FIELD OF THE INVENTION

This application pertains to industrial filtration devices, and in particular, filter media for use with industrial filtration devices, such as pressure or vacuum filters (e.g., horizontal filter presses provided with a plurality of filter plates). More particularly, this application pertains to improvements to filter media which are designed to indicate wear, alert an operator of the status of the filter media, improve performance, and maximize longevity.

BACKGROUND OF THE DISCLOSURE This disclosure relates generally to the field of filtration. More particularly, the disclosure relates to methods for improving the functionality of filter media, such as filter cloths for industrial filtration devices. In particular, the disclosure relates to filter media for use within horizontal filter presses that comprise a plurality of filter plates. Additionally, the disclosure relates to improved filter media comprising a conductive element which may be insulated. The conductive element may be used as an RFID antenna or used in a live circuit to measure and/or locate wear to the filter media as will be described hereinafter.

Conventional filter media typically comprises a polymeric non-woven and/or a woven material. WO 201 1 /092376 suggests filter cloths being equipped with identifiers or means for storing cloth specific data. US 7,360,701 suggests generating a report characterizing maintenance of a serviceable item based on time reference (e.g., managing a maintenance schedule for use in maintaining beverage tap filters based on unique identification labels affixed separately to each of the beverage tap filters). The aforementioned innovations are not adequately designed to detect wear to a filter media, detect where on filter media that wear is occurring fastest, and/or detect if/when a filter media fails.

There exists a need for technologies which could improve the lifespan and wear life of filter media - in particular, filter cloths for use on plates in horizontal filter presses. There also exists a need to keep industrial filtration devices running as long and as economically practically possible between maintenance cycles in order to minimize downtime and maximize filtration production.

There also exists a need for technologies which could provide a way in which to precisely indicate exactly where areas of wear to a filter cloth are occurring, so that an operator may be able to easily and readily identify which areas of a filter cloth might need repair or refurbishment during regularly scheduled maintenance and overhaul. Information gathered through such needed technologies might be useful in predicting wear patterns and/or anticipated locations of wear within certain filtration apparatus for various types of slurries to be dewatered. Information gathered through such needed technologies might also assist filter media engineers with enhancing filter media design and developing more robust filter cloths.

OBJECTS OF THE INVENTION

It is, therefore, an object of the invention to provide an improved industrial filtration device or to improve an existing industrial filtration device by employing filter media components therein which have an increased ability for data-gathering and wear monitoring.

It is another object of the invention to increase the wear life and maximize usable lifespan of filter media components within an industrial filtration device, including a filter cloth provided to a filter plate within a stack of filter plates within a horizontal filter press. Yet another object of the invention is to prevent or minimize machine downtime and maintenance costs associated with lengthy filter cloth removal procedures, time-consuming detection procedures for identifying damaged filter cloths, and improve speeds at which those procedures are executed.

Yet another object of the invention is to enable advanced data collection which can help filtration media engineers and experts design more robust filter media and/or better select filtration media based on a number of inputs such as slurry composition, filtration cycle time, and filter settings (e.g., pressure or vacuum settings).

These and other objects of the invention will be apparent from the drawings and description herein. Although every object of the invention is believed to be attained by at least one embodiment of the invention, there is not necessarily any one embodiment of the invention that achieves all of the objects of the invention.

BRIEF SUMMARY OF THE INVENTION

Disclosed, is an improved filter media that may be used within an industrial filtration device. The filter media may comprise a filter cloth for an industrial filtration device. The filter cloth may comprise a thin porous sheet of filtering material 4 configured for dewatering slurry and further configured for separating solids from said slurry to produce filtrate. The filtering material 4 may comprise at least one of the group consisting of: non-woven material, woven material, and sintered porous material, without limitation.

The filter cloth may be characterized in the fact that the filter cloth may comprise one or more conductive elements 3. The one or more conductive elements 3 may be provided in the form of a filament or thread. The filament or thread may be comprised of electrically-insulated conductive material. In some embodiments, the insulative material may comprise an adhesive material, without limitation. The filament or thread may, for example, form a portion of at least one of the group consisting of: an RFID antenna, a series circuit, and a parallel circuit, without limitation. In some embodiments, the filament or thread may surround, be placed adjacent to, or form a portion of a pore 6 of the filter cloth 1 . The filament or thread may also operatively communicate with a module 2.

In some embodiments, the filament or thread may form a portion of an RFID antenna, or it may form a complete RFID antenna. The filter cloth 1 may be configured such that in use, when an interrogation signal is generated by an RFID reader/interrogator (i.e., receiver), the filter cloth 1 may provide a normal response signal comprising unique identifier information (e.g., a UID) back to the RFID reader/interrogator, if/when the filament or thread is undamaged.

The filter cloth 1 may be configured such that in use, if/when the RFID antenna has been damaged by wear or abrasion from slurry particles, the response signal provided by the filter cloth 1 may change from normal, may not be generated or provided by the filter cloth 1 , may not be received by the RFID reader/interrogator, and/or may not be able to be detected by the RFID reader/interrogator. The aforementioned occurrence(s) may provide an indication that repair or replacement of the filter cloth 1 is needed.

The indication that repair or replacement of the filter cloth 1 is needed may comprise any one or more of: the emission of a light signal, the emission of a sound signal, the delivery of a wireless control signal, an alarm sounding, stopping or shutting down of the industrial filtration device, a messaging signal being sent to a distributed control system (DCS), or a combination thereof, without limitation. In some embodiments, the filament or thread may form a portion of a series circuit, and the module 2 may comprise a power supply which is configured to provide current to the series circuit. The filter cloth 1 may be configured such that in use, the filter cloth 1 provides a normal response signal if or when the filament or thread is undamaged.

In the aforementioned paragraph, signals and/or other indications that repair or replacement of the filter cloth 1 is needed may be emitted from a module 2 of the affected filter cloth 1 and/or emitted from another device, such as a control unit 7 in wireless communication with the module 2. In some instances, the signals and/or other indications that repair or replacement of the filter cloth 1 is needed may be emitted from a module 2 of the affected filter cloth 1 and received by another device, such as a control unit 7.

