FIELD
The subject matter disclosed herein relates to heating, venting, and air-conditioning systems, and in particular to air filters used in conjunction with and duct covers, such as air-return grills.
BACKGROUND
Vent covers, registers, and grilles, (collectively “grilles”) are essential components of Heating, Ventilation, and Air Conditioning (“HVAC”) systems, including residential HVAC systems. They are designed to allow the flow of air into and out of ducts of an HVAC system while also blending into or matching the ceiling, wall, or floor through which the duct is exposed, thus preventing the unsightly duct from being viewed. Often, a filter is disposed adjacent to or proximate to the grille to filter air passing into or out of the duct and to trap pollutants such as dust, allergens, and other particles. Such helps improve indoor air quality. Because these filters collect pollutants during use, they become saturated with the pollutants and cease to work effectively to remove additional pollutants. Therefore, they should be regularly replaced to maintain efficient airflow and improved air quality, typically every one to six months.
FIG. 1 depicts an air return vent that is mounted on a ceiling 104. The vent has a sheet-metal frame 101 and a sheet-metal grille 103, which is attached to frame 101. As depicted in FIG. 1, grille 103 is partially attached to frame 101 to expose a commercially available air filter 102, such as one having 16 inch×20 inch dimensions. When grille 103 is fully attached to frame 102, filter 102 is held in place over an HVAC duct.
Although filters are often light weight, being made from materials such as paper and fiberglass, the grilles are often much heavier, typically because they are made from metals, such as aluminum or steel, and because they are intended to last for many years or even the entire life of the structure in which they are installed. Likewise, the grilles, particularly grilles over air-return ducts, collect air contaminants (e.g., dust) because they are upstream of the filter behind them. Accordingly, the grilles should be periodically cleaned at least to avoid a dirty and dusty appearance.
The actions of removing and reattaching the grille during the activity of removing an expired filter and installing a new filter can be difficult to accomplish due to various factors, such as: 1) the grille's weight; 2) the grille's size; and 3) the grille's location, such as an overhead location high up a vertical wall or in the ceiling. Moreover, individuals who lack sufficient coordination, balance, or strength might have particular difficulty performing the replacement by themselves and might risk bodily injury to themselves or damage to floors or walls caused by dropping the grille during removal or by falling off of a stool or ladder. Even those individuals who might be able to remove and replace the grille with little fear of injury might avoid or delay doing so for various reasons, including forgetfulness, not wanting to spend approximately 15-30 minutes on the task, and not having a stool or ladder. Likewise, property owners might avoid or delay hiring someone to replace the filters due to the efforts and cost of hiring help. Accordingly, many dirty filters remain in use well after the time they should be replaced, thus compromising indoor air quality, dirtying the internal workings of the HVAC system, and lowering the electrical efficiency of the HVAC system cause by reduced airflow through a filter that is saturated with pollutants.
BRIEF DESCRIPTION OF DRAWINGS
While the specification concludes with claims, which particularly point out and distinctly claim the subject matter described herein, it is believed the subject matter will be better understood from the following description of certain examples taken in conjunction with the accompanying drawings, in which:
FIG. 1 depicts a prior-art sheet-metal frame mounted on a ceiling and connected to a grille for supporting a filter;
FIG. 2 depicts a frame for use with a filter-grille device;
FIG. 3 depicts the frame of FIG. 2 in the frame of FIG. 1;
FIG. 4 depicts a frame for use with a filter-grille device;
FIG. 5 depicts the frame of FIG. 4 mounted on a ceiling;
FIG. 6 depicts a filter-grille device;
FIG. 7 depicts a filter-grille device;
FIG. 8 depicts a filter-grille device;
FIG. 9 depicts a filter-grille device;
FIG. 10 depicts a positioning tool for a filter-grille device;
FIG. 11 depicts a magnified cross-section view the positioning tool of FIG. 10 mated to the filter-grille device of FIG. 6;
FIG. 12 depicts an installation of the filter-grille device of FIG. 6 using the positioning tool of FIG. 10.
