Note : Les descriptions sont présentées dans la langue officielle dans laquelle elles ont été soumises.
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DIRECT REPLACEMENT AIR FILTER WITH AUTOMATIC
FILTER MEDIA ADVANCE AND WIRELESS COMMUNICATIONS
BACKGROUND OF THE INVENTION
[001] Field of the Invention
[002] The invention is directed to a direct replacement air handler filter,
in an exemplary
embodiment having a unitary housing. The unitary housing having a standard
width for air
handler filters so as to be a direct replacement for existing standard filters
and future air
filters. The housing contains a movement member, a motor, a power source, a
controller and
a filter media. The product strives to be both directly replaceable with a
filter and disposable
with minimum environmental impact The replacement air handler filter being
further
located within a channel in the air handler unit wherein the air is passed
within the channel
and passed through the filter media. The replacement air filter having a
compacted or stored
portion of the filter media that is moved out to replace the initial and
subsequent sections of
filter media exposed by the invention to air within the air handler unit.
Additional aspects of
the invention include remote monitoring and communication with the air
filtration unit or air
handler, enabling monitoring and alert for replacement of the air filter.
Additionally, the air
filtration unit or air handler may be enabled to monitor and communicate air
quality and to
take further actions in response to alerts sent through a network.
[003] Background of the Invention
[004] An important component in almost all Heating, Ventilation and Air
Conditioning
(HVAC) and air filtration units in general is a filtration mechanism for
removal of
particulates and contaminants from the air flow. In HVAC systems this is
preferably before
or sometimes after coming into contact with heat exchanging elements. The
removal of the
contaminants helps prevent reduction in heat transfer associated with
accumulation of the
contaminants on the heat exchanger elements. Additionally, the removal of
these
contaminants also improves the quality of the air circulated by the HVAC air
handling
system. The timing for replacing or renewing these filtration mechanisms is
therefore
important in both improving efficiency and maintaining air quality in most air
filtration
applications.
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[005] In most systems a filter is used through which the air is passed.
Dirty filters result in
lower flow rates of air which translates to lower efficiency in air
filtration, especially in
HVAC systems where it equates to less heat exchange in the HVAC equipment. The
equipment must run longer to accomplish the intended goals, for example
contaminant
filtration and/or temperature control. In HVAC for instance, air conditioning
equipment may
freeze up due to inadequate heat exchange. Additionally, the motors and other
components
must run longer and harder resulting in increased wear on the entire system,
reducing its
useful life. Thus, the filtration systems of air handler units require
constant attention and
maintenance. In commercial and industrial applications, it is often the case
that the air
handling functions are monitored by a control center and maintained based on
performance
measurements. For example, when utilizing multiple refrigeration units in
chemical
processing the timing and performance of the cooling units is often integral
to the
manufacturing process, these systems are therefore monitored and maintained
based on
sensor reports, typically from within the system itself or based on hours of
operation. Upon
determination by the controller or by a set schedule, the filters on such
systems are replaced.
Similarly, in residential settings, many HVAC companies sell maintenance
contracts to
residential clients, typically annual or bi-annual in nature, to address
routine maintenance.
However the removable, replaceable filters that are typically in these units
require more
frequent replacement by these clients.
10061 Filters for most residential and commercial air filtration and air
handling equipment are
typically removable, replaceable, rigid, framed units. Rigid framed filters
can be time
consuming to replace or clean and often require frequent replacement,
typically monthly.
This also requires an added amount of attention by an industrial or commercial
maintenance
staff or residential unit owner. For instance, in a commercial setting the
restaurant owner or
similar commercial customer must provide an even greater amount of attention
to cleaning
and/or replacing these types of filters. The filters often go unchanged as
users forget to
change the filter regularly. This shortfall has been well known and several
attempts have
been made in the past to provide long lasting filters. Several attempts have
been made to
provide a reel system, see for example US Patent Application No. 2006/0102006,
Japanese
Patent No. JP06233945, German Patent No. DE19654844 Al, US Patent Nos.
6168646,
4470833,6152998, 4221576.
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10071 Though these have extended lengths of service, in each instance, the
resulting device
requires either modification of the HVAC unit or extension of the device from
the standard
width and location of the filter. Additionally, these devices are often
hardwired into the
electrical system of the existing unit, requiring modification of the
electrical connections
within the existing HVAC unit. This makes these existing devices impractical
for easy use
by a typical end user. For example, as seen in US Patent Nos. 6,152,998,
6,632,269,
6,491,735, 6,402,822, and 6,743,282 and the commercially available OPTIMAIR
system,
often the reels are located outside the unit and are located in a reel storage
area that is non-
uniform in width. This also prevents direct replacement of the existing filter
with these types
of units as the footprints are completely different and these systems are not
direct
replacement for the existing filter.
[008] Other commercial applications use sheets that are stretched between
rolls on either side
of an air duct, see for example U.S. Patent 6,632,269 to Najm, 4,331,576 to
Phillips Jr., or
U.S. Patent 6,152,998 to Taylor. In each embodiment, significant modifications
to the
HVAC or cooling system would need to be made to install the devices or they
use a non-
standard footprint. The systems do not provide retrofitting the filter
structure to existing
HVAC equipment and moreover, they require significant installation steps as
outlined above
with respect to residential units that operate in a similar manner.
[009] Additional attempts have been made to address the issue in a
commercial HVAC
application, for instance U.S. Patent 7,186,290 to Sheehan. In U.S. Patent
7,186,290, a stack
of filters is cycled through the device. This system requires a large amount
of modification
to incorporate into existing devices, as with other existing designs.
