Patent Application
20070221061
The present application is directed to an air purifier for removing particles from air. The air purifier preferably removes dust and other particles from a room, typically in a household environment. More particularly, the present application is directed to an air purifier that provides an aesthetically pleasing appearance and removes the particles from air in the room.
As room air and the atmosphere in general becomes contaminated, dusty or otherwise dirtied, the general population becomes aware of discomforts and other disadvantages associated with contaminated air. Air purification and/or filtration devices of various shapes, sizes and capacities have become more popular as a result of the increased awareness of household air quality and air quality in general. Various air purifiers or air filtration devices are available for home or industrial use but are often unsightly.
It would be desirable to construct an air purifier that removes particles, including dust, from air and provides an aesthetically pleasing appearance. It would also be desirable to construct an air purifier that has an aesthetically pleasing appearance that is adaptable to user preferences and includes an air filter that may be removed and replaced with a replacement filter or is otherwise cleanable to increase the useful life of the air filter.
Briefly stated, a preferred embodiment of the present invention is directed to an air purifier for removing particles from air and providing an aesthetically pleasing appearance. A housing includes an air inlet, an air outlet and an airflow path therethrough. An air filter is mounted within the housing in the airflow path and a motor is mounted within the housing. The motor includes a motor shaft and a fan is mounted to the motor shaft for urging air into the air inlet, through the airflow path and out of the air outlet. An air cowl is removably mounted to the housing and includes a peripheral edge. The air inlet or the air outlet is defined between the peripheral edge of the air cowl and the housing.
In another aspect, a preferred embodiment of the present application is directed to a method of operating an air purifier including a housing having an airflow path therethrough and an air outlet. A motor is mounted within the housing and a fan is positioned within the airflow path driven by the motor. An air filter is positioned within the airflow path and an air cowl having a peripheral edge and a decorative pattern is mounted to the housing. An air inlet is defined between the peripheral edge of the air cowl and the housing. The method includes the steps of mounting the air cowl to the housing such that the peripheral edge defines the air inlet with the housing, positioning the air purifier within a room and actuating the motor to drive the fan and urge the air into the air inlet, through the air filter and out of the air outlet.
The foregoing summary, as well as the following detailed description of a preferred embodiment of the invention, will be better understood when read in conjunction with the appended drawings. For the purpose of illustrating the invention, there is shown in the drawings an embodiment which is presently preferred. It should be understood, however, that the invention is not limited to the precise arrangements and instrumentalities shown. In the drawings:
Certain terminology is used in the following description for convenience only and is not limiting. The words, “right”, “left”, “lower”, “inwardly”, “outwardly” and “upper” designate directions toward and away from, respectively, the geometric center of the air purifier and designated parts thereof. The words “up”, “down”, “right” and “left” designate directions in the drawings that correspond to the orientation of the preferred air purifier and designated parts thereof, but are not limiting. The terminology includes the above-listed words, derivatives thereof and words of similar import.
Referring to the drawings wherein like numerals indicate like elements throughout, there is shown in
Referring to
In the preferred embodiment, the air outlet 16 is comprised of a first louvered vent 16a and a second louvered vent 16b integrally molded into a rear surface of the housing 12. The louvers of the first and second louvered vents 16a, 16b permit airflow through the air outlet 16 and generally prevent insertion of objects or appendages of a user's body into the outlet 16 and potentially into contact with moving parts of the air purifier 10 within the housing 12. The air purifier 10 is not limited to including the first and second louvered vents 16a, 16b to form the air outlet 16 and the air outlet 16 may be comprised of nearly any penetration, hole or air permeable surface on the housing 12 that permits airflow out of the housing 12 from the airflow path. For example, the air outlet 16 may be comprised of a hole in the housing 12, the hole being covered by an air permeable sheet or a plurality of holes in the housing 12 that permit flow of air out of the housing 12.