FIG. 13 depicts a detail view of a cross section of the filter-grille device of FIG. 6 disposed in the frame of FIG. 2;
FIG. 14 depicts a positioning tool for a filter-grille device;
FIG. 15 depicts a magnified cross-section view the positioning tool of FIG. 14 mated to the filter-grille device of FIG. 6;
FIG. 16 depicts a positioning tool for a filter-grille device;
FIG. 17 depicts a magnified cross-section view the positioning tool of FIG. 16 mated to the filter-grille device of FIG. 6;
FIG. 18 depicts a removal tool for a filter-grille device;
FIG. 19 depicts the removal tool of FIG. 18 mated to the filter-grille device of FIG. 6;
FIG. 20 depicts a positioning tool for a filter-grille device;
FIG. 21 depicts an end-of-life filter indicator;
FIG. 22 depicts a positioning device;
FIG. 23 depicts the positioning device of FIG. 22 in an open configuration;
FIG. 24 depicts a filter-grille device;
FIG. 25 depicts a positioning device comprising an elevator mechanism including linkages;
FIG. 26 depicts a positioning device having a grille; r
FIG. 27 depicts a positioning device comprising an elevator mechanism including cables;
FIG. 28 depicts a positioning device comprising an elevator mechanism including cables and linkages;
FIG. 29 depicts a positioning device;
FIG. 30 depicts a positioning tool for use with the positioning device of FIG. 29;
FIG. 31 depicts the positioning tool of FIG. 30 being used with the positioning device of FIG. 29
FIG. 32 depicts a positioning device comprising retaining features;
FIG. 33 depicts a first housing portion of a filter-grille device; and
FIG. 34 depicts a kit comprising a filter-grille device in a frame and additional filter-grille devices.
MODES OF CARRYING OUT THE INVENTION
The following detailed description should be read with reference to the drawings, in which like elements in different drawings are identically numbered. The drawings, which are not necessarily to scale, depict selected embodiments and are not intended to limit the scope of the invention. The detailed description illustrates by way of example, not by way of limitation, the principles of the invention. This description will clearly enable one skilled in the art to make and use the invention, and describes several embodiments, adaptations, variations, alternatives and uses of the invention, including what is presently believed to be the best mode of carrying out the invention.
As used herein, the terms “about” or “approximately” for any numerical values or ranges indicate a suitable dimensional tolerance that allows the part or collection of portions or components to function for its intended purpose as described herein. More specifically, “about” or “approximately” may refer to the range of values ±10% of the recited value, e.g. “about 90%” may refer to the range of values from 81% to 99%.
FIG. 2 illustrates a frame 201 into which a filter-grille device described herein, such as filter-grille device 601 (FIG. 6) may be disposed. Frame 201 can be made as a single piece or multiple pieces of corners 211 and connecting pieces 203. Frame 201 typically should have a rectangular shape for the purpose of mating to an existing frame 101. However, if an existing frame has a different shape, e.g., ovular, frame 201 may also have that same shape. Further, as it is the outside of frame 201 that mates to existing frame 101, the shape of the outside of frame 201 and the shape of the inside of frame 201 need not be of the same shape. Accordingly, for example, the outer shape of frame 201 could be rectangular while the inner shape of frame 201 could be ovular. Whatever the inner shape of frame 201 might be, the filter-grille devices described herein should have a shape matching the inner shape of frame 201 so that the filter-grille device can be mated therein. Frame 201 is made from a non-magnetic material yet includes one or more magnets 205 disposed at multiple locations around the frame, such as at each of its four corners. The magnets 205 can be any shape, e.g., round, square or rectangular. Frame 201 also may include slanted surfaces 213 to help guide a filter-grille device into position during its installation. Slanted surfaces 213 can be a continuous surface all around frame 201, as shown, or intermittent slanted surfaces positioned around frame 201, such as ribs with slanted surfaces. The angle α of the slanted surface 213 relative to a horizontal reference line is between about ten degrees an eighty degrees, e.g., about forty-five degrees.