Additionally, the stacks
of stored filters require a significant amount of space in or around the HVAC
unit. Thus,
existing systems require either significant additional modifications or
additional space to
operate and provide extended use filter systems. Moreover, no economical
method of
providing a self-renewing or extended use air filter within the standard
footprint of the
existing filter housings has been provided.
polo] A direct replacement filter would be one that fits into existing
filter footprints as defined
by the OEM. A uniform and industry standard width is provided in almost all
residential and
most commercial filters. Similarly, industrial applications, though often
purpose built, have
specific filter footprints after completion and replacement of these custom
sizes is also
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contemplated. The filters shown in all of the above noted patents and
publications are not
direct replacement filters as they would require extensive modifications to
fit in the place of
the existing filters in these air handler and HVAC systems. In addition to not
fitting a
standard footprint, filter units like those shown would require opening and
disposal of the
spent filter media, exposing the user and the device to the contaminants that
were already
collected. Further the installation of the systems would require additional
wiring and would
likely require professional installation. Additionally, little or no
communications are
provided at the source of filtration, therefore, these systems cannot
effectively communicate
the status of the air being handled or further communicate with machinery or
other devices.
[0011] To date, no commercially successful system has been produced for use
in conventional
air filtration or HVAC systems without modification or extending beyond the
footprint
provided for the replaceable filter, in other words a direct replacement for
the filter. A direct
replacement filter having a footprint that fits in the standard width provided
in today's
HVAC systems that has an extended use, while being more environmentally
friendly and
remaining sealed preventing re-exposure or re-admission of contaminants to the
air and the
system is needed. Moreover, no economical method of providing a self-renewing
or
extended use air filter within the standard footprint of the existing filter
housings has been
provided. Additionally, no filter to date with such extended use and standard
footprints
exists that can both store and communicate air quality through a sensor to a
communications
network and, based on that communication, prompt an alert to a user or control
center.
[0012] There is, therefore, a need for a method and apparatus for providing
for a self-renewing
or extended use air filter for air handling and HVAC applications that has a
standard
footprint that fits within existing commercial and residential apparatus,
provides extended
useful life to the filter, requires little or not modification to install in
existing equipment,
facilitates and enhances communication of the air quality, communicates with
other elements
of the air handler or a network, and has a minimal impact on the environment
when
discarded. Further, though the exemplary embodiments are shown for replacement
air
handler filters, in addition to air handlers and HVAC systems, the instant
invention is
adaptable to other air filtration applications, some non-limiting examples
being spray booths,
computers, room and building air purification, gaming machines, clean rooms,
electronics
manufacturing, and other applications utilizing air filtration with framed
filters.
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SUMMARY OF THE INVENTION
[0013] An object of the invention is to provide an extended life direct
replacement air handler
filter that is fully disposable and is constructed with "green" materials so
as to have a
minimum impact on the environment when it is discarded.
[0014] Yet another object of the invention is to provide a sealed direct
replacement air handler
filter to minimize re-admission and exposure to the collected contaminants
during operation
and replacement, the spent filter being contained within the sealed housing.
Unlike many
roller systems which require removal or handling of the spent filter material,
the instant
invention minimizes this contact and the potential for readmission to the air
handler.
[0015] A still further object of the instant invention is to provide a
direct replacement air filter
having a pleated, folded filter media with a controller, the pleated filter
media and the
controller being in a sealed housing and the pleated media filter being
distributed across a
grid and folding at its pleats in the presence of air within an airflow
channel. The controller
moves the media within the sealed housing over an extended period of time,
while the
housing fits a standard width or footprint for an existing air filter.
00161 Yet another object of the invention is to provide measurement and
reporting of the status
or quality of the air being handled, with enhanced communications directly
from the air
handler filter through sensors on the unit and provide communications with
other devices or a
network or both.
00171 The invention includes an apparatus and a method for moving air
filter media within the
apparatus. The apparatus of the invention includes a direct replacement
automatic media
advancing air handler filter within an air flow channel having a unitary
housing with a
uniform thickness throughout the length and width of the unitary housing and
an at least one
exposure slot. An at least one filter media storage area is provided having
unexposed filter
media stored therein, the unexposed filter media being pleated, folded, and
stacked to be
compactly held within the at least one filter media storage area and an at
least one motor
coupled to an independent power supply and in communication with a controller,
the at least
one motor moving an at least one movement member that advances or pays out an
unexposed
portion of the at least one filter media into the at least one exposure slot
and exposes the
unexposed portion of the at least one filter media to the air flow channel
creating an exposed
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portion of the at least one filter media. The exposed portion is being paid
out across an at
least one supporting member with the at least one supporting member forcing
the at least one
filter media to fold at its pleats into a zig-zag pattern when placed into an
air flow in the air
flow channel and the paying out the at least one filter media being based on
output from the
controller. A containment area is also provided, wherein the exposed portion
of the at least
one filter media is collected and retained within the containment area.
100181 The at least one movement member can be an at least one cord, wire,
or string, and the at
least one cord, wire, or string is further attached to the pleated filter
media via reinforcement
tabs, wherein the at least one cord, wire, or string is rolled up on a take-up
roller for a pre-
determined time or length and the exposed filter media is moved to the
collection area and
the exposed media is folded at its pleats and stored in a compacted state.
00191 The at least one movement member can also be an at least one track
with an at least one
supporting spanning member, the at least one track member being moved by the
motor and in
turn moving the at least one spanning supporting member which engages the
unexposed filter
media at a pleat and carries the unexposed filter media from the at least one
filter media
storage area to the slot and then, upon a signal from the controller the motor
further moves
the track member and the at least one supporting and spanning member to move
the now
exposed filter media to the containment area.
