The present invention is generally directed to air purifier devices. More particularly, the present invention is directed to air purifier devices and high efficiency particulate air (“HEPA”) filters used in such purifier devices.
In recent years there has been a growing interest in improving environmental air conditions as the general ambient air has become more polluted. As more information is made available to consumers concerning environmental conditions, there has been an increased demand for products which can be used to effectively improve air quality, particularly within the home or office. As the number of airborne pollutants continues to increase, the effects upon the public have resulted in an increased number of complaints of respiratory infections, burning eyes, allergies, asthma attacks and other symptoms which are directly related to air pollution. One need only to consider the types of airborne particles which are inhaled by the average person on a daily basis to understand that the problem with airborne pollutants is ever increasing and its side effects growing. People are constantly inhaling particles of dust, smoke, pollen, molds, bacteria and the like.
Due to the ever increasing public awareness and the increasing health problems resulting from air pollution, an increasing demand has arisen for products which can be used by the general public to clean the air and improve air quality conditions in homes and places of employment. As a result, air purifiers for removing airborne particles are presently used in many homes and offices. Such purifiers often include a HEPA filter. In operation, these purifiers use one or more fans to cause air to be drawn into the purifier, through the filter to remove airborne particulates, and subsequently the filtered air is then emitted from the purifier through an outlet. HEPA filters have gained increasing acceptance for use in purifiers directed to consumers as they remove 99.97% of particles having a size equal to or greater than 0.3 microns.
Since HEPA filters arrest up to 99.97% of all particles, even the smallest amount of unfiltered air bypassing the HEPA filter and later mixing with the filtered air will bring the filtering efficiency down significantly. Thus, it is important to insure that the installation of the filter within the purifier is optimized and that no unfiltered air is permitted to bypass the filter. Because the filter employed in the the air purifier requires replacement when spent, the ability to easily remove and replace the filter is important. Critically, a filter must be properly aligned and installed within the purifier if it is to seal against unfiltered air bypassing the filter in order for the air purifier to function properly and achieve its maximum filtering efficiency.
One of the known disadvantages of prior art air purifiers is that the air filter can be easily misaligned or improperly installed into the air purifier by the consumer. This results in the phenomenon commonly known as “short-circuiting” wherein the air drawn into the air purifier will seek the path of least resistance and tend to flow around and bypass the filter, rather than pass through the filter, if the filter is not properly installed in the device. This results in less than satisfactory performance as the pollutants in the air are not removed by the filter but are emitted back into the ambient air.
While many air purifiers and air filters are known to the art and are described in the patent literature, there remains a real need for further improvements to such purifier/filter combinations. It is to such need and to such improvements that the present invention is directed.
In accordance with a first aspect of the invention, the air purifier is designed to create an audible signal to alert a user if the air purifier is operated without an air filter or if the air filter is improperly installed in the air purifier.
In accordance with a second aspect of the present invention, therein is provided a magnetically operated interlock device wherein the filter must be properly installed within the air purifier to enable closure of an electrical switch within the air purifier, thereby completing an electrical circuit and permitting the air purifier motor and fan to operate.
The present invention has overcome the aforementioned problem by utilizing either one or both of: (i) an arrangement whereby an audible signal is produced to alert the consumer that the air purifier is operating either without an air filter or with an air filter that has been improperly installed, and/or (ii) a magnetic interlock arrangement to prevent the consumer from operating the air purifier at all if a filter is not installed or if the filter is improperly installed within the air purifier housing.
An air purifying device is provided for removing airborne particles. Such an air purifier generally includes a housing including an air inlet and an air outlet. A fan is positioned within the housing for drawing air into the interior of the housing through the air inlet and expelling filtered air through the air outlet. A filter assembly is positioned within an opening, within the housing, between the air inlet and the fan. The opening is configured to receive a filter assembly. The filter assembly includes a filter element, e.g, a folded or pleated type filter element, mounted within a frame or gasket such as a flexible foam gasket. In accordance with a first aspect of the invention, a portion of the housing of the air purifier, preferably at or near the opening of the housing, includes a vent hole or other passageway which contains a whistle or other instrument (e.g. a reed or a pair of reeds which may be vibrated, such as found in a harmonica). This instrument emits an audible sound when air is drawn into the passageway when the air purifier fan is operated and the filter assembly is either not installed or is improperly positioned within the housing by the user. Ideally, such a whistle or other reeded instrument will emit a sound within the audible frequency range for most persons (20 Hz-20 kHz) and be loud and/or of a high pitch so that it can plainly be heard by most persons above the operating noise of the air purifier fan.
