Patent Application
20170246583
The present disclosure relates to air filters. More particularly, it relates to adjustably sized air filter systems capable of use in a window opening.
Windows are available in a large variety of sizes and can include vertically or horizontally operable sashes to provide air flow between an exterior and an interior of a building structure. Occupants of a building structure often desire opening windows to let fresh air into an interior of a home, business, or otherwise enclosed space. However, in many locations, such as highly populated areas of China, the outside air is more contaminated than the indoor air. Novel filtering solutions are needed to let the fresh aspects of the outdoor air in without letting in the pollution or contaminants. Outdoor contaminants may include larger particles such as pollen, dust, and mold spores and smaller particles such as those forming PM2.5, bacteria, and viruses. Gaseous outdoor pollutants such as odors, NOx, SO2, ozone, and others may also be of concern in some locations.
The inventors of the present disclosure recognized that, in light of the above, a need exists for an air filter that protects users from air quality contaminants, allows fresh air get into the home through windows, can be easily installed and used by consumers, is versatile to fit in most locations, and/or has minimal impact on lighting and visibility. In some embodiments, the filter is a window air filter.
The inventors of the present disclosure invented various embodiments of air filters, methods of making air filters, and methods of using air filters.
Some embodiments relate to an air filter comprising filter media assembly configured in a roll, the filter media assembly including filter media having a leading end opposite a trailing end and first and second opposed side edges extending between the leading end and the trailing end.
In some embodiments, the air filter further comprises a housing for containing the filter media assembly. In some embodiments, the leading edge can be releasably retained on at least one of the exterior or interior of the housing. In some embodiments, the filter media assembly is replaceable within the housing. In some embodiments, at least one of the leading edge and the trailing edge includes a looped structure, a hooked structure, and/or a fastening device. In some embodiments, the first end includes a handle. In some embodiments, the filter media assembly is retractable on the roll. In some embodiments, the roll includes a central member that is under spring tension. In some embodiments, the central member provides stopping points. In some embodiments, the filter media assembly includes sufficient filter media for multiple uses. In some embodiments, the filter media assembly includes separation and/or perforation lines or points.
Some embodiments further include a hinged attachment mechanism. In some embodiments, the hinged attachment mechanism is combined with the housing or attached to the central member. In some embodiments, the hinged attachment mechanism is rotatable.
In some embodiments, the filter media is at least one of moisture-resistant, moisture-repellant, electrostatically charged, an electret nonwoven web, and/or not electrostatically charged. In some embodiments, the filter media includes at least one of carbon, activated carbon, a nonwoven, a thermoplastic, a thermosetting material, a porous foam, fiberglass, paper, a high loft spunbound web, a low loft spunbound web, a meltblown web, and/or bi-modal fiber diameter meltblown media. In some embodiments, the filter media is pleated. In some embodiments, the filter media is at least one of self-supporting and non-self-supporting.
Some embodiments further include a cutting device capable of cutting the filter media to a desired size. In some embodiments, the cutting device is integrated into the housing.
In some embodiments, the air filter is a window air filter.
Some embodiments relate to a kit comprising an air filter as described above or herein and a cutting device capable of cutting the filter media to a desired size. In some embodiments, the cutting device is integrated into the housing.
Some embodiments relate to a kit comprising an filter as described above or herein and an attachment device capable of permanently or semi-permanently attaching the air filter to a window. In some embodiments, the attachment device is at least one of a nail, a screw, a hook, an adhesive, and/or an adhesive backed interlocking strip.
Various embodiments and implementations will be described in detail. These embodiments should not be construed as limiting the scope of the present application in any manner, and changes and modifications may be made without departing from the spirit and scope of the embodiments and implementations. For example, many of the embodiments, implementations, and examples are discussed with specific reference to window air filters, but these should not be construed to limit the application scope to this one exemplary implementation. Further, only some end uses have been discussed herein, but end uses not specifically described herein are included within the scope of the present application. As such, the scope of the present application should be determined by the claims.
One embodiment of a retractable filter 20 useable in a window in accordance with principles of the present disclosure is illustrated in
In general terms, the adjustable length of the filter media assembly 30, due to the retractable nature, allows it to fit in a wide variety of window sizes. The retractable filter 20 can be attached to a partially opened window. The retractable filter 20 can fit a wide variety of window sizes. The retractable filter 20 can be employed in a partially open window, where only 10-30% of the window area is blocked, for example, leaving a large percentage of the window area still open for light passage and visibility.