00201 The containment area can be sealed within the housing by a separate
sealing element.
The movement member can re-fold the at least one pleated filter media after
its exposure and
store it compactly in the containment area. When the at least one filter media
is moved to the
collection area and the exposed media can be folded at its pleats and stored
in a compacted
state, such that readmission of the filtered contaminants is minimized.
00211 The unitary housing can be comprised of at least one of an
environmentally friendly
cellulose, an environmentally friendly cardboard, an environmentally friendly
paper, and an
environmentally friendly organic plastic like compound or plastic and the
power source
further comprises a lithium ion battery.
00221 The controller can further include a clock or a programmed
advancement profile, wherein
the at least one movement member is engaged based on the clock or the
programmed
advancement profile.
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[0023] The at least one movement member can be an at least one roller, the
roller paying out the
filter media from the pleated, folded storage area and taking up the exposed
filter material
and rolling it about the roller in a containment area. The at least one
movement member can
also be an at least one set of pinch rollers, the pinch rollers pulling the
filter to pay out the
filter media from the pleated, folded storage area and feeding the exposed
filter media into a
containment area. The at least one independent power supply can be a battery
or battery
pack. The unitary housing can be sealed throughout to prevent opening of the
unitary
housing.
[0024] The apparatus of the invention also includes a direct replacement
air handler filter system
within an air flow channel within an air handler unit having a unitary housing
comprised of at
least one of at least one of an environmentally friendly cellulose, an
environmentally friendly
cardboard, an environmentally friendly paper, and an environmentally friendly
organic
plastic like compound or plastic having a uniform thickness of between about
one inch and
three inches throughout its length and width and having an exposure slot there
through and
the unitary housing being sealed throughout to prevent opening of the unitary
housing; a
motor coupled to a lithium ion battery power source and in communication with
a controller
having an at least one sensor input or a timer; and a filter media storage
area located on one
end of the unitary housing, with a pleated, folded filter media folded and
compactly stored
inside the filter media storage area, and an exposed filter media containment
area located on
an opposed end within the unitary housing with the filter media extending
therebetween, the
filter media being paid out from said filter media storage area across the
housing and the
exposure slot while being supported by an at least one support member where it
is exposed to
air within the air flow channel and folds along its pleats into a zig-zag
pattern and removes
contaminants from the air and is further passed through to a containment area
where the filter
media is re-folded, collected, and compactly stored with the filtered
contaminants, the motor
being activated by said controller in response to input from the at least one
sensor or based
on a timed input from said timer or programmed to move based on sensor data
and moving
an at least one movement member to move the filter media across the exposure
area.
[0025] The method of the invention includes a method of moving a pleated
filter media within a
uniform length and width, direct replacement air handler filter frame
comprising the method
steps of: storing an unexposed folded, pleated filter media compactly within
an at least one
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filter media storage area storage; engaging an at least one motor coupled to
an independent
power supply in communication with a controller and the at least one motor
moving an at
least one movement member; paying out through the movement of the at least one
movement
member by the at least one motor an unexposed portion of the at least one
filter media into an
at least one exposure slot and exposing the unexposed portion of the at least
one filter media
to the air flow channel creating an exposed portion of the at least one filter
media, the
exposed portion being paid out across an at least one supporting member with
the at least one
supporting member forcing the at least one filter media to fold at its pleats
into a zig-zag
pattern when placed into an air flow in the air flow channel and the paying
out of the at least
one filter media being based on output from the controller; and collecting in
a containment
area the exposed portion of the at least one filter media and retaining it
within the
containment area.
[0026] The apparatus of the invention also includes a direct replacement
air handler filter within
an air flow channel having a housing with an at least one exposure slot. An at
least one filter
media storage area within the housing is provided, having unexposed filter
media stored
therein, the unexposed filter media being pleated, folded, and stacked to be
compactly held
within the at least one filter media storage area. An at least one motor
coupled to a power
supply and in communication with a controller is also provided. The at least
one motor
moving an at least one movement member that pays out an unexposed portion of
the at least
one filter media into the at least one exposure slot and exposes the unexposed
portion of the
at least one filter media to the air flow channel creating an exposed portion
of the at least one
filter media. An at least one processing module is included and an at least
one transceiver
module on the controller and an at least one sensor, the controller
communicating with the at
least one sensor, the at least one sensor communicating data to the processing
module and the
controller, and the transceiver module transmitting data from the filter to a
network or a
storage device. A containment area is also included, wherein the exposed
portion of the at
least one filter media is collected and retained within the containment area.
[0027] The at least one sensor measures temperature, mold count, carbon
monoxide, carbon
dioxide, Volatile Organic Compounds (VOCs), smoke, fire, noxious gases, and
air particle
concentrations. The at least one sensor can also measure air flow and report
estimated
energy consumption to the network or storage device. The controller can
communicate
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through the transceiver module with a further network interface device. The
network
interface device can be a wi-fl enabled device or an interne gateway. The the
filter
communicates through the controller and transceiver module as a wi-fl enabled
device to the
network.
The filter communicates through the controller and transceiver module
communicate data from the at least one sensor to a network which in turn
reports it to an alert
device. The alert device, can be but is certainly not limited to: a cell
phone, computer, or
network enabled interface device. The alert device is a Network Operations
Center or
control center.
0028] The method of the invention further includes a method of
reporting a status of an at least
one air handler filter to a computer network including the steps of activating
and registering a
network enabled air filter with a network; starting operation of the at least
one air filter
within the air handler; monitoring the operation and performance of the at
least one air filter
through an onboard controller in communication with an at least one sensor in
the air filter
sending data to a controller; processing and comparing the data sent to the
controller and
comparing data against a set of parameters; reporting when the processed data
is outside the
set of parameters; and sending an alert to an alert device in communication
with the network.