Frame 201 may optionally include edges or panels 220 disposed around a periphery 222 of the frame. The depicted embodiment includes four panels 220, one on each side, although only two are shown in the perspective view and the other two are hidden to allow for visibility and identification of other structures and features of frame 201. Panels 220 provide primarily an aesthetic purpose, which is to cover existing frame 101 or unsightly details at or proximate to the vent opening through the ceiling or wall, as seen in FIG. 3.
Frame 201 also has through holes 207 and 209 located at various positions to allow retrofitting it onto an existing air return vent. For example, a bolt may be disposed through hole 207, a screw may be disposed through hole 207, or both. As seen in FIG. 3, no grille 103 is attached to frame 101. Instead, frame 201 is positioned against ceiling 100 and frame 101.
FIG. 4 depicts frame 401, which is the same as frame 201 except for the lip 402 provided around the perimeter of frame 410. With lip 402, frame 401 is suitable for a new installation or any installation where frame 101 has been removed from a vent's exit through a wall or ceiling. In other words, frame 410 may be attached directly to the ceiling, preferably ceiling beams 501, as depicted in FIG. 5. Inasmuch as frame 401 is intended for new installations, it can have any internal shape that is matable to the filter-grille devices described below.
FIG. 6 depicts a filter-grille device 601 comprising a housing 602 and a filter 607 disposed in housing 602, between a first housing portion 610 and a second housing portion 612. First housing portion 610 and second housing portion 612 may be provided as discrete components, such that first housing portion 610 is a first housing portion 610 and such that second housing portion 612 comprises a second housing portion 612. When so provided, they may be directly attached to each other via any suitable means, including, e.g., glue, clips, tab and slot, or tongue and groove. Alternatively, when provided as discrete components, first housing portion 610 and second housing portion 612 may be indirectly attached to each other. For example, in contemplated designs, the first housing portion and second housing portion might not contact each other at or proximate to their perimeters, in which case the housing of the filter-grilled device may additionally include a third housing portion, such as third housing portion 615 for filter-grilled device 601 that fills any peripheral gap between housing portions 610 and 612, and also indirectly attaches them. In this manner, air cannot escape through the sides of device 601. Third housing portion 615 may be attached to the other housing portions 610 and 612 via any suitable means including, e.g., glue, clips, tab and slot, or tongue and groove.
Housing 602 is preferably fabricated from lightweight and nonmagnetic materials, such as paper, cardboard, plastic, or a strong but low-density wood, e.g., balsa wood. These materials are chosen in accordance with key unmet user needs for removing and reattaching current commercially available grilles to replace expired filters with new filters, i.e., making the replacement process easier, faster, and less likely to cause injury to body or property from, e.g., dropping a heavy metal grille or falling off a stool or ladder. The lightweight materials of housing 602 eliminate the need to remove, manipulate, and replace a heavy metal grille. Likewise, the materials of housing 602 are inexpensive compared to metal grilles. Furthermore, the materials may be recycled materials, recyclable materials, or sustainable materials. Accordingly, the entirety of filter-grille 601, and not just filter 607, may be discarded and replaced whenever filter 607 needs to be replaced, e.g., every one to six months.
An exemplary posterboard used to fabricate a filter-grille device is the 22 inch×28 inch UCreate® metallized posterboard sold by Dixon Ticonderoga Co. of Appleton Wisconsin. Whereas a standard sheet-metal air-return grill used for a 16 inch×25 inch filter weighs approximately three to five pounds, the filter-grille device fabricated from the metallized posterboard for use with a 16 inch×25 inch filter weighs about one half of a pound. Therefore, the filter-grille device enables a technique for exchanging an expired filter for a new filter without the need to handle a heavy and unwieldy grille while it is overhead. The first housing portion, as it serves as the grille and remains visible following installation, may be fabricated in a range of colors and styles to match the wall or ceiling color, or otherwise suit a preferred style.