Referring to
Referring to
The preferred filter box 22 permits mounting of the air filter 18 therein and aids in the proper alignment of the air filter 18 within the housing 12 in the airflow path. In addition, the arcuate-shape of the inlet cowl 20 of the preferred air purifier 10 guides or funnels air from the room into the air inlet 14 and into the airflow path during use of the air purifier 10. Further, the airflow grate 22a aids in properly positioning the air filter 18 within the airflow path in the housing 12 and securing the air filter 18 in a preferred location in the airflow path. The air purifier 10 is not limited to inclusion of the single-piece inlet cowl 20, filter box 22 and airflow grate 22a and these components may be separately or alternately constructed or not included in the air purifier 10 without significantly impacting the operation of the air purifier 10. However, the inlet cowl 20 is preferred for guiding the flow of air into the air inlet 14 and the filter box 22 and airflow grate 22a are preferred for aiding in positioning of the air filter 18 in a preferred location in the airflow path and securing the air filter 18 within the housing 12 in a preferred location.
Referring to
A fan 28 is mounted to the motor shaft 26 for urging air into the air inlet 14, through the airflow path and out of the air outlet 16. In the preferred embodiment, a first scroll 30 is mounted within an upper portion of the housing 12 in the airflow path and a second scroll 32 is mounted within a lower portion of the housing 12 in the airflow path. In addition, the motor output shaft 26 preferably includes a first end 26a and a second end 26b. The fan 28 preferably includes a first fan 28a and a second fan 28b secured to the first motor shaft end 26a within the first scroll 30 and to the second motor shaft end 26b in the second scroll 32, respectively. Accordingly, in the preferred embodiment, the motor 24 drives the motor shaft 26 with the first and second fans 28a, 28b mounted to the first and second motor shaft ends 26a, 26b to draw air into the air inlet 14 and expel air from the housing 12 through the air outlet 16. The first and second fans 28a, 28b are preferably mounted within the scroll housings 30, 32 to improve the effectiveness of the fans 28a, 28b and the flow of air through the airflow path. The air purifier 10 is not limited to inclusion of the first and second fans 28a, 28b mounted to the first and second ends 26a, 26b of the motor shaft 26 within the first and second scrolls 30, 32 and may be comprised of a single fan that draws air into the air inlet 14, through the air filter 18, airflow path and out of the air outlet 16. In addition, the air purifier 10 may include a plurality of motors that drive a plurality of fans to urge air flow through the housing 12 along the airflow path. In the preferred embodiment, the first and second fans 28a, 28b are comprised of basket-like fans, which are described in U.S. reference. The basket-like fans are generally well known to those having ordinary skill in the art and will not be described in further detail.
In the preferred embodiment, the first scroll 30 includes a first outlet chute 30a and the second scroll 32 includes a second outlet chute 32a. The first and second outlet chutes 30a, 32a preferably include first and second terminal edges 30b, 32b, respectively, that are positioned proximate an inner surface 12a of the housing 12 proximate the first louvered vent 16a and the second louvered vent 16b, respectively, to direct air out of the air outlet 16. Preferably, the first and second terminal edges 30b, 32b of the first and second outlet chutes 30a, 32a are in facing engagement with the inner surface 12a of the housing 12 at a periphery of the first and second louvered vents 16a, 16b to channel or urge air directly out of the first and second louvered vents 16a, 16b. The scrolls 30, 32 are not limited to inclusion of the first and second outlet chutes 30a, 32a or to the first and second terminal edges 30b, 32b being in facing engagement with the inner surface 12a at a periphery of the first and second louvered vents 16a, 16b. For example, the scrolls 30, 32 may include outlets that are spaced from the air outlet 16 or the first and second scrolls 30, 32 and may be constructed such that they do not include the first and second outlet chutes 30a, 32a, respectively. However, it is preferred that the first and second terminal edges 30b, 32b of the first and second outlet chutes 30a, 32a are in facing engagement with the inner surface 12a proximate a peripheral edge of the first and second louvered vents 16a, 16b to urge air directly out of the air outlet 16 from the housing 12 to improve airflow through the airflow path.