0029] The monitoring step can include monitoring an amount of filter
media through the at least
one sensor and the method further comprises the method step of sending a
further alert when
the amount of filter media remaining reaches a preset minimum. The step of
sending a
further alert can also activate a dispensing step, the dispensing step
comprising the mailing of
a replacement filter to a specified address for the registered air filter. The
sending of an alert
can also send the alert to an end user and communicate the status of the air
filter to a user
through the alert device. The sending of an alert sends an alert to a security
responder for an
emergency response. The data from the at least one sensor can also measure and
report
estimated energy consumption to the alert device.
0030] The apparatus of the invention further includes an air filtration
direct replacement filter
deployed within an air flow channel including a housing with an at least one
exposure slot
and an at least one filter media storage area within the housing, having
unexposed filter
media stored therein, the unexposed filter media being pleated, folded, and
stacked to be
compactly held within the at least one filter media storage area. An at least
one motor is
coupled to a power supply and in communication with a controller, the at least
one motor
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moving an at least one movement member that advances an unexposed portion of
the at least
one filter media into the at least one exposure slot and exposes the unexposed
portion of the
at least one filter media to the air flow channel creating an exposed portion
of the at least one
filter media. An at least one processing module and an at least one
transceiver module on the
controller and an at least one sensor are included. The controller
communicates with the at
least one sensor, the at least one sensor communicates data to the processing
module and the
controller, and the transceiver module transmits data from the filter to a
network or a storage
device. A containment area, is provided wherein the exposed portion of the at
least one filter
media is collected and retained within the containment area. The at least one
movement
member comprises a first roller containing the unexposed filter media with
pleats contained
thereon and a second roller collecting the exposed, pleated filter media and
further
comprising an at least one support assisting in supporting the filter media on
the pleats and
assisting in producing a zig-zag pattern.
00311 Moreover, the above objects and advantages of the invention are
illustrative, and not
exhaustive, of those which can be achieved by the invention. Thus, these and
other objects
and advantages of the invention will be apparent from the description herein,
both as
embodied herein and as modified in view of any variations which will be
apparent to those
skilled in the art.
BRIEF DESCRIPTION OF THE DRAWINGS
0032] Embodiments of the invention are explained in greater detail by way
of the drawings,
where the same reference numerals refer to the same features.
00331 Figure 1 illustrates a top view of an embodiment of the instant
invention.
0034] Figure 2 shows a side view of the embodiment of Figure 1.
0035] Figure 3 shows a top view of a further embodiment of the instant
invention.
0036] Figure 4 shows a side view of the embodiment of Figure 2.
0037] Figure 5 shows a side view of a further embodiment of the invention.
0038] Figure 6 shows another side view of a further embodiment of the
invention.
0039] Figure 7 shows another side view of a still further embodiment of
the invention.
0040] Figure 8 shows a still further embodiment of the invention.
0041] Figure 9 shows a plan view of an exemplary embodiment of the
invention
communicating with other devices or a network or both.
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DETAILED DESCRIPTION OF THE INVENTION
[0042] In describing the invention, the following definitions are
applicable throughout.
[0043] A "computer" refers to any apparatus that is capable of accepting a
structured input,
processing the structured input according to prescribed rules, and producing
results of the
processing as output. Examples of a computer include: a computer; a general
purpose
computer; a supercomputer; a mainframe; a super mini-computer; a mini-
computer; a lap top;
a net book; a smart phone; a workstation; a micro-computer; a server; an
interactive
television; a hybrid combination of a computer and an interactive television;
and application-
specific hardware to emulate a computer and/or software. A computer can have a
single
processor or multiple processors, which can operate in parallel and/or not in
parallel. A
computer also refers to two or more computers connected together via a network
for
transmitting or receiving information between the computers. An example of
such a
computer includes a distributed computer system for processing information via
computers
linked by a network.
[0044] A "computer-readable medium" refers to any storage device used for
storing data
accessible by a computer. Examples of a computer-readable medium include: a
magnetic
hard disk; a floppy disk; an optical disk, such as a CD-ROM and a DVD; a
magnetic tape; a
memory chip; a thumb drive; and a carrier wave used to carry computer-readable
electronic
data, such as those used in transmitting and receiving e-mail or in accessing
a network.
[0045] "Software" refers to prescribed rules to operate a computer.
Examples of software
include: software; code segments; instructions; computer programs;
applications; and
programmed logic.
[0046] A "computer system" refers to a system having a computer, where the
computer
comprises a computer-readable medium embodying software to operate the
computer.
[0047] A "network" refers to a number of computers, computer systems and
associated devices
that are connected by communication facilities. A network involves permanent
connections
such as cables or temporary connections such as those made through telephone
or other
communication links. Examples of a network include: an internet, such as the
Internet; an
intranet; a local area network (LAN); a wide area network (WAN); a cellular
network; a wi-fl
enabled network of computers; a network of security systems; and a combination
of
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networks, such as an internet and an intranet or a WAN enabled Wi-Fi network
through a
wireless provider or any similar network element or network.
[0048] An "information storage device" refers to an article of manufacture
used to store
information. An information storage device has different forms, for example,
paper form and
electronic form. In paper form, the information storage device includes paper
printed with
the information. In electronic form, the information storage device includes a
computer-
readable medium storing the information as software, for example, as data.