In some embodiments, a roll of filter media assembly 30 has a first, or leading, end 36 and a second, or trailing, end (not shown) opposite the first end 36 adjacent to a central member 34. First and second side edges 38, 40 extend between the first end 36 and the second end. In some embodiments, the filter media assembly 30 is generally rectangular when extended. In some embodiments, the first end 36 can include a handle 42 for increased usability. In some embodiments, one or both of the first and second side edges 38, 40 can include a looped structure (generally indicated by dashed line 44) or other fastening device, as is discussed in more detail below.
As illustrated in
In some embodiments, the filter media assembly 30 is retractable onto the roll 33 and unwound, or expanded, from the roll 33, as indicated by arrow “A” of
In some embodiments, the filter media assembly 30 includes filter media 32 of suitable size to fit a wide variety of window dimensions. In some embodiments, the filter media assembly 30 may be longer than needed for a single use. In some embodiments, the filter media assembly 30 has a length suitable to provide for one or more filter media 32 changes, for example, wherein the dirty filter media 32 is discarded, and a clean segment of filter media 32 is unwound from the next section on the filter media assembly 30. In some embodiments, the filter media assembly 30 can be cut to expose a new length of clean filter media 32, providing for multiple filter changes from a single filter media assembly 30. With particular reference to
In some embodiments, the filter media assembly 30 may incorporate looped structures 44, for example, either integrally or by addition, such as lamination, into one or both of the first and second side edges 38, 40. The loop structure 44 may be mated to a hook structure (see, e.g.,
The particular filter media 32 selected for the filter media assembly 30 can be particularly suited have any of the particular desired characteristics described herein. In some embodiments, the filter media assembly 30 is constructed from moisture-resistant materials. In some embodiments, the filter media may include additional layers or features to specifically block or repel water, such as rain. In some embodiments, an electrostatic charge is optionally imparted into or onto material(s) of the filter media 32. In some embodiments, an electrostatically charged media 32 may be used, of which many grades are available, and many of which offer high efficiency with low pressure drop. In some embodiments, the filter media 32 can be an electret nonwoven web. Electric charge can be imparted to the filter media 32 in a variety of ways as is well known in the art, for example by hydrocharging, corona charging, etc. (e.g., as described in U.S. Pat. No. 7,947,142, the entirety of which is incorporated by reference herein).
In other embodiments, the filter media 32 is not electrostatically charged. In some embodiments, additional multi-functional media grades, which incorporate activated carbon or other materials for purifying gas-phase pollutants, may also or alternatively be incorporated into the filter structure. In some embodiments, the filter media 32 can be constructed, for example, from nonwoven fibrous media formed of thermoplastics or thermosetting materials such as polypropylene, linear polyethylene and polyvinyl chloride. Other suitable, non-limiting materials for the filter media include porous foams, nonwovens, papers, fiberglass, or the like. In some embodiments, the filter media 32 comprises a filter media that attracts and captures dust, allergens (such as pollen and mold spores), and/or fine particle pollution from the outdoor air.
Other nonwoven webs useful with the filter media 32 can be a high loft spunbond webs, such as described, for example, in U.S. Pat. No. 8,162,153 to Fox et al., the entirety of which is incorporated herein. In other embodiments, the filter media 32 can be a low loft spunbond web, such as is described in U.S. Pat. No. 7,947,142 to Fox et al., the entirety of which is incorporated herein. In yet other embodiments, nonwoven webs useful with the filter media 32 are generated by other techniques and/or have other characteristics, such as the meltblown nonwoven webs disclosed in U.S. Pat. No. 6,858,297 to Shah et al., the entirety of which is incorporated herein. Other non-limiting example of useful nonwoven web formats include bi-modal fiber diameter meltblown media such as those described in U.S. Pat. No. 7,858,163, the entirety of which is incorporated herein.
In some embodiments, the filter media 32 is an electrostatically charged nonwoven type of media. In some embodiments, the filter media 32 can be a pleated filter media including at least a portion that has been folded to form a configuration comprising rows of generally parallel, oppositely oriented folds. In some embodiments, pleats can be formed in the filter media 32 (or in the pleated filter media assembly 30) using various methods and components as are well known in the art, e.g., to form a pleated filter for use in applications such as air filtration., for example those described in U.S. Pat. No. 6,740,137 to Kubokawa et al. and U.S. Pat. No. 7,622,063 to Sundet et al., the entire teachings of both of which are incorporated herein by reference.