Referring to
Referring to
In the preferred embodiment, the dust sensor 38 is comprised of a Particulate Matter Sensor, Model No. PPD4NS, sold by Shinyei Kaisha Electronic Instruments Division. The dust sensor 38 is preferably an optical sensor that senses particulates in the air and sends a signal to the controller 36 related to the optically measured particulate matter, dust or other contaminants suspended in the air of the room. The dust sensor 38 is not limited to the above-described particulate matter sensor and may be comprised of nearly any sensor that is able to sense particulates, dust or other contaminants in air and convey a signal to the controller 36 related to the amount of particulate, dust or other contaminant in the air.
In the preferred embodiment, a control dial 40 is in communication with the controller 36 and is actuatable between automatic, low or whisper clean, medium and high or quick clean operating modes of the air purifier 10. In addition, an array of indicator lights 42 is preferably mounted to an external surface of the housing 12. The array of indicator lights 42 are preferably also in communication with the controller 36 and provide a visual indication of the dust readings from the dust sensor 38 and an indication of whether the air purifier 10 is powered. The control dial 40 and array of indicator lights 42 are preferably mounted and secured to a top surface of the housing 12 of the air purifier 10 for ease of access by a user and relatively simple visual locating of the control dial 40 and array of indicator lights 42. The control dial 40 and array of indicator lights 42 are not limited to inclusion in the air purifier 10 or to mounting at the top surface of the housing 12. For example, the control dial 40 and array of indicator lights 42 may be eliminated from the air purifier 10 without significantly impacting the operation of the air purifier 10 or may be adapted for other specific uses of the air purifier 10. However, the control dial 40 is preferably included for selection of various operating modes of the air purifier 10 and the array of indicator lights 42 are preferably mounted to the housing 12 for providing an indication to a user of the dust signal or amounts of particulates, contaminants or dust suspended in the air proximate the air purifier 10 and an indication of whether the air purifier 10 is powered.
In the preferred embodiment, the control dial 40 is actuable between the above-listed automatic, low, medium and high operating modes of the air purifier 10. The air purifier 10 is powered and the controller 36 preferably illuminates at least one of the array of indicator lights 42. In the automatic mode, the air purifier 10 samples the particulates or dust in the air using the dust sensor 38, the dust sensor 38 sends a signal to the controller 36 and based upon the signal, the controller 36 actuates the motor 24 to operate at a determined speed. For example, if the dust signal indicates a relatively high amount of particulates or dust in the air, the controller 36 may actuate the motor 24 to operate at a high speed such that a relatively large volume of air is drawn through the air filter 18 to purify or condition a relatively large volume of air in a short amount of time. Conversely, if the dust reading indicates a relatively low amount of particulate or dust in the air, the controller 36 may actuate the motor 24 to operate at a relatively slow speed to urge a lower volume of air through the air filter 18, in comparison to the same amount of time that the relatively large amount of air flows through the air filter 18 when the motor 24 is operated at the high speed. In addition, the array of indicator lights 42 provides a visual indication to the user regarding the amount of particles or dust that are sensed in the air based upon the dust readings from the dust sensor 38. For example, if a large or relatively large dust reading is transmitted to the controller 36 from the dust sensor 38, the controller 38 may illuminate each of the array of indicator lights 42 associated with the dust sensor 38, while one or none of the array of indicator lights 42 is illuminated if the dust reading is relatively low. The array of indicator lights 42 may include nearly any number of individual indicator lights, however, in the preferred embodiment, the array of indicator lights 42 includes four individual lights.