[0049] The instant invention is directed to a direct replacement air
handler filter having a sealed
housing. In the exemplary embodiments, the sealed housing is a unitary sealed
housing
having a uniform thickness throughout and being of a standard width for air
handler filters so
as to be a direct replacement filter for existing HVAC systems. The unitary
housing
contains, at least in part, an at least one motivator or movement element, a
motor, and a
power source, all of these elements being green friendly, a controller and a
filter media. The
product is therefore both replaceable and disposable with minimum
environmental impact.
The replacement air handler filter being further located within a channel in
the air handler
unit wherein the air is passed within the channel and passed through the
filter media.
00501 The exemplary embodiments of the invention shown utilize a compacted
"clean" portion
of the filter media that is deployed, exposed, and collected within the
housing. In most of the
exemplary embodiments shown, the filter media is folded or pleated and stored
in a storage
section. A movement element in the embodiments is attached to the media. In
response to
the controller the motor moves the movement element, the movement element in
turn moves
the existing exposed media into a collection section where it folds and is
stored and draws an
unexposed portion into the exposure area and also draws or moves unexposed
filter into the
air channel. This movement of the filter media is produced by the movement
element. This
movement and storage of the media results in an extended length of operation
for the direct
replacement air handler filter that does not require special installation,
minimizes
environmental impact after disposal, and is self-contained, thus minimizing
readmission of
containments. The filter media can, in an exemplary embodiment, be a pleated,
folded filter
media, the pleats providing added surface area in the exposure area. The
filter media is
collected and stored in a containment area preventing re-admission and re-
exposure of the
collected contaminants to the air or the air handler system.
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00511 Figure 1 illustrates a top view of an embodiment of the instant
invention. An air handler
unit direct replacement air filter 1 is shown. The direct replacement air
filter is located such
that it is in a path or channel of the air being handled by an air handler
(not shown). The
direct replacement air filter 1 has a unitary housing 10. The unitary housing
10 has a uniform
thickness throughout its length and width and is sealed and self-contained so
as not to be
opened by an operator or end user. The thickness typically being of a standard
width for air
handler filters so as to be a direct replacement in existing air handlers, for
example but
certainly not limited too 1" in thickness for residential HVAC systems. In
similar
commercial applications these thicknesses can be for instance, but certainly
not limited to,
between one and three inches. An exposure area, vent, opening, or slot 7 is
provided within
the housing, the exposure area 7 being of sufficient size to permit air from
the air channel to
be flowed there through. The unitary, sealed housing 10 contains an at least
one motivator or
movement device 20, in this instance a roller or shaft, the movement device 20
being driven
by a motor 40 with a power source 50, a controller 60 and a filter media 70.
00521 The unitary, sealed housing 10 can be in an exemplary embodiment,
for example but
certainly not limited to, environmentally friendly stiffened plastics, paper
or cellulose
product, organic plastic like compounds, or similarly green materials. The
housing contains
an at least one motivator or movement device 20, in this instance a take up
shaft 21, having
the filter media 70 attached thereto. In the embodiment shown, the take up
shaft 21 is
coupled to the motor 40 which is in turn coupled to the power source 50 and to
the controller
60. The power source 50 is in this case being an environmentally friendly
disposable battery,
such as but certainly not limited to a lithium ion battery.
0053] The controller 60 selectively powers the motor 40 based on inputs
from an at least one
sensor 80 in the exemplary embodiment In further embodiments, see Figures 8
and 9 below
for example, the sensors and controller can further communicate with
additional elements of
the air handler or a network or both. The controller 60 can, for example,
comprise a printed
circuit board having a microprocessor in communication with the at least one
sensor 80. The
at least one sensor 80 can for instance be a magnetic sensor that determines
the position of
the filter media 70 based on imbedded magnetic tags in the filter media 70. In
the exemplary
embodiment, the controller 60 is activated at installation and tracks days or
hours in
operation.
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[0054]
In the exemplary embodiment the controller 60 can count, for example but
certainly not
limited to, three months and activate the motivator or movement device 20, in
this case the
take up shaft 21 with motor 50. Based on the sensor input the controller 60
can determine
the position of the media filter 70 and stop when a "clean" element or
measured portion of
filter media 70 is in position. The controller 60 can also be used to sense a
condition of the
air, the filter media 70, or a combination of both through communication with
the at least one
sensor 80. The controller 60 can also be used to advance the take up shaft 21
based on the
sensed conditions or as a timed or pre-programmed operating profile or based
on sensor data
in further embodiments.
[0055] The advance of the shaft pays out or unfolds the uncontaminated
filter media 72 on a first
or feed side, designated by "A" in Figure 1, of the housing 10. While
simultaneously on the
opposite side, a filter media take-up compartment 90 is located on a second or
take up side,
designated by "B" in Figure 1 collecting the spent or contaminated filter
media 75 in a
designated containment area. In the embodiment of Figure 1, spanning or
support members
105 are laid in a grid and the unexposed filter media is drawn along it, as
best see in Figure 2.
The filter media 70 has pleats already placed in it. The filter media 70 has
an unexposed
portion that is folded and compactly stored in the media storage area of the
housing, the
unexposed, folded portion of the filter media 72 when exposed to the airflow
is oriented such
that the pleats are matched against and pushed onto spanning or support
members 105
through the pressure exerted by the passing air. This allows for a zig-zag
pattern to form and
increases the overall surface area of the filter media presented to the
airflow in the channel.
00561 In the instant embodiment the contaminated filter media 77 is
folded on itself and thereby
stores and captures the collected particulate matter. In additional
embodiments, the
contaminated filter media 77 is contained in a containment area 90 having a
seal 100 to retain
the contaminated filter media and any captured contaminants.