The module 2 may be further configured such that in use, if or when the series circuit has been compromised or damaged by wear or abrasion, a change in current through the series circuit, a change in voltage across the series circuit, and/or a change in resistance across said series circuit can be recognized by the module 2; thereby providing an indication that repair or replacement of the filter cloth 1 is needed. In this regard a notification or alarm can inform an operator of a failed cloth 1 .

In some embodiments, the indication that repair or replacement of the filter cloth 1 is needed may comprise the emission of a light signal, without limitation. In some embodiments, the indication that repair or replacement of the filter cloth 1 is needed may comprise the emission of a sound signal, without limitation. In some embodiments, the indication that repair or replacement of the filter cloth 1 is needed may comprise the delivery of a wireless control signal which is configured to provide an instruction for performing a function or action (e.g., update an electronic inventory value, increase an item count in a web-based online shopping cart, automatically order from a web-based online shop or storefront, stop or shut down the industrial filtration device, etc.), without limitation. In some embodiments, the indication that repair or replacement of the filter cloth 1 is needed may comprise the sounding of an audio device or alarm, without limitation. In some embodiments, the indication that repair or replacement of the filter cloth 1 is needed may comprise recording the failure cycle count (i.e., cycle count at failure), without limitation. In some embodiments, the indication that repair or replacement of the filter cloth 1 is needed may comprise emphasizing or communicating when a cycle count of the filter cloth 1 has exceeded a replacement cycle count threshold value (e.g., using color, bolded text, sound, flashing, vibration, and other sensory indications) without limitation. In some embodiments, the indication that repair or replacement of the filter cloth 1 is needed may comprise updating and/or recording an electronic inventory value, without limitation. In some embodiments, the indication that repair or replacement of the filter cloth 1 is needed may comprise increasing an item count in a web-based online shopping cart, without limitation. In some embodiments, the indication that repair or replacement of the filter cloth 1 is needed may comprise the action of stopping or completely shutting down the industrial filtration device, without limitation.

The filament or thread may form a portion of a parallel circuit; and the module 2 may comprise a power supply which is configured to provide current to the parallel circuit. Accordingly, the filter cloth 1 may be configured such that in use, it provides a normal response signal when the parallel circuit is undamaged. The module 2 may be further configured such that in use, if the parallel circuit has been compromised or damaged by wear or abrasion, a change in current through the parallel circuit, a change in voltage across the parallel circuit, and/or a change in resistance across said parallel circuit may be recognized by the module 2; thereby providing an indication that repair or replacement of the filter cloth 1 is needed. For example, if the module 2 discovers a change in current through the parallel circuit, a change in voltage across the parallel circuit, and/or a change in resistance across said parallel circuit, an alarm signal may be produced which is configured to provide a notification that damage to the filter cloth 1 may have or actually has occurred. The indication that repair or replacement of the filter cloth 1 is needed may comprise, for example, at least one of the group consisting of: emission of a light signal, emission of a sound signal at a frequency, delivery of a wireless control signal configured to provide an electronic instruction, sounding of an audio device such as an alarm, and an action being taken such as stopping or shutting down of the industrial filtration device, without limitation.

In some embodiments, one or more conductive elements 3 of a filter cloth 1 may be bonded to the filtering material 4 using an adhesive.

In some embodiments, one or more conductive elements 3 may be provided to a back side of filtering material 4; that is, on a side of the filter cloth 1 which is not intended to directly interface with or contact slurry to be dewatered or a filter cake.

In some embodiments, one or more conductive elements 3 may be configured in the form of a sticker or decal which can be applied to and permanently bonded to the filtering material 4, without limitation.

A method for determining an operational status of a filter cloth 1 is further disclosed. The method may comprise providing a filter cloth 1 as described above, to an industrial filtration device; operating the industrial filtration device with the filter cloth 1 installed therein; and monitoring for a change in a wireless response signal provided by the filter cloth 1 (if the filament or thread forms a portion of RFID antennae) and/or monitoring for a change in current, voltage, or resistance associated with the one or more conductive elements 3 (if the filament or thread forms a portion of a parallel circuit or series circuit). The step of monitoring may be facilitated via a module 2. The method may further comprise the step of determining if wear has occurred to the filter cloth 1 by virtue of acknowledging a change in a wireless response and/or a change in current, voltage, or resistance.

According to some embodiments, the method may also comprise the step of determining which portion of or location of the filter cloth 1 experienced wear (e.g., the most wear, the least wear, or the amount of wear that has affected the filter cloth performance). According to some embodiments, the method may further comprise the step of recording information pertaining to which location of the filter cloth 1 experienced wear. According to some embodiments, the information recorded may be aggregated, and then analyzed, in order to improve the wear characteristics of the filter cloth 1 . For example, using wear information collected from a number of filter cloths 1 , a filter cloth 1 design may be changed/re-designed based upon what is learned during the step of analyzing the information aggregated. For example, areas, materials, locations, design features, and/or portions of a filter cloth which are deemed to be prone to wear, based on the aggregated information, may be re-designed to improve wear performance, without limitation.

In some embodiments, the method may involve electronically updating an inventory value, or increasing an item count in a web-based shopping cart, without limitation. This step of electronically updating an inventory value or increasing an item count in a web-based shopping cart may be taken, for example, if the step of determining if wear has occurred to the filter cloth 1 reveals that wear has, indeed, occurred to the filter cloth 1 . In some embodiments, the step of determining if wear has occurred to the filter cloth 1 may comprise the step of providing an indication that repair or replacement of the filter cloth 1 is needed. The indication that repair or replacement of the filter cloth 1 is needed may be any one or more of those already mentioned above.

Various methods for fabricating a filter cloth 1 for an industrial filtration device are also disclosed. The methods may include providing a thin porous sheet of filtering material 4 configured for dewatering slurry and further configured for separating solids from said slurry to produce filtrate; the filtering material 4 comprising at least one of the group consisting of: non-woven material, woven material, and sintered porous material. The methods may be characterized in that they further comprise the step of providing one or more conductive elements 3 in the form of a filament or thread, the filament or thread being comprised of electrically-insulated conductive material wherein the filament or thread forms a portion of at least one of the group consisting of: an RFID antenna, a series circuit, and a parallel circuit. In some embodiments, fabrication methods may comprise the step of applying the one or more conductive elements 3 to a side of the filtering material 4 using adhesive.