Referring to
In the preferred embodiment, the air cowl 44 has an exposed face 46a and an internal face 46b. In the preferred embodiment, a pair of alignment arms 48, generally having a hook-like-shape extend generally perpendicularly from the internal face 46b proximate a lower portion of the peripheral edge 44a and an engagement arm 50 extends generally perpendicularly from the internal face 46b proximate an upper portion of the peripheral edge 44a of the air cowl 44. The air cowl 44 is not limited to inclusion of the pair of alignment arms 48 having the hook-shape or to the engagement arm 50 extending generally perpendicularly from the internal face 46b proximate the top peripheral edge 44a. However, the air cowl 44 preferably includes the pair of alignment arms 48 and the engagement arm 50 to mount the air cowl 44 to the housing 12 in a removable manner, as will be described in greater detail below.
Referring to
The air cowl 44 also preferably includes a plurality of spacers 56 extending generally perpendicularly from the internal face 56b proximate the peripheral edge 44a. The spacers 56 are preferably integrally molded with the air cowl 44 and have a generally cylindrical-shape. The spacers 56 are not limited to extended generally perpendicularly from the internal face 46, to being integrally molded with the air cowl 44 or to having a generally cylindrical-shape. For example, the plurality of spacers 56 may be separately mounted rubber or polymeric blocks having a generally square or rectangular shape and mounted to the internal face 46 or may be mounted to the air cowl 20 or the air filter 18. However, the spacers 56 are preferably integrally molded, have a generally cylindrical-shape and extend generally perpendicularly from the internal face 46b to perform the function of the spacers 56 as will be described in greater detail below.
In a preferred assembled configuration, the spacers 56 locate the internal face 46a a first distance D1 from an upstream-face of the air filter 18. In the preferred embodiment, the first distance D1 is approximately X inches (X″) but is not so limited. The first distance D1 may comprise nearly any value that creates a space between the internal face 46b and the upstream face of the filter 18 such that air is able to flow between the internal face 46b and the air filter 18 and the air is able to flow into the entire upstream-face of the air filter 18. The spacers 56 preferably provide a consistent first distance D1 between the internal face 46b and the upstream-face of the air filter 16 such that the air purifier 10 consistently filters or purifies air in operation. The internal face 46b is also not limited to being generally planar and may be sloped and/or curved to direct airflow from the inlet 14 toward the air filter 18 depending upon the configuration of the air purifier 10, as will be understood by one having ordinary skill in the art. For example, the internal face 46b may be curved to channel or funnel air toward a specific portion of the air filter 18 or the air purifier 10 may include multiple separate air filters (not shown) that are mounted in the housing 12 with air flow channeled into the separate air filters by channeling features constructed on the internal face 46b.
Referring to
Referring to
When the air purifier 10 is in the assembled configuration, the air purifier 10 is positioned within a room and the motor 24 is actuated to drive the first and second fans 28a, 28b to urge air from the room into the air inlet 14, through the air filter 18, specifically through the filter material 18a, and out of the first and second louvered vents 16a, 16b. Specifically, the user manipulates the control dial 40 to place the air purifier 10 in one of the automatic, low or whisper clean, medium and high or quick clean modes. When one of the modes is selected and the motor 24 is actuated to begin rotation of the first and second fans 28a, 28b, air is drawn into the air inlet 14. Specifically, air is drawn into the air inlet 14, defined between the peripheral edge 44a of the air cowl 44 and the inlet cowl 20. Defining the air inlet 14 between the peripheral edge 44a and the inlet cowl 20 permits construction of the air cowl 44 with the relatively large, continuous exposed face 46a that may include the decorative pattern thereon including the wavy ribs 58. The relatively large, continuous, uninterrupted exposed face 46a provides many options for a user to include an aesthetically pleasing photo, sculpture or alternative aesthetically pleasing design configuration on the exposed face 46a. Such a relatively large, continuous exposed face 46a is relatively uncommon in air purifiers as inlets 14 and outlets 16 of typical air purifiers are generally comprised of louvered vents or holes in a housing that are generally not adaptable for aesthetically pleasing designs or configurations.
