Diffusion element with boundary zone treatment

Claim 2

A rigid, monolithic, porous, gas diffusion element said element being formed of a body of solid particles which has been shaped, pressed and rendered coherent by bonding or sintering in a compacted form having pores, said element including a generally horizontal portion having a specific permeability in the range of about 6 to about 200 SCFM per square foot of gas discharge surface per inch of thickness at 2 inches of water gauge, said generally horizontal portion, when viewed in vertical cross section while positioned with its maximum dimension extending horizontally, having a ratio of said maximum horizontal dimension relative to the thickness of said portion in the range of at least about 4 to 1, said generally horizontal portion including an upper gas discharge surface which is generally horizontal and has a bubble release pressure in water in the range of about 2 to about 20 inches of water, said element including central, outward and boundary zones beneath said gas discharge surface, said outward zone surrounding said central zone and said boundary zone surrounding said outward zone, said element including a peripheral zone surrounding said boundary zone and having a lesser permeability than a portion of said outward zone, or having therein solid particles which have been pressed to a greater density than the particles in a portion of said outward zone, or having a lesser height than a portion of said outward zone, the solid particles within said central zone having been pressed to a greater apparent volumetric compression ratio as compared to the particles in said outward zone, and the solid particles within said boundary zone having been pressed to a greater apparent volumetric compression ratio as compared to the particles in said outward zone.

Claim 3

A diffusion element according to claim 10 wherein the apparent volumetric compression ratio of said boundary zone has been enhanced by effecting, during pressing, relatively larger and smaller ratios of thickness reduction in said boundary zone and in the outward zone, respectively.

Claim 4

A diffusion element according to claim 2 wherein said larger and smaller percentages of thickness reduction have been effected by performing said pressing in a press having a ram and die cavity with spaced, opposed compression faces and wherein there are respectively smaller and larger clearances in those portions of the space between said faces which correspond to the positions of said boundary zone and outward zone in said diffusion element.

Claim 5

A diffusion element according to claim 3 wherein said smaller clearance is provided by a protuberance on the compression face of said die cavity.

Claim 6

A diffusion element according to claim 3 wherein said smaller clearance is provided by a protuberance on the compression face of said ram.

Claim 7

A diffusion element according to claim 1 wherein the apparent volumetric compression ratio of the central zone is at least about 2% greater than that of said outward zone.

Claim 8

A diffusion element according to claim 1 wherein the apparent volumetric compression ratio of the central zone is about 2 to about 20% greater than that of said outward zone.

Claim 9

A diffusion element according to claim 1 wherein the apparent volumetric compression ratio of the central zone is about 3 to about 15% greater than that of said outward zone.

Claim 10

A diffusion element according to claim 1 wherein the apparent volumetric compression ratio of said boundary zone is at least about 10% greater than that of said outward zone.

Claim 11

A diffusion element according to claim 1 wherein the apparent volumetric compression ratio of said boundary zone is about 10 to about 35% greater than that of said outward zone.

Claim 12

A diffusion element according to claim 1 wherein the apparent volumetric compression ratio of said boundary zone is about 35 to about 100% greater than that of said outward zone.

Claim 13

A diffusion element according to claim 1 having a bubble release pressure in the range of about 4 to about 15 inches of water.

Claim 14

A diffusion element according to claim 10 having a bubble release pressure in the range of about 5 to about 10 inches of water.

Claim 15

A diffusion element according to claim 1 having a pore size in the range of about 60 to about 600 microns as computed in applying the bubble release pressure to the equation D=30γ/p, wherein D=maximum pore diameter, γ=surface tension of the test liquid in dynes/cm, and p=pressure in mm of Mercury.

Claim 16

A diffusion element according to claim 1 having a pore size in the range of about 90 to about 400 microns, as computed in applying the bubble release pressure to the equation D=30γ/p, wherein D=maximum pore diameter, γ=surface tension of the test liquid in dynes/cm, and p=pressure in mm of Mercury.

Claim 17

A diffusion element according to claim 1 having an average pore size in the range of about 120 to about 300 microns, as computed in applying the bubble release pressure to the equation D=30γ/p, wherein D=maximum pore diameter, γ=surface tension of the test liquid in dynes/cm, and p=pressure in mm of Mercury.

Claim 18

A diffusion element according to claim 1 wherein said particles are of organic or inorganic material.

Claim 19

A diffusion element according to claim 17 wherein said particles include silica.

Claim 20

A diffusion element according to claim 17 wherein said particles include alumina.

Claim 21

A diffusion element according to claim 17 wherein said particles include synthetic resin.

Claim 22

A diffusion element according to claim 1 having a modulus in compression of at least about 0.2×10 5 psi.

Claim 23

A diffusion element according to claim 1 having a modulus in compression in the range of about 0.2×10 5 to about 4×10 5 psi.