In some embodiments, fabrication methods may comprise the step of providing the one or more conductive elements 3 in the form of a sticker or decal which is initially separate from the filtering material 4. The step of applying the one or more conductive elements 3 to a side of the filtering material 4 using adhesive may comprise adhering the sticker or decal to the side of the filtering material 4.

In some embodiments, fabrication methods may comprise the step weaving the one or more conductive elements 3 into the filtering material 4, without limitation.

In some embodiments, fabrication methods may comprise the step laminating the one or more conductive elements 3 onto the filtering material 4, without limitation.

Various methods for fabricating smart filter media, in particular, a filter cloth for use in a horizontal filter press provided with a plurality of filter plates (and configured to detect wear), may also be inferred from this disclosure and the accompanying figures.

BRIEF SUMMARY OF THE DRAWINGS

To complement the description which is being made, and for the purpose of aiding to better understand the features of the invention, a set of drawings illustrating new filter media apparatus for industrial filtration devices is attached to the present specification as an integral part thereof, in which the following has been depicted with an illustrative and non-limiting character. It should be understood that like reference numbers used in the drawings (if any are used) may identify like components. Figure 1 shows an embodiment of a filter cloth according to the invention, wherein the filter cloth comprises an insulated conductive thread which forms an RFID antenna or a parallel circuit.

Figure 2 shows an embodiment of a filter cloth according to the invention, wherein the filter cloth comprises an insulated conductive thread which forms an RFID antenna or a series circuit. Figure 3 shows an embodiment of a filter cloth according to the invention, wherein the filter cloth comprises an insulated conductive thread which forms an RFID antenna or a series circuit.

Figure 4 shows an embodiment of a filter cloth according to the invention, wherein the filter cloth comprises an insulated conductive thread which forms an RFID antenna or a series circuit.

Figure 5 shows an embodiment of a filter cloth according to the invention, wherein the filter cloth comprises an insulated conductive thread which forms an RFID antenna or a series circuit.

Figure 6 shows an embodiment of a filter cloth according to the invention, wherein the filter cloth comprises an insulated conductive thread which forms an RFID antenna or a series circuit.

Figure 7 shows an embodiment of a filter cloth according to the invention, wherein the filter cloth comprises an insulated conductive thread which forms an RFID antenna or a parallel circuit. Figure 8 shows an embodiment of a filter cloth according to the invention, wherein the filter cloth comprises insulated conductive thread which forms multiple RFID antennae or parallel circuits. Figure 9 shows an embodiment of a filter cloth according to the invention, wherein the filter cloth comprises insulated conductive thread which forms multiple RFID antennae or parallel circuits.

Figure 10 shows an embodiment of a filter cloth according to the invention, wherein the filter cloth comprises an insulated conductive thread which forms an RFID antenna or a series circuit.

Figure 1 1 shows an embodiment of a filter cloth according to the invention, wherein the filter cloth comprises an insulated conductive thread which forms multiple RFID antennae or series circuits.

Figures 12 and 13 show embodiments of a filter cloth according to the invention, wherein the filter cloth comprises a weft of insulated conductive thread which is weaved between a warp of non-conductive thread to form a semi-metallic filter media.

Figure 14 shows a method according to some embodiments, wherein an RFID antenna is formed as an integral part of a filter cloth by weaving non-conductive thread of filtering material to and/or around an RFID antenna to secure it thereto.

Figure 15 shows a method according to some embodiments, wherein an RFID antenna is formed as an integral part of a filter cloth by laminating or bonding filtering material to an RFID antenna. Figure 16 shows a method according to some embodiments, wherein a semi- metallic filter cloth is produced by weaving non-conductive threads with conductive threads in a loom. Figure 17 shows a method of data collection and automatic reordering of filter cloths according to some embodiments.

Figure 18 shows a method of data collection and making design/operational improvements based on the data, according to some embodiments.

Figure 19 shows a system wherein multiple plants, each having multiple filters may comprise a local database configured to store data in memory regarding each filter cloth. The data in the local databases may be aggregated and stored in a larger remote database. The larger remote database may be accessible by local or remote users via a network (e.g., internet, intranet, cellular, etc.).

Figure 20 shows that a filter cloth according to embodiments of the invention may be placed on a filter plate. The filter plate may comprise a plate type, plate number, plate location within a filter, accompanying filter number, etc. Moreover, data (e.g., unique identifier information) associated with a filter cloth may comprise information regarding which side of a plate 121 the filter cloth is installed (e.g., a head side 122 of the plate, or a tail side 123 of the plate).

Figures 21 -23 suggest that data (e.g., unique identifier information) associated with a filter cloth may comprise information regarding or corresponding to portion(s) of the filter cloth 1 which are or might be damaged.

In the following, the invention will be described in more detail with reference to drawings in conjunction with exemplary embodiments. DETAILED DESCRIPTION

While the present invention has been described herein using exemplary embodiments of improved filtration media for an industrial filtration device, it should be understood that numerous variations and adaptations will be apparent to those of ordinary skill in the field from the teachings provided herein. The detailed embodiments shown and described in the text and figures (e.g., filter cloth for a filter plate) should not be construed as limiting in scope; rather, the provided embodiments should be considered to be exemplary in nature. Accordingly, this invention is only limited by the appended claims.

The inventors have recognized a novel and heretofore unappreciated method of forming filter media for industrial filtration apparatus, and utilizing the filter media in the industrial filtration apparatus. In particular, preferred embodiments of the method generally involve manufacturing or providing filter media which can assist a user determine a functional condition of the filter media. In some embodiments, the filter media may determine an area of suspected wear on a filter cloth. In some embodiments, the filter media may determine which filter cloth of a number of filter cloths in an industrial filtration apparatus needs to be mended or replaced.