In some embodiments, the filter media 32 can consist of the filter media or web alone or can include one or more additional components or structures applied or assembled to the filter media 32 so long as the resultant filter media assembly 30 can at least be transitioned from the rolled condition to the unrolled condition without significantly damaging the structural integrity of the filter media assembly 30. In some embodiments, the filter media can be repeatedly transitioned between the rolled and unrolled conditions without significantly damaging the structural integrity of the filter media assembly 30. The filter media 32 of the assembly 30 can be self-supporting or non-self-supporting. For example, where the filter media assembly 30 consists of the filter media 32 alone, the filter media or web can be self-supporting or non-self-supporting. In some embodiments, where the filter media assembly 30 consists of the filter media or web 32 and a support structure, the filter media 32 can be non-self-supporting with an additional supporting structure rendering the filter media assembly 30, as a whole, to be self-supporting. For example, the filter media 32 can be wire-backed. As used herein, the term “self-supporting filter media or web” can describe at least one of the following conditions: (1) a filter media or web that is deformation resistant without requiring stiffening layers, adhesive or other reinforcement in the filter media web; or (2) the filter media generally maintains its shape when subjected to an airstream as described, for example, in U.S. Pat. No. 7,169,202 to Kubokawa, the entire teachings of which are incorporated herein by reference; or (3) a web or media having sufficient coherency and strength so as to be drapable and handleable without substantial tearing or rupture. As used herein, the term “non-self-supporting” can denote an air filter media that is not capable, in the absence of a support frame and/or a support grill, of withstanding the forces encountered due to typical air flow.
In some embodiments, the retractable air filters 20 are useful in protecting users from outside air quality contaminants As discussed above, an electrostatically charged media 32 may be used. Additional multi-functional media grades, which incorporate activated carbon or other materials for purifying gas-phase pollutants, may also be incorporated into the filter media assembly 30. By incorporating an extended surface area and by covering moderate portion of the window, in combination with using a low pressure drop web enabled by the electrostatic charging, a reasonably low pressure drop can be achieved for the filter, which may help provide moderate airflow through the filter.
Finally, similar to the vertical sliding window 180 of
The air filters of the present disclosure can be placed in any desired frame or housing. Some exemplary frames are described in, for example, U.S. Patent Application No. 62/041,496 and 62/041,499, both of which are incorporated in their entirety herein. The air filter assembly of the present disclosure can be used in a powered air filtration system such as, for example, that described in U.S. Patent Application No. 62/041,501, incorporated herein in its entirety. The air filter assembly or media of U.S. Pat. No. 62/206,928 can be used in the air filters of the present disclosure.
The terms first, second, third and the like in the description and in the claims, are used for distinguishing between similar elements and not necessarily for describing a sequential or chronological order. It is to be understood that the terms so used are interchangeable under appropriate circumstances and that the embodiments of the invention described herein are capable of operation in other sequences than described or illustrated herein.
All references mentioned herein are incorporated by reference in their entirety.
Moreover, the terms top, bottom, over, under and the like in the description and the claims are used for descriptive purposes and not necessarily for describing relative positions. It is to be understood that the terms so used are interchangeable under appropriate circumstances and that the embodiments of the invention described herein are capable of operation in other orientations than described or illustrated herein.
The recitation of all numerical ranges by endpoint is meant to include all numbers subsumed within the range (i.e., the range 1 to 10 includes, for example, 1, 1.5, 3.33, and 10).
Those having skill in the art will appreciate that many changes may be made to the details of the above-described embodiments and implementations without departing from the underlying principles thereof. Further, various modifications and alterations of the present invention will become apparent to those skilled in the art without departing from the spirit and scope of the invention. The scope of the present application should, therefore, be determined only by the following claims and equivalents thereof.
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/US15/46490 | 8/24/2015 | WO | 00 |
| Number | Date | Country | |
|---|---|---|---|
| 62041496 | Aug 2014 | US | |
| 62041499 | Aug 2014 | US | |
| 62041500 | Aug 2014 | US | |
| 62041501 | Aug 2014 | US | |
| 62206928 | Aug 2015 | US |