If the whisper clean or low mode is selected, the controller 36 actuates the motor 24 to operate at a relatively low speed to rotate the motor shaft 26 and first and second fans 28a, 28b at a relatively low speed. Such a relatively low speed rotation of the motor shaft 26 and first and second fans 28a, 28b permits the air purifier 10 to operate at a relatively low noise level. As the first and second fans 28a, 28b begin to rotate, air is drawn through the air inlet 14 between the peripheral edge 44a and the inlet cowl 20, into the space between the internal face 46b and the upstream-face of the air filter 18 created by the first distance D1, through the air filter 18 and into an area within the housing 12 proximate the first and second scrolls 30, 32. The air is then drawn into either upper or lower open ends of the first and second scrolls 30, 32, flows past the basket-like first and second fans 28a, 28b, into the first and second outlet chutes 30a, 32a and out of the first and second louvered vents 16a, 16b. In operation, the outlet air preferably flows past the ionizer needle 34, charging the particles remaining in the initially filtered air with an electrical charge such that the particles are attracted to a surface or to each other and generally do not remain suspended within the air. In the medium and quick clean or high modes, the air purifier 10 operates in nearly an identical manner to the whisper clean or low mode with the motor 24 actuated by the controller 36 to operate at a medium or high speed, respectively, and draw an a larger volume of air into the air purifier 10 when compared to operation in the low or whisper clean mode.
When the user selects operation in the automatic mode, the dust sensor 38 senses a dust reading, comprised of a level of dust, particles or other contaminants in the air, and transmits the dust reading to the controller 36. The controller 36 illuminates the array of indicator lights 42 to provide a visual indication to the user of the level of particulates or dust in the air proximate the air purifier 10. In addition, based upon the dust readings, the controller 36 actuates the motor 24 to operate at one of the low, medium or high speeds. For example, if the dust reading is relatively low, the controller 36 actuates the motor 24 to operate at the low speed and if the dust reading is relatively high, the controller 36 actuates the motor 24 to operate at the high speed. In addition, the dust sensor 38 continuously senses the level of particulates, contaminants or dust in the air proximate the air purifier 10, transmits the dust readings to the controller 36 and the controller 36 preferably, automatically modifies the operating speed of the motor 24 based upon the changing dust readings. Further, the controller 36 modifies the visual indication of the array of indicators 42 to correspond to the dust readings as the dust readings change.
In the preferred operation of the air purifier 10, the ionizer needle 34 is constantly emitting a charge to particles and air in or proximate to the air outlet 16. The controller 36 is not limited to constantly powering the ionizer needle 34 and may selectively power or charge the ionizer needle 34 based upon the dust readings or the mode of operation selected by the user, as will be understood by one having ordinary skill in the art.
Referring to
To replace or clean the air filter 18 of the air purifier 10, the air cowl 44 is removed by pivoting the upper peripheral edge 44a away from the inlet cowl 20 such that the magnetic plate 50a is disengaged from the first magnetic number 54. The air cowl 44 preferably pivots about the alignment arms 48 and the alignment indentation 52 and the user removes the air cowl 44 from engagement with the housing 12. If the air filter 18 is fixed, force-fit or permanently secured in the filter box 22 or housing 12, a user may clean the upstream-face of the air filter 18 using a vacuum or other cleaning methods. If the air filter 18 is disposable and removable from the filter box 22 or housing 12, the user grasps the air filter 18, removes the air filter 18 from the filter box 22 and inserts a replacement filter 18 into the filter box 22. The contaminated or dirty air filter 18 may be disposed of or may be cleaned for subsequent use. The air cowl 44 is then mounted to the housing 12 to secure the replacement air filter 18 in the filter box 22. When the motor 24 is actuated to draw air into the air inlet 14, the removable and replaceable air filter 18 is generally drawn into facing engagement with the airflow grate 22 to secure the air filter 18 in the airflow path.
It will be appreciated by those skilled in the art that changes could be made to the embodiment described above without departing from the broad inventive concept thereof. It is understood, therefore, that this invention is not limited to the particular embodiment disclosed, but it is intended to cover modifications within the spirit and scope of the present invention, as defined by the appended claims.