In some embodiments, the filter media may be provided with one or more conductive elements (e.g., one or more electrically insulated filaments or insulated conductive threads). The one or more conductive elements may be woven into a woven cloth filter media. Alternatively, the one or more conductive elements may be embedded within a non-woven filter cloth media (e.g., needled felt), sandwiched between filtration materials, laminated, or bonded to filtration material. In some embodiments, the one or more conductive elements may be provided as an RFID antenna or as RFID antennae which can be woven into a filter cloth, or otherwise attached to filtration material to form a filter cloth (e.g., affixed by an adhesive layer or bonding material). The one or more conductive elements may be strategically placed in areas of the filter media which are prone to wear. The one or more conductive elements may be operatively connected to a module. The module may comprise an onboard power supply and CPU. The CPU may comprise a programmable logic controller, memory, and executable software. The executable software may be uploaded to the CPU by a data port or via a wireless upload/download.

If a portion of the filter media experiences wear adjacent an area in which the one or more conductive elements are located, a portion or portions of the one or more conductive elements may be compromised. The module may sense or detect that one or more of the one or more conductive elements may be compromised, based on a change or changes in voltage, amperage, or resistance within the compromised or affected conductive element(s). Upon sensing or detecting that one or more of the one or more conductive elements may be compromised or affected, the module may, by virtue of the executable software and programmable logic controller, relay an alarm to an operator. The alarm may comprise an emission of light(s), sound(s), data, instructions to perform a specified task, and/or the actual performance of that task (e.g., shut down the industrial filtration device which comprises the compromised or affected conductive element(s)).

In some embodiments, the one or more conductive elements may be provided in the form of filament wire, which may be adequately configured to be spooled into a cloth looming device and woven into any type of textile filter cloth, in any type of predetermined pattern or configuration. Wearing of the filament wire within filter media may advantageously allow an end user to not only track cycle counts and wear patterns on filter media. Different models and sizes of filter media may be manufactured and retrofitted into many different makes and models of industrial filtration devices, regardless of brand or manufacturer, and regardless of whether or not the industrial filtration devices are new or currently in operation.

In some embodiments, the one or more conductive elements may be provided in the form of one or more RFID antennae, so as to enable the filter media to doubly function as both a filtering element surface and as an RFID tag. The one or more RFID antennae may be passive or active and may be energized by a local power supply (e.g., an onboard battery). The one or more RFID antennae provided to the filter media may each have unique identifiers. In some embodiments, if more than one RFID antennae are provided within the same piece of filter media (i.e., provided to the same filter cloth), then each RFID antenna within that piece of filter media may share a common or similar unique identifier. In some embodiments, if more than one RFID antenna is provided within the same filter media, the RFID antennae may have different unique identifiers to indicate and/or isolate areas or precise instances of filter media wear.

The one or more RFID antennae provided to a filter media may respond to an interrogation signal generated from an RFID interrogator, with a response signal containing unique identifier information pertaining to the one or more RFID antennae. While the filter media is in operation within an industrial filtration device, when a particular RFID response signal is no longer received, an alarm may be tripped to notify an operator of the industrial filtration device that filter media within the industrial filtration device may be damaged because one or more conductive elements provided to the filter media have been compromised or otherwise affected in some way by wear. Similarly, while the filter media is in operation within an industrial filtration device, if a particular RFID response signal weakens below a predetermined signal strength threshold, or, if a particular RFID response signal mutates from an original baseline signal, an alarm may be tripped to notify an operator that filter media within the industrial filtration device may be damaged because one or more conductive elements provided to the filter media have been compromised or affected. The alarm may comprise an emission of light(s), sound(s), data, instructions to perform a specified task, and/or the actual performance of that task (e.g., shut down the industrial filtration device which comprises the compromised or affected conductive element(s)). Practicing the method may allow quicker cloth change-outs and longer operational life. Embodiments aim to facilitate operation and maintenance of industrial filtration devices.

Although it is acknowledged that the design, composition, order, and structure of the inventive apparatus and processes may be altered from what is precisely described herein, the inventors have discovered a reliable and reproducible process for producing improved filter media for industrial filtration devices. Several exemplary embodiments will be described hereinafter in greater detail.

Turning to FIG. 1 , a module 2 may be operatively connected to and/or may operatively communicate with one or more conductive elements 3. As shown, the one or more conductive elements 3 may be provided to filter media 1 (e.g., a filter cloth), and may form an integral portion thereof. The module 2 may also be provided to the filter media 1 and may also form an integral portion thereof.

As shown, the one or more conductive elements 3 may comprise an electrically- insulated metallic filament or thread. The filament or thread may be provided in a parallel circuit, wherein the module 2 may provide a voltage or current thereto. The module 2 may monitor changes to the parallel circuit (e.g., to the voltage or current) over time. If too much wear occurs at a particular location of the filter media 1 and a portion of the parallel circuit within the affected region of the filter media 1 becomes damaged due to abrasive wear, then the voltage, current, or a resistance within the parallel circuit may change. Upon detecting such a change in voltage, current, or resistance, the module 2 may provide an indication that replacement or repair to the filter media 1 is necessary. Provision of the indication may be accomplished through local signaling (e.g., via the emission of sound or light from a diode provided to the module), or by remotely wirelessly signaling a separate control unit 7 (e.g., via the emission of a wireless alarm signal or control instruction emitted from the module 2). For example, in some instances, the module 2 may comprise an onboard wireless communications device (e.g., an active RFID tag) which is configured to communicate with a separate control unit 7 via a suitable wireless protocol. The onboard wireless communications device may intermittently or continuously generate signals relating to an operational status of the filter media 1 (e.g., “normal”,“worn”;“green” (i.e., good),“red” (i.e., bad); or the like, without limitation).

At the point in time where one or more conductive elements experience enough wear to affect a response signal or detect a measurable change in voltage, current, or resistance therein, the module 2 of the affected filter media 1 may emit a signal (via an active RFID within the module 2) indicating the same to a control unit 7. The signal may be machine readable or interpreted, and is preferably externally receivable. Of course, various forms of communication may be used to emit signals from the module 2 (e.g., 2400-2483.5 MFIz Bluetooth, 2.4 GFIz or 5 GFIz Wi-Fi, low-rate WPAN (LR-WPAN) 900 MHz/868 MHz/2.4 GHz ZigBee®) to a control unit 7 as depicted in FIG. 20. The data may be recorded, stored, processed, and/or aggregated in a local 140 or remote 160 database(s) via a network 150 (see FIG. 19).