In both cases, the
contaminated filter media 77 is being collected within the containment area 90
and further
within the unitary housing 10 so as to minimize exposure for reintroduction of
the
contaminants from the exposed or contaminated filter media 77 and,
simultaneously,
preventing contact of the containments with the operator or the environment
during
replacement. The HVAC filter media 70 is provided with a greater amount of
filter material
70 stored in the filter media storage area 75 than existing rigid frame,
stationary filters,
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allowing for extended life. For example, sufficient uncontaminated filter 72
media can be
provided to make, for example, a multi-month, six or twelve month filter.
[0057] Once the uncontaminated filter 72 media is emptied, the controller
can activate an
indicator element 120. The indicator element can be, but is not limited to an
audible alarm or
visual indicator element or LED. Similarly, a scent material may be utilized
on all but the
last piece of the uncontaminated filter 72 media such that the absence or
presence of the scent
is an indicator that the filter needs to be replaced. Either after a specified
time period or once
the indicator element 120 is activated, the user simply removes and replaces
the existing
device in its entirety. The spent or contaminated filter media 77 is contained
and the re-
admission of the filtered contaminants is minimized. The expired HVAC filter 1
can then be
safely disposed of with minimal environmental impact.
[0058] Figure 2 shows a side view of the embodiment of Figure 1. As can be
seen in the side
view, the filter media 70 is pleated and compacted in a storage area 75. The
movement
member 20 is provided here via a cord, wire, or string 22 and take up shaft
21. The string 22
is attached to the pleated filter media 70 via reinforcement tabs 25. As noted
above, as
determined by the controller 60, the motor 40 and take up shaft or roller 21
are activated and
roll the string 22. The string 22 is drawn for a predetermined time or length
and accumulated
on the roller 21. The expended or contaminated filter media 77 is then
accumulated in a
containment or storage area 90 as described above. The reinforcement tabs 25
can be made
so that they release from the string 22 when it reaches the collection area
90.
100591 Figure 3 shows a top view of a further embodiment of the instant
invention. The
embodiment utilizes a similarly dimensioned direct replacement air filter
having a sealed
housing 10 that permits for direct replacement and use in existing HVAC units.
The housing
10, controller 60, filter media 70 in its pleated and compacted state in a
filter media storage
area 75 are similar to the embodiment shown in Figure 1. The motivator or
movement
device 20 in the exemplary embodiment of Figure 3 can comprise a track member
230 and
supporting members 240 the supporting members 240 spaced to fit within the
pleats of the
filter media 70. The track member 230 is moved by the motor 40. The motor 40
drives gear
set 210 that drives a driveshaft 232. The driveshaft 232 in turn drives chain
drive 215 which
engages and turns a drive sprocket 220 that couples to the track 250. This in
turn moves the
filter media 70 from the stored, pleated area 75 unfolding an uncontaminated
portion 70
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therein, exposing the uncontaminated portion 72 to the air and contaminants in
the air
channel, and then moves the contaminated filter media portion 77 of the filter
media to the
spent or containment area 90 where it is stacked again and stored.
00601 Figure 4 shows a side view of the embodiment of Figure 3. The track
member 230 with
cross or support members 240 can be more clearly seen in this figure. The
track member 230
is continuous and recycles the cross members 240. The pleats fold over the
cross members
240 and are pulled by the cross members 240. The unexposed air filter media 72
is thus
exposed to the air in the air channel and the air filtered. The cross members
230 allow the
pleated, unexposed air filter media 72 to replace the spent or contaminated
filter media 77 in
the air channel. The air in the air channel also pushes the filter media into
a zig-zag form
along the pleats similar to the formation shown in the embodiment of Figure 1.
This zig-zag
form increases the surface area of the filter media 70 exposed to the air in
the air channel.
00611 Figure 5 shows a side view of a further embodiment of the invention.
In the embodiment
shown, again the housing 10, motor 40, controller 60, filter media 70 in its
pleated and
compacted state in a filter media storage area 75 are all similar to the
embodiment shown in
Figures 1 and 2. The motivator or movement device 20 is simplified to an at
least one set of
puller or pinch rollers 510, that is the motivator or movement element pulls
the filter media
70 from the pleated and compacted state in the filter media storage area 75 on
the command
of the controller 60 and moves it across the grid of lattice like members 105,
as previously
described above. In further embodiments the at least one set of puller or
pinch rollers 510
can also be a star or toothed roller for added traction on the material or
similar rollers that
provide for efficient movement of the filter media within the device.
00621 The lattice like members 105 allow the filter media 70 to more
easily fold into its zig-zag
pattern and act to support the media in place. As the filter media 70 is moved
by the at least
one set of "puller roller" set 510 from the stored, pleated area 75 unfolding
an
uncontaminated portion 72 therein, exposing the uncontaminated portion 72 to
the air and
contaminants in the air channel, and then moves the now contaminated filter
media portion
77 of the filter media, on a command from the controller 60, to the spent or
containment area
90 where it is stacked again and stored.
0063] The embodiment as shown has an at least one set of puller rollers
510, here a single puller
roller set. However, the embodiment could use multiple sets of rollers as
needed. The single
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puller roller set is located at an end of the exposure slot 7 that is closest
to the containment
area 90. It is within the spirit of the invention to locate the puller roller
set at or near the
stored, pleated area 75. Similarly, additional roller sets can be employed to
move the filter
media 70 as noted, for example a second puller roller set near the stored,
pleated area 75.
[0064] Figure 6 shows another side view of a further embodiment of the
invention. Similar
elements to those of Figures 1-3 are shown and not numbered for brevity.