In accordance with a second aspect of the invention, the filter assembly and housing of the air purifier together provide a magnetic interlock device. In this aspect, permanently affixed to a part of the housing, is provided a conventional electrical switch which is switchable between an open and a closed position. Such switching may occur as a direct result of the movement of a moveable post or one or more moveable elements forming part of the electrical switch, or switching may occur via movement of a lever arm forming part of the electrical switch. A permanent magnet may be affixed to the post of the electrical switch or, where the switch includes a lever arm, a permanent magnet may be permanently affixed on the lever arm preferably close to its moveable end. Concurrently, at an appropriate position in close proximity to the magnet associated with the electrical switch, there is embedded either within the filter element or within the frame or gasket, a ferous metal body or a magnet. Any form of a ferrous metal body may be used and embedded, e.g., an iron pin, disk, rod, wire or discrete particles such as pellets or filings, as long as such is of sufficient size to cause the electrical switch to be switched when the filter is properly installed within the opening of the housing. Similarly, when an embedded magnet is used, it is necessarily of sufficient strength and should be installed with appropriate polarity facing the magnet associated with the electrical switch so as to cause the electrical switch to be switched when the filter is properly installed within the opening of the housing. In use, when a removable filter assembly is properly installed in the housing, the electrical switch is switched responsive to the proximate location of the embedded ferrous body or embedded magnet, consequently closing or opening a circuit and allowing the motor and fan of the air purifier to operate.
In accordance with a third aspect of the invention, the filter assembly and housing of the air purifier together provide a magnetic interlock device. In this aspect, permanently affixed to a part of the housing is provided an electrical reed switch which is switchable between an open and a closed position responsive to the presence of a magnet or other magnetized body in sufficient proximity to the electrical reed switch causing it to open or close. The filter assembly according to this aspect of the invention is as described with reference to the second aspect of the invention, but desirably includes a magnet. In use, when a removable filter assembly is properly installed in the housing, the electrical reed switch is switched responsive to the proximate location of the embedded magnet or embedded magnetized body, consequently closing or opening a circuit and allowing the motor and fan of the air purifier to operate.
According to a fourth aspect of the invention, there is provided a filter assembly and housing of an air purifier which together provide a magnetic interlock device as generally described in accordance with the first, second and third aspects of the invention, but which differs in that the activation of the switch activates an indicator device which may be one or more electrically-actuated visual devices such as a lamp or LED, or one or more electrically-actuated audible devices such as a buzzer, siren bell or other tone generator, thereby providing a visual and/or audible indicator to the user of the device indicating incorrect installation of the filter or absence of the filter within the air purifier. According to this embodiment, the fan of the air purifier may operate independently of the magnetic interlock device, or alternately may be controlled by the magnetic interlock device.
According to a further aspect of the invention there is provided an air purifier device which includes the features according to one or more of the first, second or third aspects of the invention described herein.
Therefore, should the filter assembly be improperly installed within the opening of the housing of the air purifier by the user, either an audible signal will be emitted by the air purifier and/or the air purifier will not operate. In either instance, one or both of these conditions alert the user that the filter assembly is improperly installed within the air purifier and the filter assembly needs to be properly reinstalled within the housing for the air purifying device to work properly, or that a proper filter assembly is absent from the air purifier and needs to be properly installed.
These and other aspects of the present invention will be more apparent from the following description including the description of preferred embodiments as well as from a review of the accompanying drawings in which:
It is believed that the present invention will be better understood from the following description of preferred embodiments, taken in conjunction with the accompanying drawings, in which like reference numerals identify identical elements throughout each of the figures.
With initial reference to
Housing
Referring now to
Referring now to
Referring to
As described in more detail below, the purpose of producing such an audible sound is to alert the user either that: (a) the filter assembly is not inserted into the device 10 and that continued operation of the device in this manner will not produce the desired effect of removing particulate matter from the ambient air, or (b) that the filter assembly has been improperly seated into the housing 12, again resulting in the same undesirable effect.
In a further aspect of the present invention, referring to
The housing 12 preferably will also accommodate a control knob 56 for adjusting the fan speed to control the flow of air into the housing through the air inlet 36 disposed in the front cover 14. Control of the fan speed may be by use of a conventional resistor block, or other solid state means for varying the rotational speed of the fan
The housing 12 and the removable front cover 14 are preferably made from a light weight durable material such as any of a number of synthetic thermoformable or thermosettable polymers which are preferably non-conductive and which are sufficiently rigid in order to maintain the shapes of the various elements used to construct the air purifier device. Exemplary synthetic polymers include polystyrene, polyalkylene terepthalates, polyamides, polysulfones, as well as other synthetic polymers not elucidated herein. Such synthetic polymers and blends may further include one or more additional filler and stiffening materials such as carbon fibers, glass fibers, glass beads and the like.