In some instances, the data recorded, stored, processed, and/or aggregated may include information pertaining to: where (on/within the filter media 1 ) wear might have occurred, where (on/within the filter media 1 ) wear occurred the most, and/or where wear did not noticeably occur, without limitation. For example, the data may include location information regarding which portion(s) of filter media 1 have been worn (e.g., upper left corner, upper center area, upper right corner, middle left side area, center area, upper right side area, lower left corner, lower center area, lower right corner (refer to FIG. 21 ), or, the data may include information regarding which locations of the filter media 1 might comprise a worn or broken electrically- conductive element, such as a broken filament or thread, without limitation. Alternatively, the module 2 may comprise an optional battery and circuitry of an active RFID tag, wherein the one or more conductive elements 3 may comprise a filament or thread which forms a portion of an RFID antenna, or entirety forms an RFID antenna. An active RFID response signal may be generated or provided by the RFID antenna, wherein if there is a change in the RFID response signal due to wearing out of the one or more conductive elements 3, an indication that replacement or repair to the filter media 1 is necessary may be relayed to a control unit 7. Alternatively, the module 2 may comprise a passive RFID tag and a mechanism which terminates, alters, or disrupts the transmission of passive response signals from the passive RFID tag in response to interrogation signals if/when there is a change in the RFID response signal due to wearing out of the one or more conductive elements 3. In this regard, a control unit 7 may be notified that the filter media 1 has been affected by wear when the passive RFID response signal is no longer being generated or received by an interrogator/receiver (or has changed in some way).

FIG. 2 shows an embodiment wherein the filter media 1 comprises one or more conductive elements 3 forming a series circuit, rather than a parallel circuit. For example, as shown, the series circuit may comprise a single loop of insulated conductive wire, which may be energized with current. The conductive wire may be provided as a thin filament or thread. The thin filament or thread may be used as a weft/woof (e.g., in a weave pattern of a filter cloth comprising a weft). In the event there is wearing out or breakage of the one or more conductive elements 3, a change in voltage, current, or resistance may be detected by the module 2 and an indication that the filter media 1 is damaged may be relayed. The indication may be any of those described above, without limitation.

As previously discussed, the module 2 (as with any module 2 described herein) may comprise a battery or circuitry of an active RFID tag, and the one or more conductive elements 3 may comprise a filament or thread which forms a portion of, or an entirety of an RFID antenna. A passive or active RFID response signal may be generated or provided by the RFID antenna formed by the one or more conductive elements 3. If there is a change in the RFID response signal due to wearing out of the one or more conductive elements 3 (e.g., failure to generate a signal, signal change, signal interference), then an indication that replacement or repair to the filter media 1 is necessary may be relayed. T urning now to FIG. 3, an alternative embodiment of that shown in FIG. 2 is shown. Flowever, FIG. 3 namely suggests an embodiment wherein the one or more conductive elements 3 are provided with more turns of weft/woof, within the warp of the woven structure of filter media 1 , than the number of turns shown for FIG. 2.

Turning now to FIG. 4, filter media 1 according to the invention may comprise an insulated conductive filament or thread which forms a portion or the entirety of a passive RFID antenna (or a series circuit). In the event insulated conductive filament or thread is used to form a portion or the entirety of a passive RFID antenna, an interrogation signal may be provided to the one or more conductive elements 3, and a response signal comprising a UID (e.g., a UID which is unique to that specific filter media 1 ) may be generated and emitted.

Turning now to FIG. 5, filter media 1 such as the type described for and shown in FIG. 4, may comprise a module 2 which is centrally or internally-placed, relative to outer surfaces and/or edges of the filter media 1 . Whereas FIG. 4 suggests filter media 4 comprising a peripherally-located, circumferentially-arranged module 2, FIG. 5 shows a module 2 embedded within or positioned radially inwardly from outer edges of the filter media 1 , without limitation.

Turning now to FIG. 6, filter media 1 may comprise a serpentine/sinusoidal RFID antenna pattern or series circuit pattern, alternative to what is shown in FIGS. 2 and 3, without limitation.

Turning now to FIG. 7, filter media 1 may comprise an RFID antenna pattern or parallel circuit pattern, alternative to what is shown in FIG. 1 , without limitation. Turning now to FIG. 8, in some embodiments, filter media within the scope of this invention may comprise multiple circuits, multiple RFID antennae, or a combination thereof, without limitation. For example, as shown in FIG. 8, embodiments of filter media 1 may comprise multiple insulated conductive filaments or threads, and may therefore comprise a plurality of RFID antennae or parallel circuits (e.g., four, as shown), without limitation. In this regard, upon wear or breakage of a conductive element, it can be known which portion (e.g., which quadrant) of the filter media 1 may be damaged.

When relaying an indication that the filter media may be compromised, location information (e.g., which part of the filter cloth is affected) may also be relayed. This additional location information pertaining to where wear is occurring on filter media 1 may be aggregated and then used with analytics to design better, more robust filter media (or identify improvements for existing filter media 1 ), without limitation. Turning now to FIG. 9, as suggested by FIG. 8, multiple RFID antennae or parallel circuits may be provided to filter media.

Turning now to FIG. 10, one or more conductive elements 3 may form a circuit or RFID antenna within filter media 1. As shown, portions of the circuit or RFID antenna formed by the one or more conductive elements 3 may be more densely spaced in certain locations or portions of the filter media 1 than in others. For example, as shown in FIG. 10, a number of coils made up of electrically insulated conductive wire (e.g., metallic filament or thread) may be joined together or otherwise connected to form a single series circuit. Both ends of the series circuit may be connected to a module 2 provided to a filter cloth. Each end of the electrically insulated conductive wire may be operatively electronically connected to the module 2 (e.g., via leads, cables, soldered connections, electrical connectors, physical/electrical integration with a PCB or flex circuit, or the like, without limitation). The electrically insulated conductive wire may coil or wind or wrap in a densely packed configuration at a first location (e.g., Upper Left corner of filter media 1 ), and then traverse open filter cloth space and extend to a second location (e.g., Upper Center area of filter media 1 ) where it may similarly coil or wind or wrap in a densely packed configuration. The electrically insulated conductive wire may then traverse open filter cloth space and extend to a third location (e.g., Upper Right corner of filter media 1 ) where it may similarly coil or wind or wrap in a densely packed configuration. This may continue for a number of different locations (e.g., to a Lower Right corner as shown), without limitation.