When the housing comprises a foldable material, e.g., cardboard or posterboard, the first and second housing portions may be formed from a single or unitary blank sheet of the material that includes airflow holes, tabs and slots, tongues and grooves, or some combination thereof, provided therein (e.g., punched or cut through the material of the blank). The blank may be folded, with any tabs mated to their slots and any tongues mated to their grooves, to create a housing having a first portion, like first portion 610, and a second portion, like second portion 612.
In whatever manner the housing is fabricated, a space should be defined between the first housing portion and the second housing portion in which filter 607 may be disposed such that it is maintained in a stationary position between housing portions 610 and 612. That is, it should not slide or jostle around when the filter-grilled device is moved or rotated. Accordingly, filter 607 should contact inner surface of the housing portions, and, optionally, may be bonded to one or both of the housing portions using, e.g., glue.
As noted above, housing 602 may have any profile that mates with a frame, e.g., frame 201. As shown, first housing portion 610 has a rectangular profile and second housing portion 612 has a trapezoidal profile such that its side surfaces 618 comprise slanted surfaces 619. As seen in FIG. 13, the angle θ of the slanted surface 619 relative to a horizontal reference line is between about ten degrees and eighty degrees, e.g., about forty-five degrees. Furthermore, the slanted surfaces are angled similarly to slanted surfaces of a corresponding frame, such as slanted surfaces 213 of frame 201. That is, θ and a should be about equal. Thus, upon mating a filter-grille device to a frame, e.g., filter-grille device 601 and frame 201, the respective slanted surfaces 619 and 213 conform to or abut each other.
First housing portion 610 includes a plurality of airflow holes 617, which may have any suitable shape, such as a stadium shape (i.e., a rectangle with semicircles at a pair of opposite sides), a circular shape, an elliptical shape, a square shape, a diamond shape, a rectangular shape, a triangular shape, a polygonal shape, etc., As shown, first housing portion includes four rows of twenty-four stadium-shaped airflow holes. The number, shape, and size of the airflow holes should be chosen so as to permit for sufficient air-flow through the first housing portion. Yet the number, shape, and size of the airflow holes should not result in first housing portion 610 having low structural integrity, e.g., being too “floppy,” or in being prone to ripping between the airflow holes. Furthermore, the number, shape, and size of the airflow holes should function to substantially block the filter from view, like a standard grille does. As first housing portion 610 is exposed following installation and has the appearance of a grille, first housing portion is also referred to herein as grille 610.
To be appropriate for a given filter, each filter-grille device should have base width dimensions that are at least as large and preferably somewhat larger than the base and width dimensions of the filter intended to be used in a duct's opening. For example, the base and width dimensions of a filter commonly used in a duct is 16 inches by 25 inches. Therefore, base and width dimensions for a first housing portion of a filter-grille device that includes a filter with such dimensions should have base and width dimensions of at least 16 inches and at least 25 inches. To help install the filter-grill device and maintain its position relative to the ceiling and its corresponding frame, preferred base and width dimensions of the first housing portion should each larger than the filter. For example, the base and height dimensions of the first housing portion may be about one inch greater to about five inches greater than the corresponding base and height dimensions of the filter.
To account for air flow through the first housing portion, e.g., first housing portion 610, and thus also through the filter, the percentage of total empty space through the first housing portion (typically the sum of the areas of all of the airflow holes, e.g., holes 617 for first housing portion 610) relative to the overall area (base multiplied by height) of housing portion 610 should be no less than 10%. Yet, to provide the first housing portion with sufficient structural integrity so as to minimize risk that the first housing portion may rip during installation or may be somewhat floppy and thus make installation harder than for a less floppy first housing portion, the percentage of total empty space should be no greater than 90%. Depending on various other factors as well, such as the overall size difference between the filter and the first housing portion or the filter's Minimum Efficiency Reporting Value, the preferred range of total empty space through the first housing portion may be between about 20% and about 80%, such as between about 30% and about 60%, e.g., between about 35% and 45%, preferably about 40%. As seen in FIG. 6, where the first housing portion includes four rows of twenty-four stadium-shaped airflow holes, the percentage of total empty space is about 40%.