Filter Assembly
Referring to
In another embodiment, as shown in
Desirably, the filter element 58 portion of the filter assebly 16 is a high efficiency particulate air (“HEPA”) filter. The HEPA filter shown in
It is to be understood that the placement of the ferrous metal body 70 or magnet need not be limited to placement within or on the pleated portions 62 of the filter element 16. In a further embodiment the ferrous metal body could be placed within the foam gasket 44 either as a series of discrete ferrous particles or as a ferrous rod or wire. The important part is that the placement of the ferrous body 70, regardless of its shape, size, or placement on or within the filter element or gasket, be in sufficiently close proximity to the magnet 72 associated with the switch 74 when the air filter assembly 16 is oriented and positioned within the opening 32 of the housing 12, to cause the switch to move from its open position to its closed position, thus completing the electrical circuit and allowing the fan 20 and motor 22 within the air purifier to operate. The proximity between the magnet 72 and the ferrous metal body 70 at which the switch 74 will be actuated will vary depending upon the strength or flux of the magnet and the size of the ferrous metal body. It is contemplated, however, that the distance between the magnet and the metal body will be less than four inches, more preferably less than three inches, and most preferably less than two inches.
The filter assembly 16 of air purifier 10 is easily removed when the filter element 58 becomes soiled from the particulate matter captured by the filter element from the ambient air drawn into the housing 12. The front cover 14 is first removed and then the spent filter assembly 16 is removed from the channel 40 by pulling on, for example, a tab or ring 78 (see
Safety Cage
As shown in
Fan and Motor
Also within the housing 12, positioned between the safety cage 18 and the rear wall 28 of the housing is a centrifugal fan 20 driven by an electric motor 22. The fan 20 is positioned within the housing so that air is drawn through the air inlet 36 of the front cover 14, through the filter element 58 of the filter assembly 16, and then through the openings in the safety cage whereupon the now filtered air is subsequently exhausted through the air outlet 38 formed in the top wall 24 of the housing 12 as shown in
The fan 20 can be of any type suitable of generating sufficient air movement to draw ambient air into the housing through the air inlet, then through the filter element, and then exhausting the filtered air out of the housing through the air outlet disposed in, for example, the top wall 24. Preferably the fan is of the type known in the art as a centrifugal or “squirrel cage” fan, although it can also be a propeller-type fan.
In operation, the control knob 56 on the housing 12 is turned by the user to select the desired fan speed. Rotation of the fan blades causes air to be drawn into the air inlet 36 and through the filter element 58. Since the filter assembly 16 restricts the airflow, considerable suction is created across the surface of the filter assembly 16 causing the filter assembly to be drawn into the housing 12 towards the safety cage 18. This force enhances the engagement of the gasket 44 within the channel 40 to ensure that unfiltered air does not bypass or short-circuit the filter assembly 16 prior to passing through the safety cage and exiting the housing through the air outlet 38.
Thus, in one aspect of the present invention, operation of the air purifying device 10 will be prevented if the filter assembly 16 containing a ferrous metal body or magnet is either not placed within housing 12 containing a switch and magnet arrangement as described or if the filter assembly is not properly oriented and positioned within the housing such that the ferrous metal body or magnet is displaced too far away from the magnet of the switch and the magnet cannot act upon the ferrous metal body or corresponding magnet. This is particularly advantageous in that it will prevent the by-pass of untreated and unfiltered air around the filter assembly.
Additionally, in a further aspect of the present invention, an audible sound such as a whistle will be generated if the air purifying device 10 is operated either without a filter assembly 16 or if the filter assembly is improperly aligned or installed within the housing 12 so that the orifice 48 is not covered. This is again particularly advantageous in that it alerts a user that either air is being circulated without any treatment or that untreated air is by-passing the filter assembly.
Yet further as has been briefly discussed above, the air purifying device 10 includes an indicator device which may be one or more electrically-actuated visual devices (e.g., a lamp or LED) or one or more electrically-actuated audible devices (e.g., a buzzer, siren, bell or other tone generator) thereby providing a visual and/or audible indicator to the user of the device indicating incorrect installation of the filter or absence of the filter.
The preferred embodiments of the present invention have been illustrated and described herein. However, it is to be understood that the present invention is not limited to the preferred embodiments described herein. Various alternatives and modifications can be devised by someone skilled in the art without departing from the invention. Accordingly, the present invention is intended to embrace all such alternatives, modifications and variances which fall within the scope of the appended claims.
Number | Date | Country | Kind |
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0424882.9 | Nov 2004 | GB | national |
Filing Document | Filing Date | Country | Kind | 371c Date |
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PCT/GB05/04247 | 11/3/2005 | WO | 00 | 5/4/2007 |