In the exemplary non-limiting embodiment shown, nine locations of filter media 1 are shown to each comprise areas of densely spaced conductive element(s) 3 in the form of coils. However, it should be understood that a larger or smaller number of locations on the filter media 1 may each comprise areas of densely spaced conductive element(s) 3. Any number of coils, winds, or wraps may collectively make up an individual RFID antenna, without limitation. The specific locations/portions of filter media 1 which comprise densely paced configurations of electrically insulated conductive wire may be chosen or designed to be at areas or positions of known or expected wear. Permutations and design configurations are endless and can be different from what is shown and described herein.

Turning now to FIG. 1 1 , one or more conductive elements 3 may form a plurality of circuits and/or a plurality of antennae within filter media 1 . For example, the one or more conductive elements 3 may, as shown, comprise a plurality of conductive elements 3 which form individual circuits or individual antenna, each being provided with its own module 2, to a filter cloth. Accordingly, certain locations, areas, or portions of the filter media 1 may have conductive elements 3 that are more densely spaced than others. Certain locations, areas, or portions of the filter media 1 may have no conductive elements 3 therein, or may perhaps have less- densely spaced conductive elements 3, without limitation. For example, as shown in FIG. 1 1 , a number of coils, winds, or wraps may form a number of individual series (or parallel circuits) or a number of individual RFID antennae. Each coil, wind, or wrap may contain a module 2, wherein a module 2 may be unique to a particular coil, wind, or wrap - or to a particular group of coils, winds, or wraps without limitation. In the exemplary non-limiting embodiment shown, sixteen locations of filter media 1 are shown to comprise areas of densely spaced conductive element(s) 3.

During normal operation, a conductive element 3 may provide a response signal in response to an interrogation signal. The response signal may contain a UID, for example, if configured as an RFID antenna. If a response signal is not generated, it can be assumed that the RFID antenna has been damaged, worn, or otherwise compromised by wear. Using the UID information associated with the affected RFID antenna, a control unit 7 may determine (specifically) which filter cloth, and/or what portion of said filter cloth may be damaged. Moreover, using the UID information associated with the affected RFID antenna, a control unit 7 may further determine where the affected media is located (e.g., in which filter, in which plant, on which filter plate, and/or on which side of said plate the affected media is located).

FIG. 12 and FIG. 13 illustrate various types of ways to incorporate one or more conductive elements 3 into filter media by weaving. Particularly shown, are non limiting examples of providing a woof or weft of electrically insulated wire filament or thread and weaving it with a warp of non-conductive thread (e.g., nylon, polyester, polyurethane, polypropylene, etc.), to form filter media 1 , in particular, a woven filter cloth. It is anticipated that felts and other non-woven filtering material can accommodate conductive elements 3 through bonding with adhesives, thermal joining, or stitching, without limitation.

Turning now to FIGS. 14-16, various methods of forming and using intelligent semi- metallic filter media 1 are disclosed, according to some embodiments. Figure 14 suggests a non-limiting embodiment wherein an active or passive RFID antenna may be woven into a substrate using non-conductive thread to form filtration media having an active or passive RFID antenna contained therein. It would be readily appreciated by those ordinarily skilled in the art that one may alternatively weave a preferably electrically-insulated conductive element to non- conductive thread to form an active or passive RFID antenna within filtration media (e.g., a filter cloth).

Figure 15 suggests a non-limiting method according to some embodiments, wherein an RFID antenna may be formed as an integral part of a filter cloth by laminating or bonding filtering material to conductive material (e.g., to one or more conductive elements which are preferably electrically-insulated). In some instances, bonding may be achieved with the use of an adhesive, one or more heating methods (e.g., laminating, heat-sintering, co-molding), or a combination thereof, without limitation. For example, in some embodiments, one or more conductive elements may be combined with filtering material by disposing the one or more conductive elements between two porous sheets of sintered particles, and then joining the resulting structure together via heat and/or pressure; wherein the porous sheets bond with the conductive element disposed therebetween. The sintered particles may comprise polymers, metallic materials, ceramics, or a combination thereof (e.g., cermets) without limitation.

In some embodiments an RFID antenna may be formed separately from a filter cloth and provided in the form of a sticker or decal which can be adhered to a back side of the filter cloth which is not intended to be in direct contact with filter cake or slurry to be dewatered in a filter. Accordingly, if particles become entrained in filtrate leaving the back side of the filter cloth, the particles may wear away portions of one or more conductive elements within the sticker or decal as they pass the back side of the filter cloth. This, in turn, would cause an alarm signal to be delivered via RFID signal from module 2. Alternatively, particles wearing away portions of one or more conductive elements within the sticker or decal may result in an absence of a response signal from the RFID antenna upon an interrogation signal being delivered to the RFID antenna (e.g., if passive). This lack of response from the RFID antenna in the sticker or decal to an interrogation signal would similarly indicate a malfunction alert to an operator, suggesting that the filter media substrate may be compromised by wear (e.g., a hole, tear, break, or opening in the filter cloth may be present in such a situation).

The sticker or decal may be provided by applying adhesive over one or more conductive elements connected to an RFID tag. The adhesive may also doubly serve as an insulator over the one or more conductive elements. The adhesive may form part or all of the insulator of the one or more conductive elements. The sticker or decal may be adhered across the entire back side of a filter cloth, or to one or more select portions of the filter cloth 1 which are most prone to wear or breakage. For example, for filter cloths which are to be used on filter plates within filter presses, one or more stickers or decals comprising an RFID antenna (or antennae) may be placed in areas of the filter cloth which are intended to be located adjacent filtrate ports, pips, stay bosses, or feed eye regions of a filter plate, without limitation. While the above embodiments are described in relation to RFID technology, stickers or decals may also or alternatively comprise the series or parallel circuits described above.

