filter 120. However, incorporating the anti-scale media 52 in fluid communication with the carbon pre-filter 120 is configured to deter biofilm growth thereon during stagnation. More particularly, chlorine is removed from the water before it reaches the reverse osmosis device 122 (since it is susceptible to chlorine damage), which may tend to cause the formation of biofilm. Adding the anti-scale media 52 in the same filter housing 114 as the reverse osmosis device 22 can help stop biofilm formation on the RO filter membrane 134 during stagnation. In other words, the synergy' of having the anti-scale media 52 with the reverse osmosis membrane 134 in the same filter housing 114 is configured to help fight the formation of biofilm.

[0030] More particularly, it is illustratively beneficial to have the anti-scale media 52 in the same filter housing 114 as the carbon pre-filter 120 and sediment filter layer 118 to prevent biofilm growth on them since chlorine is removed by the carbon. For example, in stagnation the anti-scale media 52 can help fight the formation of biofilm on the other components within the housing 114, including the carbon pre-filter 120, the sediment filter layer 118 and the reverse osmosis device 122.

[0031] With reference to FIGS. 5-8, a further illustrative anti-scale pre-filter 216 is shown as including a housing 244 defining a chamber 246 extending between a first or proximal end 243 and a second or distal end 245. The chamber 246 is in fluid communication with the inlet 14 and the outlet 18. In the illustrative embodiment, the inlet 14 and the outlet 18 are axially aligned along a longitudinal axis 247 of the housing 244. It should be appreciated that positions of the inlet 14 and the outlet 18 could vary. For example, the inlet 14 and the outlet 18 could be reversed from the position shown.

[0032] Illustratively, a first or inlet fluid coupler 248 is received within the inlet 14, and a second or outlet fluid coupler 250 is received within the outlet 18. Both the first fluid coupler 248 and the second fluid coupler 250 may be a conventional quick-connect fitting, such as a John Guest fitting available from Reliance Worldwide Corporation of Atlanta, Georgia USA.

[0033] The housing 244 is illustratively formed of a polymer and includes a cylindrical side wall 252 extending axially from an end wall 254. Illustratively, the chamber 246 has a diameter of approximately 2 inches and an axial length of approximately 4 inches. The end wall 254 defines the inlet 14. More particularly, the first fluid coupler 248 is supported by an opening 256 formed in a cylindrical projection 258 extending axially from the end wall 254. An end cap 260 is illustratively coupled to the distal end 245 of the housing 244 and defines the outlet 18. More particularly, the second fluid coupler 250 is supported by an opening 262 formed in a cylindrical projection 264 extending axially from the end cap 260. [0034] With reference to FIGS. 5 and 6, a bracket 266 may be operably coupled to the housing 244 for securing the anti-scale pre-filter 216 to a support surface, such as a wall (not shown). Illustratively, the bracket 266 includes opposing arms 268a and 268b that snap-fit over the housing 244, and an opening 270 to receive a fastener 272 (e.g., a screw) for receipt within the wall.

[0035] The anti-scale media 52 is illustratively received within the chamber 246. For clarity, only a portion of the anti-scale media 52 is shown in FIGS. 6-8. In an illustrative embodiment, the anti-scale media 52 fills approximately 80 percent of the chamber 246.

[0036] While a preferred orientation of the anti-scale filter 216 is shown in FIGS. 5-8, it should be appreciated that it may oriented in different positions. In the orientation of FIGS. 5-8, gravity causes the anti-scale media 52 to settle to a bottom of the chamber 246 (e.g.. the proximal end 243) wherein upflow of water promotes mixing of the media 52.

[0037] FIGS. 5-7 show the anti-scale pre-filter 216 in a shipment mode where first and second plugs 274 and 276 are received within the first fluid coupler 248 and the second fluid coupler 250, respectively. The plugs 274 and 276 help retain the anti-scale media 52 within the housing 244 and/or prevent oxidation of the media 52 during shipping of the antiscale pre-filter 216 and prior to installation. FIG. 8 shows the anti-scale pre-filter 216 in a use or operating mode where the plugs 274 and 276 are removed. Instead, a first or inlet fluid tube 278 and a second or outlet fluid tube 280 are received within the first fluid coupler 248 and the second fluid coupler 250, respectively. As such, the inlet fluid tube 278 and the outlet fluid tube 280 are in fluid communication with the chamber 246.