Claim 24

A diffusion element according to claim 1 having a modulus in compression in the range of about 4×10 5 to about 6×10 5 psi.

Claim 25

A diffusion element according to claim 1 having a circular shape in plan view.

Claim 26

A diffusion element according to claim 1 wherein said generally horizontal portion, viewed in vertical cross section includes a lower gas infusion surface which is generally horizontal.

Claim 27

A diffusion element according to claim 25 wherein said lower gas infusion surface is generally parallel to said upper gas discharge surface.

Claim 28

A diffusion element according to claim 25 wherein said lower gas infusion surface is substantially planar.

Claim 29

A diffusion element according to claim 1 wherein the peripheral portion of the element, viewed in vertical cross section, includes generally upward and generally downward facing upper and lower surfaces.

Claim 30

A diffusion element according to claim 1 wherein substantially the entire upper surface of said element is generally horizontal.

Claim 31

A diffusion element according to claim 1 wherein substantially the entire lower surface of said element is generally horizontal.

Claim 32

A diffusion element according to claim 1 wherein substantially the entire upper and lower surfaces of said element are generally horizontal.

Claim 33

A diffusion element according to claim 1 wherein substantially the entire upper and lower surfaces of said element are parallel.

Claim 34

A diffusion element according to claim 1 wherein said upper gas discharge surface is planar.

Claim 35

A diffusion element according to claim 1 wherein upper gas discharge surface includes a depression above said central zone and spaced inwardly from the periphery of said element.

Claim 36

A diffusion element according to claim 34 wherein the outline of said depression is generally similar to that of the element as a whole.

Claim 37

A diffusion element according to claim 34 wherein the outline of said depression is generally circular.

Claim 38

A diffusion element according to claim 36 wherein the outline of said element is generally circular.

Claim 39

A diffusion element according to claim 34 wherein the area of said depression comprises about 10 to about 80% of the total area of said gas discharge surface.

Claim 40

A diffusion element according to claim 34 wherein the area of said depression comprises about 25 to about 75% of the total area of said gas discharge surface.

Claim 41

A diffusion element according to claim 34 wherein the area of said depression comprises about 45 to about 65% of the total area of said gas discharge surface.

Claim 42

A diffusion element according to claim 34 wherein the average depth of said depression relative to the thickness of said horizontal portion is in the range of about 2 to about 20%.

Claim 43

A diffusion element according to claim 34 wherein the average depth of said depression relative to the thickness of said horizontal portion is in the range of about 4 to about 15%.

Claim 44

A diffusion element according to claim 34 wherein the average depth of said depression relative to the thickness of said horizontal portion is in the range of about 5 to about 10%.

Claim 45

A diffusion element according to claim 34 wherein the area and average depth of said depression are sufficient for significantly enhancing the uniformity of gas distribution laterally across the horizontal gas discharge portion of said element.

Claim 46

A diffusion element according to claim 34 wherein the depth of said depression varies within the outline of said depression.

Claim 47

A diffusion element according to claim 45 wherein there is no depression within a portion of said outline.

Claim 48

A diffusion element according to claim 45 wherein said variation occurs gradually along gradually sloping portions of said upper gas discharge surface.

Claim 49

A diffusion element according to claim 1 wherein the solid particles have been pressed to a greater apparent volumetric compression ratio in the boundary zone as compared to the outward zone by forming the upper gas discharge surface above the boundary zone with a downward and outward slope at an angle in the range of about 10° to 70° relative to the surface of the outward zone.

Claim 50

A diffusion element according to claim 1 wherein the solid particles have been pressed to a greater apparent volumetric compression ratio in the boundary zone as compared to the outward zone by forming the upper gas discharge surface above the boundary zone with a downward and outward slope at an angle in the range of about 10° to about 80° relative to the horizontal.

Claim 51

A diffusion element according to claim 49 wherein said angle of depression is in the range of about 20° to about 70° relative to the horizontal.

Claim 52

A diffusion element according to claim 49 wherein said angle of depression is in the range of about 25° to about 65° relative to the horizontal.

Claim 53

A diffusion element according to claim 1 which is free of through-holes other than gas diffusion pores.

Claim 54

A diffusion element according to claim 1 having a specific permeability in the range of about 12 to about 70 SCFM.

Claim 55

A diffusion element according to claim 1 having a specific permeability in the range of about 15 to about 35 SCFM.

Claim 56

A diffusion element according to claim 1 wherein the ratio of the maximum horizontal dimension of the generally horizontal portion relative to the thickness of said portion is at least about 6 to 1.

Claim 57

A diffusion element according to claim 1 wherein the ratio of the maximum horizontal dimension of the generally horizontal portion relative to the thickness of said portion is at least about 8 to 1.