Figure 16 describes a non-limiting method according to some embodiments, wherein a semi-metallic filter cloth may be produced by weaving non-conductive threads with conductive threads in a loom.

Figure 17 describes a non-limiting method of data collection and automatic reordering and/or payment of filter cloths according to some embodiments.

Figure 18 describes a non-limiting method of data collection and making design improvements to filtration media and/or operational changes to increase overall filtration performance or efficiency, based on the data collected, according to some embodiments.

Figure 19 shows a non-limiting system 100 according to some embodiments, wherein one or more plants 130 (e.g., a plurality of plants having different operations) may exist within the system, and wherein each of said one or more plants may comprise one or more industrial filtration devices (e.g., multiple pressure or vacuum filters) therein. The one or more plants 130 may each comprise a local database configured to store data in memory regarding each filter cloth operating within its respective plant operation(s). The data stored in each of the local databases 140 may be aggregated and stored in a larger remote database 160. The larger remote database may be accessible by users via a network 150 (e.g., internet, intranet, cellular, etc.). The network 150 may comprise various network components 1 10 which might allow for cloud computing or cloud data architecture. For example, network components 1 10 may comprise, without limitation, Cloud server, PSTN, internet device (LAN/WAN/router/modem), wireless communication device, cellular network tower, satellite, communications system hardware, etc., or the like, without limitation.

While not explicitly shown, it will be readily appreciated that various applications may access, extract, modify, process, or perform computations or other exercises using data/information stored in databases 140, 160. For example, the data/information stored in databases 140, 160 may be used with analytics software to identify key trends, suggest themes (e.g., problematic issues, areas commonly associated with higher wear, etc.), or determine various statistical probabilities within findings (e.g., chance of wear based on type or composition of material being filtered, probability of wear-out within a specified timeframe, recommended settings of an industrial filtration device based upon past data and machine type, proposed filtration environment input variables, etc.), without limitation. Figure 20 suggests that a filter cloth according to embodiments of the invention may be placed on a filter plate. The filter plate may comprise one or more of: a plate type, a plate number, a plate location within its respective filter, a filter number associated with its respective filter (i.e., the filter comprising the filter plate), etc. Moreover, data (e.g., unique identifier information (UID)) associated with a filter cloth may comprise information regarding which side of a plate 121 the filter cloth is installed or to be installed on (e.g., a head side 122 of the plate, or a tail side 123 of the plate), without limitation.

Figures 21 -23 suggest that data (e.g., unique identifier information) associated with a filter cloth may comprise information regarding which portion(s) of the filter cloth 1 is or may have been damaged (or more specifically, which area of a filter cloth has experienced wear, and/or the amount of wear experienced at each affected or predetermined location). In particular, FIG. 21 shows examples of location information for a generally rectangular filter cloth for a filter press. FIG. 22 shows location information for a loop or belt-style filter media for a tower filter press, belt filter, drum filter, or the like. FIG. 23 shows examples of location information for a disk filter cloth. While not shown, location information may pertain to a side of the filter cloth (e.g., front side or back side of planar filtration media; inside or outside surface of loop or belt-style filtration media), without limitation.

EXAMPLES

The subject matter of this disclosure is now described with reference to the following examples.

In some embodiments, filter media may comprise a single RFID tag (e.g., which may be battery-powered or not). The single RFID tag may be used to monitor the cycles completed (e.g., record a number of filtration cycles encountered). The single RFID tag may also be used with location-based systems in order to determine when the filter media is in a service rack versus when it is located in a filter. In this regard, the total number of filtration cycles that any given piece of media completes until failure may be counted, tracked, and logged throughout the course of its lifecycle.

In some embodiments, filter media may comprise multiple RFID tags (e.g., which may be battery-powered or not). Each of the multiple RFID tags may be provided to areas of a filter cloth which are known wear areas or areas of filter media which are notorious for being problematic. Each piece of media may be conceptually broken into a number of sections (e.g., four quadrants, 9 units, or 12 modules) so that data can be obtained and analyzed. Using this data, it can be determined where breaches are typically occurring (and/or originating), thereby helping engineers develop more effective and robust filter media.

In some embodiments, an antenna of an RFID tag provided to a filtering material may be provided as a filament, so that if, during the course of its use and/or operation, it breaks or becomes damaged, the RFID tag may stop pinging the relevant monitoring control system with a normal response signal, thereby signaling a breach of the filter media.

The filament may comprise a woven weft, a weft-knitted weft, or a warp-knitted warp, without limitation. Supporting structures, such as non-conductive fibers or threads may act as a support for the filament, without limitation. For example, as suggested in FIGS. 1 1 and 12, a filament may comprise an electrically-insulated conductive weft thread, which is woven around/through a warp of one or more non- conductive elements 5. In this regard a structural mesh may be formed which may form the filter media or may make up a portion of the filter media.

It should be understood that the filter media and cloth 1 described herein may have multiple layers including multiple filtration layers, support layers (e.g., scrim), or redundant filtering layers, without limitation. Layers within the filter media may be similar in composition or different. Layers within the filter media may be similar in porosity or not. Layers within the filter media may have different flexibility or stiffness characteristics, without limitation.

Conductive elements described herein, including RFID tags (passive and/or active), antennae, and circuits (series and/or parallel) may be used for many different types of filtration media, including the filter media described in the Applicant’s co-pending patent applications (e.g., WO 2014209698 A1 and/or WO 2016061 178 A1 ), without limitation.

The above Examples are provided herein for the purpose of illustration only, and in order to disclose one possible mode of successfully practicing the inventive concepts described herein. The subject matter of this application is not intended to be unduly limited to the particulars of these Examples. Rather, the inventive concepts encompass all variations which are evident as a result of the teachings provided herein.

Where used herein, the term“module” may comprise, without limitation, any one or more of the following: electronic circuitry, a printed circuit board (PCB), flexible electronic circuit, processor, chip, PID controller, RFID tag, wireless communication device.