[0038] With reference to FIGS. 6-8, an inlet flow deflector 282 and an outlet flow deflector 284 are illustratively in fluid communication with the chamber 246. Illustratively, the inlet flow- deflector 282 is supported by the proximal end 243 of the housing 244, and is positioned intermediate the inlet 14 and the anti -scale media 52. Illustratively, the outlet flow deflector 284 is supported by the end cap 260 and is positioned intermediate the anti-scale media 52 and the outlet 18.

[0039] Both the inlet flow deflector 282 and the outlet flow deflector 284 include a disc shaped body 286 including an annular peripheral edge 288. The flow deflectors 282 and 284 each include a solid center portion 290, and an outer portion 292 extending radially outw ardly from the center portion 290. The outer portion 292 includes a plurality of circumferentially spaced openings 294. Filter screens or membranes (not show n) may cooperate with the flow deflectors 282 and 284 to assist in retaining the anti-scale media 52 within the filter housing 244.

[0040] In an illustrative operation of the anti-scale filter 216, water flows from the inlet fluid tube 278 into the first fluid coupler 248 (as shown by arrow s 296 in FIG. 8). The inlet flow deflector 282 disperses water flow entering the chamber 246 to reduce channeling of water flow⁷ through the anti-scale media 52. Dispersing of the water by the inlet flow deflector 282 also helps with mixing of the anti-scale media 52 to prevent clumping. More particularly, axial water flow' from the inlet fluid tube 278 though the inlet 14 impacts the center portion 290 of the inlet flow' deflector 282, causing the w ater to deflect radially outwardly through the openings 294.

[0041] Next, the water flows though the anti-scale media 52 within the chamber 246 towards the outlet 18 (as shown by arrows 298 in FIG. 8). Water is dispersed by the outlet flow deflector 284 and flows through the second fluid coupler 250 to the outlet fluid tube 280 (as shown by arrows 300 in FIG. 8). More particularly, water flows through the openings 294 of the outlet flow deflector 284 and is directed to the outlet fluid tube 280 via the outlet 18. As noted above, a screen or membrane may be included within the chamber 246 to help prevent the anti-scale media 52 from exiting the housing 244.

[0042] The outlet flow deflector 284 is useful in providing an anti-channeling benefit in certain orientations, thereby making the anti-scale filter 216 reversible, and in case of back washing. However, depending upon installation in the water treatment system 10, 110 and operation thereof, the outlet flow deflector 284 is optional.

[0043] Although the invention has been described in detail with reference to certain preferred embodiments, variations and modifications exist within the spirit and scope of the invention as described and defined in the following claims.

Claims

CLAIMS:

1. A water treatment system comprising: a reverse osmosis device; and a pre-filter fluidly coupled to the reverse osmosis device, the pre-filter including a filter housing and a process media received within the filter housing, the process media including copper zinc redox media.

2. The water treatment system of claim 1 , wherein the copper zinc redox media includes between 48% and 52% copper granules, and between 48% and 52% zinc granules.

3. The water treatment system of claim 1, wherein the copper zinc redox media includes between 83% and 87% copper granules, and between 13% and 17% zinc granules.

4. The water treatment system of claim 1, further comprising carbon media received in fluid communication with the copper zinc redox media.

5. The water treatment system of claim 4, wherein the copper zinc redox media and the carbon media are received within the filter housing.

6. The water treatment system of claim 5, wherein the copper zinc redox media, the carbon media and the reverse osmosis device are received within the filter housing.

7. The water treatment system of claim 4, wherein the copper zinc redox media and the reverse osmosis device are positioned within the filter housing, and the carbon media is positioned in spaced relation to the filter housing.

8. The ater treatment system of claim 1, wherein the filter housing includes an axial flow inlet to the copper zinc redox media, a radial flow passageway to the reverse osmosis device, and an axial flow outlet.

9. The water treatment system of claim 8, wherein the inlet is coaxially aligned with the outlet.

10. The water treatment system of claim 1, wherein approximately 200 grams of the copper zinc redox media is received within the filter housing.