Claim 58

A diffusion element according to claim 1 wherein the coefficient of variation of the bubble release pressure of the gas discharge surface is not greater than about 0.25, based on the values of bubble release pressure measurements of at least 5 equally spaced points along each of the two perpendicular reference lines extending across said surface of the element and through the center thereof.

Claim 59

A diffusion element according to claim 57 wherein said coefficient is in the range of about 0.05 to about 0.25.

Claim 60

A diffusion element according to claim 57 wherein said coefficient is less than about 0.05.

Claim 61

A diffusion element according to claim 1 wherein the boundary zone is adjacent to said peripheral zone.

Claim 62

A diffusion element according to claim 60 wherein said apparent volumetric compression ratio has been enhanced in said boundary zone by effecting, during pressing, relatively larger and smaller ratios of thickness reduction in said boundary zone and in the outward zone, respectively.

Claim 63

A diffusion element according to claim 61 wherein said larger and smaller percentages of thickness reduction have been effected by performing said pressing in a press having a ram and die cavity with spaced, opposed compression faces and wherein there are respectively smaller and larger clearances in those portions of the space between said faces which correspond to the positions of said boundary zone and outward zone in said diffusion element.

Claim 64

A diffusion element according to claim 62 wherein said smaller clearance is provided by a protuberance on the compression face of said die cavity.

Claim 65

A diffusion element according to claim 62 wherein said smaller clearance is provided by a protuberance on the compression face of said ram.

Claim 66

A rigid, monolithic porous, gas diffusion element having the property of discharging gas in a substantially uniform manner throughout an upper gas discharge surface of said element, said element being formed of a body of solid particles which has been shaped, pressed and rendered coherent by bonding or sintering in a compacted form having pores, said element including a generally horizontal portion having a specific permeability in the range of about 6 to about 200 SCFM per square foot of gas discharge surface per inch of thickness at 2 inches of water gauge, said generally horizontal portion, when viewed in vertical cross section while positioned with its maximum dimension extending horizontally, having a ratio of said maximum horizontal dimension relative to the thickness of said portion in the range of at least about 4 to 1, said generally horizontal portion including said upper gas discharge surface, which has a bubble release pressure in water in the range of about 2 to about 20 inches of water, and a generally horizontal lower gas infusion surface, said element including central, outward and boundary zones beneath said gas discharge surface, said outward zone surrounding said central zone and said boundary zone surrounding said outward zone, said element including a peripheral zone surrounding said boundary zone and having a lesser permeability than a portion of said outward zone, or having therein solid particles which have been pressed to a greater density than the particles in a portion of said outward zone, or having a lesser height than a portion of said outward zone, the solid particles within said central zone having been pressed to a greater apparent volumetric compression ratio as compared to the particles in said outward zone, and the solid particles within said boundary zone having been pressed to a greater apparent volumetric compression ratio as compared to the particles in said outward zone, whereby said gas discharge surface has the property that its coefficient of variation is not greater than about 0.25, based on the values of bubble release pressure measurements of at least 5 equally spaced points along each of two perpendicular reference lines extending across said gas discharge surface and through the center thereof.

Claim 67

A rigid, monolithic porous, gas diffusion element having the property of discharging gas in a substantially uniform manner throughout an upper gas discharge surface of said element, said element being formed of a body of solid particles which has been shaped, pressed and rendered coherent by bonding or sintering in a compacted form having pores, said element including a generally horizontal portion having a specific permeability in the range of about 6 to about 200 SCFM per square foot of gas discharge surface per inch of thickness at 2 inches of water gauge, said generally horizontal portion, when viewed in vertical cross section while positioned with its maximum dimension extending horizontally, having a ratio of said maximum horizontal dimension relative to the thickness of said portion in the range of at least about 4 to 1, said generally horizontal portion including said upper gas discharge surface, which has a bubble release pressure in water in the range of about 2 to about 20 inches of water, and a generally horizontal lower gas infusion surface, said element including central, outward and boundary zones beneath said gas discharge surface, said outward zone surrounding said central zone and said boundary zone surrounding said outward zone, said element including a peripheral zone surrounding said boundary zone and having a lesser permeability than a portion of said outward zone, or having therein solid particles which have been pressed to a greater density than the particles in a portion of said outward zone, or having a lesser height than a portion of said outward zone, the solid particles within said central zone having been pressed to a greater apparent volumetric compression ratio as compared to the particles in said outward zone, and the solid particles within said boundary zone having been pressed to a greater apparent volumetric compression ratio as compared to the particles in said outward zone, whereby said gas discharge surface has the property that its coefficient of variation is not greater than about 0.25, based on the values of bubble release pressure measurements of at least 5 equally spaced points along each of two perpendicular reference lines extending across said gas discharge surface and through the center thereof.