Again, similar to
the previously described embodiments, the embodiment shown provides for a
housing 10,
controller 60, filter media 70 in its pleated and compacted state in a filter
media storage area
75. A portion of unexposed filter media 72 is withdrawn from the media storage
area 75,
unfolded and drawn across a grid or lattice structure 105. The portion of
unexposed filter
media 72 is then drawn across the exposure slot 7 and exposed. In this
embodiment, the
motivator or movement device 20 is a take-up roller 610. The take up roller
610 rolls up the
exposed filter media 77 in a flat roll format. The take up roller 610 is
stored in the
containment area 90 and can be sealed to prevent readmission of the filtered
contaminates
from the exposed filter media 77.
[0065] Figure 7 shows another side view of a further embodiment of the
invention. Similar to
the previously described embodiments, the embodiment shown provides for a
housing 10,
controller 60, filter media 70 in its pleated and compacted state in a filter
media storage area
75. A portion of unexposed filter media 72 is withdrawn from the media storage
area 75,
unfolded and drawn across a grid or lattice structure 105. The portion of
unexposed filter
media 72 is then drawn across the exposure slot 7 and exposed. In this
embodiment, the
motivator or movement device 20 is an at least one screw drive 700. The screw
drive 700
allows for a strong connection to the filter media 70 and for continuous
movement along the
path from the filter media storage area 75 to the collection area 77.
[0066] Figure 8 shows a still further embodiment of the invention. Similar
elements to those of
Figures 1-3 are shown and not numbered for brevity. The further embodiment
show utilizes
a further variation of a movement device 20 by utilizing a first roller 780
mounting an
unexposed roll 72 of filter material 70 and a second roller 770 rolling up the
exposed filter
material, in this instance pleated filter material, into a storage area 77.
The material being
rolled from the first of the at least two rollers then 770, after exposure,
being wound up on
the second of the at least two rollers 780. Within the filter frame 10,
supporting members
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105 span the exposure slot, with the supporting members 105 spaced to fit
within the pleats
of the filter media 70. The pleated filter material 70 being moved such that
the pleats fold
over the cross members 105 and are pulled across the cross members 105 by the
movement
of the air in the air channel. The unexposed air filter media 72 on the
unexposed roll 780 is
thus exposed to the air in the air channel and the air filtered as it is moved
from roll to roll.
The cross members 105 allow the pleated, unexposed air filter media 72 to
replace the spent
or contaminated filter media 77 in the air channel. The air in the air channel
also pushes the
filter media into a pleated, zig-zag form along the pleats similar to the
formation shown in
the embodiment of Figure 1. This zig-zag form increases the surface area of
the filter media
70 exposed to the air in the air channel. This represents yet another means of
moving the air
filter media within the filter housing. It should also be noted that the
uniform thickness and
the sealed nature of the frame may be varied in this and other embodiments.
Especially in
industrial and commercial embodiments of the invention.
00671 Figure 9 shows a plan view of an exemplary embodiment of the
invention. The inclusion
of electronics and a controller 60 on, for example, a printed circuit board on
the air handler
filter 1 provides an opportunity for added functionality in addition to
extended operating
length. As noted above with respect to Figure 1, the controller 60 can also be
used to sense a
condition of the air, the filter media 70, or a combination of both through
communication
with the at least one sensor 80. The exemplary version shown in Figure 9 can
utilize any of
the filter advance systems previously discussed to provide Air Quality
Management (AQM)
features. AQM is a system designed to be incorporated into the filter 1 to
monitor the quality
of the air as it passes through the filter 1 and interact with a network
system to monitor the
air quality at the point of filtration.
0068] The AQM system is comprised of an at least one air quality sensor
80, with added
processor modules 62 and data transceiving modules 63 on the controller 60.
The at least
one sensor is incorporated into the filter frame such that it is in the path
of air as it is drawn
though the filter frame 10 at the exposure slot 7. The processor module 62 and
transceiver
module 63 are housed within the filter frame 10 near the drive motor and are
powered from
the same power supply as the motor. The controller 60, processor modules 62,
and
transmitting modules 63 have software on them to measure and report air
quality parameters
from the at least one sensor 80. They may report the air quality parameters to
an internal
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storage device (not shown), wirelessly 1010, or via wired communication 1020
directly to a
network 1000. Alternatively, in other embodiments an external device which may
store the
data and/or be enabled to communicate with the network 1000 via wire 1020 or
wirelessly
1010 and thereby may report the parameters to the network 1000 as shown in
Figure 9 and
described herein below. These can be powered by an onboard, independent power
supply or,
for example, be powered by a dedicated external power supply in for instance
an industrial or
commercial application like a paint spray booth.
00691 The at least one sensor 80 allows the system to monitor the air and
in conjunction with
the processor, collects data regarding air contaminants along with air
quality. These sensors
may include but are not limited to sensors that detect and report temperature,
mold, carbon
monoxide, carbon dioxide, Volatile Organic Compounds, smoke, fire, Noxious
Gases, Air
Particle Concentration and other potentially dangerous compounds. The at least
one sensor
80 can also detect pressure drops and communicate that info back to the filter
1 so that the
filter 1 can set the changing cycle accordingly and advance the filter media
70 accordingly.
For example, if the filter 1 is pre-set to change the filter media 70 every
ninety days and last
twelve months but the media is being contaminated at a higher rate as detected
by the at least
one sensor 80, it will move up the next change to facilitate a consistently
clean filter. This
change can also be reported out from the filter 1 through the controller 60
and the
transmitting modules 63. This real time monitoring can be incorporated in
residential unit
applications or in industrial and commercial unit applications.
