Diffusion element

Claim 2

A rigid, monolithic, porous, gas diffusion element having an enhanced apparent volumetric compression ratio in a central zone thereof, 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 viewed in vertical cross section 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, the maximum horizontal dimension of said portion being in a ratio of at least about 4 to 1 relative to the thickness of said portion, 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 in water, and said central zone being beneath a portion of said upper gas discharge surface, within which central zone the solid particles have been pressed to a greater apparent volumetric compression ratio as compared to the material in an outward zone beneath said surface.

Claim 3

A diffusion element according to claim 1 comprising an integral, annular peripheral zone having a lesser permeability than a portion of the gas discharge surface above said outward zone.

Claim 4

A diffusion element according to claim 2 wherein the peripheral portion of the element, viewed in vertical cross-section, includes generally upward and generally downward facing upper and lower surfaces.

Claim 5

A diffusion element according to any of claims 2 through 4 wherein said upper gas discharge surface includes a depression above said central zone and spaced inwardly from the peripheral zone of said element.

Claim 6

A diffusion element according to claim 4 wherein the outline of said depression is generally similar to that of the element as a whole.

Claim 7

A diffusion element according to claim 4 wherein the outline of said depression is generally circular.

Claim 8

A diffusion element according to claim 6 wherein the outline of said element is generally circular.

Claim 9

A diffusion element according to claim 4 wherein the area of said depression comprises about 10 to about 80% of the total area of said gas discharge surface.

Claim 10

A diffusion element according to claim 4 wherein the area of said depression comprises about 25 to about 75% of the total area of said gas discharge surface.

Claim 11

A diffusion element according to claim 4 wherein the area of said depression comprises about 45 to about 65% of the total area of said gas discharge surface.

Claim 12

A diffusion element according to claim 4 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 13

A diffusion element according to claim 4 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 14

A diffusion element according to claim 4 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 15

A diffusion element according to claim 4 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 16

A diffusion element according to claim 4 wherein the depth of said depression varies within the outline of said depression.

Claim 17

A diffusion element according to claim 15 wherein there is no depression within a portion of said outline.

Claim 18

A diffusion element according to claim 15 wherein said variation occurs gradually along gradually sloping portions of said upper gas discharge surface.

Claim 19

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 20

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 21

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 two perpendicular reference lines extending across said surface of the element and through the center thereof.

Claim 22

A diffusion element according to claim 20 wherein said coefficient is in the range of about 0.05 to about 0.25.

Claim 23

A diffusion element according to claim 20 wherein said coefficient is less than about 0.05.

Claim 24

A diffusion element according to claim 1 comprising an integral, annular peripheral zone within which the solid particles have been pressed to a greater density than the particles which are beneath a portion of said outward zone.

Claim 25

A diffusion element according to claim 1 comprising an integral, annular peripheral zone having a lesser height than at least a portion of said outward zone.

Claim 26

A diffusion element according to any of claims 1-4 in which the apparent volumetric compression ratio of said central zone has been enhanced by distributing the particles in said body, prior to or during pressing, for providing a larger mass of said particles per unit of horizontal area in said central zone, as compared to the mass of particles per unit area in said outward zone.

Claim 27

A diffusion element according to claim 25 wherein said particles are distributed prior to or during pressing for providing a larger mass of particles per unit volume in said central zone as compared to the mass of particles per unit volume in said outward zone.

Claim 28

A diffusion element according to claim 25 wherein said larger mass per unit area of said particles has been provided by performing said pressing in a die having a cavity and, prior to pressing, filling a central portion and a surrounding portion of said cavity with said particles to respectively greater and lesser depths.

Claim 29

A diffusion element according to any of claims 1-24 wherein said apparent volumetric compression ratio of said central zone has been enhanced by effecting, during pressing, relatively larger and smaller ratios of thickness reduction in said central and outward zones, respectively.

Claim 30

A diffusion element according to claim 28 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 central and surrounding portions of the space between said faces.

Claim 31

A diffusion element according to claim 29 wherein said smaller clearance is provided by a protuberance on the compression face of said die cavity.

Claim 32

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 33

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 34

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 35

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 36

A diffusion element according to claim 1 having a bubble release pressure in the range of about 5 to about 10 inches of water.

Claim 37

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 relase 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 38

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=65 /p, wherein D=maximum pore diameter, γ=surface tension of the test liquid in dynes/cm, and p=pressure in mm of Mercury.

Claim 39

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=30 γ/p, wherein D=maximum pore diameter, γ=surface tension of the test liquid in dynes/cm, and p=pressure in mm of Mercury.

Claim 40

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

Claim 41

A diffusion element according to claim 34 wherein said particles include silica.

Claim 42

A diffusion element according to claim 34 wherein said particles include alumina.

Claim 43

A diffusion elemement according to claim 34 wherein said particles include synthetic resin.

Claim 44

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

Claim 45

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 46

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 47

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

Claim 48

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 49

A diffusion element according to claim 35 wherein said lower gas infusion surface is generally parallel to said upper gas discharge surface.

Claim 50

A diffusion element according to claim 35 wherein said lower gas infusion surface is substantially planar.

Claim 51

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

Claim 52

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

Claim 53

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

Claim 54

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

Claim 55

A diffusion element according to any of claims 1 through 4 wherein said upper gas discharge surface is planar.

Claim 56

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

Claim 57

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

Claim 58

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

Claim 59

A rigid, monolithic, porous, gas diffusion element having an enhanced apparent volumetric compression ratio in a central zone thereof, said 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 viewed in vertical cross section 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, the maximum horizontal dimension of said portion being in a ratio of at least about 4 to 1 relative to the thickness of said portion, 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 central zone being beneath a portion of said upper gas discharge surface, within which central zone the solid particles have been pressed to a greater apparent volumetric compression ratio as compared to the material beneath an outward zone in said surface, and said gas discharge surface having 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 60

A rigid, monolithic, porous, gas diffusion element having an enhanced apparent volumetric compression ratio in a central zone thereof, said 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 viewed in vertical cross section 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, the maximum horizontal dimension of said portion being in a ratio of at least about 4 to 1 relative to the thickness of said portion, 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 central zone being beneath a portion of said upper gas discharge surface, within which central zone the solid particles have been pressed to a greater apparent volumetric compression ratio as compared to the material beneath an outward zone in said surface, and said gas discharge surface having 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.