The disclosure of every patent, patent application, and publication cited, listed, named, or mentioned herein is hereby incorporated by reference in its entirety, for any and all purposes, as if fully set forth herein.

While this subject matter has been disclosed with reference to specific embodiments, it is apparent that other embodiments and variations can be devised by others skilled in the art without departing from the true spirit and scope of the subject matter described herein. The appended claims include all such embodiments and equivalent variations. Where used herein, the term “reader/interrogator” and the word“receiver” may be used interchangeably.

Where used herein,“industrial filtration apparatus” may encompass pressure and vacuum filters alike; and, for example, may include, without limitation: disk filters, pan filters, small drum filters, horizontal belt filters, tower pressure filters (e.g., FLSmidth® Pneumapress® filters, Outotec® Larox® PF pressure filters), and horizontal filter presses (e.g., FLSmidth® EIMCO® AFP IV™ Automated Filter Presses). There may, in some embodiments, be instances wherein the filtration media for the industrial filtration apparatus is provided in the form of a loop or belt (rather than in the form of a sheet), for use in drum filters or belt filters, without limitation. Filtration media provided in the form of a sheet may, in some instances, be generally rectangular (e.g., for installation onto a horizontal filter press plate), or, filtration media may be circular, annular, or wedge-shaped (e.g., for installation onto a disc filter disk or segment thereof). It is further envisaged that filtration media according to some embodiments may comprise monofilament and/or multifilament fabrics to ensure optimal filtration media design. In some cases one or more electrically-conductive elements may be selected to form a monofilament. In some cases one or more electrically-conductive elements may be selected to form a single strand within a multi-filament, within woven filtration media (e.g., a filter cloth).

It should be understood that while RFID antennae (e.g., passive or active) and circuits (e.g., series or parallel) described herein, and found in the disclosed filter media may be adversely affected (e.g., break or cease functioning) due to wear and/or abrasion from passage of slurry to be dewatered as designed or intended, the same RFID antennae/circuits may not necessarily be negatively affected by cyclic flexing, fatigue, bending, creasing, or other types of stresses or forces. For example, it may take a small amount of abrasive wear to destroy an RFID antenna or circuit described herein, whilst a significant amount of bending stresses or large number of fatiguing cycles may not render an RFID antenna or circuit described herein useless. Preferably, the RFID antennae and circuits described herein, which may be formed of one or more conductive elements, are robust to fatigue or breakage due to cyclic flexing, bending, chemical interactions, and/or a large number of filtration cycles, without limitation. For example, non-conductive insulator material or adhesives for the conductive elements 3 may be preferably selected to be inert and non-reactive with slurry to be dewatered.

The described embodiments are to be considered in all respects only as illustrative and not restrictive. The scope of the invention is, therefore, indicated and governed only by the appended claims, rather than by the foregoing description. All embodiments which come within the meaning and range of equivalency of the claims are to be embraced within their scope.

A contractor or other entity may provide filter media for an industrial filtration device as substantially shown and described herein. Or, a contractor or other entity may operate an industrial filtration device with filter media in whole, or in part, as shown and described. A contractor or other entity may fabricate filter media (e.g., a filter cloth) for an industrial filtration device as substantially shown and described herein. A contractor or other entity may receive a bid request for a project related to designing, fabricating, delivering, installing, operating, or performing maintenance on an industrial filtration device, horizontal filter press, filter media, filter cloth, circuit, or antenna substantially described herein. Or, a contractor or other entity may offer to design such a system, apparatus, (or provide a process or service pertaining thereto) for a client. A contractor or other entity may offer to retrofit or may retrofit an industrial filtration device with the filter media described herein, or at least one of the components of the filter media discussed herein.

The contractor or other entity may provide, for example, any one or more of the inventive devices or features thereof shown and/or described in the embodiments discussed above in any combination, permutation, or fashion. The contractor or other entity may provide such devices or features by selling those devices or features; or, by offering to sell those devices or features. The contractor or other entity may provide various embodiments that are sized, shaped, specked, and/or otherwise configured to meet the design criteria of a particular client or customer or end user of filter media or industrial filtration device spare parts.

The contractor or other entity may subcontract the fabrication, delivery, sale, and/or installation of any component(s) of the filter media apparatus disclosed, or of any component of a device which might be used to reproduce certain aspects or components of the embodiments disclosed. The contractor or other entity may also survey a site or design or designate one or more storage areas for stacking material used to manufacture the devices (e.g., including used filter media or conductive elements which are to be remanufactured and/or incorporate one or more of the inventive concepts or features disclosed herein).

The contractor or other entity may also maintain, modify, or upgrade the provided devices. The contractor or other entity may provide such maintenance or modifications by subcontracting such services or by directly providing those services or components needed for said maintenance, modifications, or upgrades; and, in some cases, the contractor or other entity may modify an existing filter cloth or filter media for an industrial filtration device by virtue of a“retrofit kit” to arrive at a modified process or modified industrial filtration system comprising one or more of the inventive method steps, design features, devices, or inventive concepts of the systems, apparatus, and processes discussed herein.

Although the invention has been described in terms of particular embodiments and applications, one of ordinary skill in the art, in light of this teaching, can generate additional embodiments and modifications without departing from the spirit of or exceeding the scope of the claimed invention. REFERENCE NUMERAL IDENTIFIERS

1 . Filter media (e.g., filter cloth)

2. Module (e.g., provided to each industrial filtration device, or provided to plant to be shared by multiple industrial filtration devices)

3. One or more conductive elements (e.g., thread, filament, weft, woof)

4. Filtering material (e.g., thin porous sheet)

5. One or more non-conductive elements (e.g., thread, fiber, warp)

6. Pore (e.g., mesh aperture)

7. Control unit

100. System

1 10. Network components (e.g., Cloud, PSTN, Internet, Cell towers, satellite, communications system hardware, etc.)

120. Individual filter (e.g., unique filter number)

121 . Plate (e.g., having a unique plate number, a unique location within a filter, and/or comprising a plate type - such as a #1 plate or #3 plate)

122. Head side of plate

123. Tail side of plate

130. Plant

140. Local database

150. Network

160. Remote database