0070] In addition to monitoring air quality, performance measures can also
be communicated as
part of the data retrieved from the at least one sensor. A non-limiting
example, as noted in
the previously described embodiments of Figures 1-8, an air flow meter can be
included in
the at least one sensor 80. This would allow, in conjunction with the
processing modules 62
on the controller, a measurement of estimated energy usage. This can be
reported through
the network 1000 by the transceiver module 63 and reported to an alert device,
including for
example but not limited to a cell phone, a computer, a network operations
center or the like.
Additionally, as part of the programming on the processing modules 62, the
controller 60 can
download program guides through the network and notify users and allow for
additional
configuration options of the air handler.
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00711 All of this information can be stored or sent in real-time or both.
The information can be
sent, for example but certainly not limited to, to a reporting station,
interne access portal,
network interface device or internet cloud server via wireless signal,
cellular or WI-
Fl/Internet Wireless Protocol technology or similar signal convention, that is
accessible to
the user via computer or smart phone or similar device, as shown in Figure 9.
The air quality
parameters and data on the operation of the filter can also be retrieved
directly from the filter
via a communications port 67 located on the filter frame, for example but
certainly not
limited to a USB port or a mini-USB port or similar communications port.
Reports can be
generated that can be retrieved showing the status of the air filter and the
air quality over
time. This can also be available for review by a report device accessed by the
homeowner
and/or building management or to a Network Operations Center (NOC) of the type
typically
found in industrial or commercial applications or provided as a function of an
alarm or alert
service in a residential setting or commercial setting.
0072] The network 1000 can then transmit the information to a wireless
device or wired device
as a network interface 1030, for example, but certainly not limited to a smart
phone or hand
held computer or netbook or similar device 1060. The network 1000 can also
report the data
to a computer or other device 1040, wired 1010 or wirelessly 1020 coupled to
the network
1000, to report air quality or other aspects of the filter 1. Finally, the
data can be
communicated to a Network Operations Center (NOC) or master control center
1050, all of
these options happening alone or in conjunction with one another, the NOC
which is actively
monitoring the filter 1 and the air quality in the air handler. A non-limiting
example of the
operation of the Network Operations Center 1050 can be a third party alarm
monitoring
company which is monitoring air quality for a customer or several customers.
Another non-
limiting example can also make the NOC part of a manufacturing facilities
control center as
part of a commercial or industrial process whereby the air handler unit is
being monitored by
the control center, for instance in chemical production or commercial painting
booths.
0073] Notification or alerts, including those previously described in
relation to Figures 1-8, may
be sent to the homeowner or building management or NOC of urgent conditions.
These can
include emergency alerts that may require immediate attention. This may be a
part of the
design of a monitoring system enabled via the network or as a paid third party
monitoring
service. This service may be offered for a monthly fee or reported to a
security monitoring
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company, for example, either via intemet, email, cellular, text message or
telephone or any
other fashion that fits the service providers reporting network. Other
responses can involve
communication from the filter or from other elements in the network which may,
in case of
sensing certain parameters i.e. dense smoke, take action with other network
components. A
non-limiting example of such an action is having the air handler controller
turn off the air
circulation system via communication with the thermostat or similar device to
prevent smoke
circulation when a smoke or fire or other dangerous substances are detected in
the air.
[0074] Thus, in addition to providing a unique air filter with the ability
to provide and extended
useful life with the movement of the filter media, the instant invention
includes a method for
alerts for replacement and possibly delivery of replacement filters.
Additionally, a method of
monitoring services is also conceived hereby for use in conjunction with or
apart from the
method of alerting and replacement.
[0075] An inventive method of seamless replacement delivery can be
accomplished by
employing the filter of Figures 1-8 with or without the AQM system. By
including just the
transceiver modules 63, with or without the additional processor modules 62,
an enhanced
convenience for air handler owners can be incorporated into the sale of the
filter. The filter
1, which as noted above can send a signal when the uncontaminated media 72 has
been
completely dispensed, with the transmission module 63 can send an alert to a
user through
one of the alert devices 1040, 1050, or 1060 and a replacement air filter can
be sent. This can
of course be conditioned on confirmation from the owner of the air handler or
can be
provided as part of a monthly service. Additionally, the alert can be sent to
a center and
service personnel dispatched as part of a standard maintenance response or as
part of a paid
for maintenance service.
00761 In yet another application application, as noted above by
incorporating the at least one
sensor 80 and the processor modules 63, in addition to sending a signal at the
completion of
the distribution of the uncontaminated filter media 72, real time monitoring
can be completed
and sent as part of a monthly service contract or as part of a regular
maintenance screening or
as part of an emergency response. The at least one sensor 80 can transmit data
through the
controller 60 and the processor modules 62 and transceiver modules 63, the
data can be
routed to a third party service provider that maintains the air handler and
monitors air quality
for a subscriber. The data can also be transmitted as part of a regular
maintenance
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monitoring or screening system in an industrial or commercial application to a
NOC or
similar central control 1050. Also, as noted, the data may also be transmitted
as part of an
emergency response to a third party or emergency responder or both and
additional signals
could be transmitted through a network to shut an air flow off and prevent
promulgation of
hazardous airborne contaminants.
[0077] The embodiments and examples discussed herein are non-limiting
examples. The
invention is described in detail with respect to preferred embodiments, and it
will now be
apparent from the foregoing to those skilled in the art that changes and
modifications may be
made without departing from the invention in its broader aspects, and the
invention,
therefore, as defined in the claims is intended to cover all such changes and
modifications as
fall within the true spirit of the invention.
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