11. The water treatment system of claim 1, further comprising a filter membrane received within the filter housing to retain the copper zinc redox media.

12. The water treatment system of claim 1, further comprising: an inlet and an outlet in fluid communication with the filter housing, the copper zinc redox media positioned intermediate the inlet and the outlet; and an inlet flow deflector positioned intermediate the inlet and the copper zinc redox media.

13. The water treatment system of claim 12. wherein the inlet flow deflector includes a solid center portion, and an outer portion extending radially outwardly from the center portion and including a plurality of openings.

14. The water treatment system of claim 12. further comprising an outlet flow deflector positioned intermediate the copper zinc redox media and the outlet.

15. A water treatment system comprising: a reverse osmosis device; and a pre-filter fluidly coupled to the reverse osmosis device, the pre-filter including: a filter housing, a copper zinc redox media received within the filter housing; and a carbon media received within the filter housing in fluid communication with the copper zinc redox media.

16. The water treatment system of claim 15, wherein the copper zinc redox media includes between 48% and 52% copper granules, and between 48% and 52% zinc granules.

17. The water treatment system of claim 15, wherein the copper zinc redox media includes between 83% and 87% copper granules, and between 13% and 17% zinc granules.

18. The water treatment system of claim 15, wherein the copper zinc redox media, the carbon media and the reverse osmosis device are received within the filter housing.

19. The water treatment system of claim 18. wherein the filter housing includes an axial flow inlet to the copper zinc redox media, a radial flow passageway to the reverse osmosis device, and an axial flow outlet.

20. The water treatment system of claim 19, wherein the inlet is coaxially aligned with the outlet.

21. The water treatment system of claim 15, wherein approximately 200 grams of the copper zinc redox media is received within the filter housing.

22. The water treatment system of claim 15, further comprising a filter membrane received within the filter housing to retain the copper zinc redox media.

23. A water treatment system comprising: a filter housing; a reverse osmosis device received within the filter housing; and a pre-filter received within the filter housing and fluidly coupled to the reverse osmosis device, wherein the pre-filter includes: a copper zinc redox media; and a carbon media received in fluid communication with the copper zinc redox media.

24. The water treatment system of claim 23. wherein the copper zinc redox media includes between 48% and 52% copper granules, and between 48% and 52% zinc granules.

25. The water treatment system of claim 23, wherein the copper zinc redox media includes between 83% and 87% copper granules, and between 13% and 17% zinc granules.

26. The water treatment system of claim 23, wherein the filter housing includes an axial flow inlet to the copper zinc redox media, a radial flow passageway to the reverse osmosis device, and an axial outlet.

27. The water treatment system of claim 26, wherein the inlet is coaxially aligned with the outlet.

28. The water treatment system of claim 23, wherein approximately 200 grams of the copper zinc redox media is received within the filter housing.

29. The water treatment system of claim 23, further comprising a filter membrane received within the filter housing to retain the copper zinc redox media.

30. A pre-filter for a reverse osmosis water treatment system, the pre-filter comprising: a filter housing defining a chamber; copper zinc redox media received within the chamber of the filter housing; an inlet and an outlet in fluid communication with the filter housing, the copper zinc redox media positioned intermediate the inlet and the outlet; and an inlet flow deflector positioned intermediate the inlet and the copper zinc redox media.

31. The water treatment system of claim 30. wherein the inlet flow deflector includes a solid center portion, and an outer portion extending radially outwardly from the center portion and including a plurality of openings.

32. The water treatment system of claim 30. further comprising an outlet flow deflector positioned intermediate the copper zinc redox media and the outlet.

33. The water treatment system of claim 32, wherein the outlet flow deflector includes a solid center portion, and an outer portion extending radially outwardly from the center portion and including a plurality of openings.

34. The water treatment system of claim 30, wherein the copper zinc redox media includes between 48% and 52% copper granules, and between 48% and 52% zinc granules.

35. The water treatment system of claim 30. wherein the copper zinc redox media includes between 83% and 87% copper granules, and between 13% and 17% zinc granules.

36. The water treatment system of claim 30, further comprising carbon media received in fluid communication with the copper zinc redox media.