Furthermore, to substantially block the filter from view as well as to provide sufficient airflow through the filter-grille device, the airflow holes through the first housing portion should be provided over an airflow region of the first housing portion, i.e., a region of the first housing portion defined as either containing all or most (e.g., >90%) of the total empty space defined by airflow holes or through which most or all of the air that reaches the filter flows. Distributing the airflow holes about the airflow region in a uniform arrangement, with a repeating pattern, a symmetric pattern (with one or more types of symmetry, e.g., vertical, horizontal, diagonal, odd, and even), or some combination thereof, provides a pleasing aesthetic and results in the first housing portion substantially blocking the filter and duct behind it from view. Additionally, such a distribution allows air to flow uniformly through the airflow holes to the filter behind the airflow region, which helps maximize the likelihood that the filter is used as intended and ages as intended. Furthermore, providing the airflow holes such that at least 50%, 60%, 70%, 80%, 90% of the airflow holes have an area of less than about 2 square inches, such as less than about 1 inch squared, e.g., about 0.5 square inches or about 0.25 square inches, helps block the filter from view more than if larger airflow holes were provided as a greater percentage of the number of airflow holes. Accordingly, the filter should be disposed proximate to the first housing portion, preferably in contact with the first housing portion, and over the airflow region. The airflow region of the first housing portion may be about 80% to 100% of the total base-times-height area of the first housing portion.
As seen in FIG. 33, an exemplary first housing portion 1710 (which may also serve as the first housing portion for any of the filter-grille devices described herein) includes an airflow region 1720, identified by the dotted-line rectangle, in which is disposed at least 90% of the total empty space bordered by all of airflow holes 1717, i.e., the sum of the areas of each airflow hole. As shown, there are four rows of forty-five airflow holes 1717. Airflow region 1720 may be considered as a grid 1780 with grid cells or sectors 1782 arranged evenly about airflow area 1720. As shown, four sectors 1782, i.e., quadrants, are depicted.
Where the area of the airflow region is expressed as A1, the total number of airflow holes i having at least a portion disposed in the airflow region is expressed as M, the area of each airflow hole or portion of each airflow hole in the airflow area is expressed as Qi, and the percentage of empty space through the first housing portion in the airflow region is expressed % ES, the approximate value of % ES may be calculated according to equation 1.
No matter the number of sectors used for the calculation (e.g., four, eight, sixteen, three, nine, twelve, eighteen), the percentage of total empty space provided by the airflow holes 1717 in each sector of the airflow region through the first housing portion should be about equal to the percentage of total empty space through the entire airflow region, irrespective of whether each of the airflow holes have equal or nonequal areas, and also whether all airflow holes have the same shape or some have different shapes than others. Accordingly, the percentage of total empty space through the first housing portion in each sector should be between 10% and 90%, between about 20% and about 80%, between about 30% and about 60%, between about 35% and 45%, or about 40%.
As seen in FIG. 6, second housing portion 612 has airflow holes 613, which may have any suitable shape, such as a rhombus shape, as shown. These airflow holes should also permit for sufficient air-flow through the second housing portion, yet their shape and size are not critical because the second housing portion is hidden from view when the filter-grille device is emplaced for use. In use, air may pass through airflow holes 613 and 617, and thus through filter 607.
Various mechanisms may be used for attaching a filter-grille device to another object that is not part of the filter-grille device, notably a corresponding frame, e.g., frame 201. For example, as depicted in FIG. 6, second housing portion 612 includes attachment components 609, which may be magnets, pieces (e.g., discs) of ferromagnetic materials, or hook and loop fasteners. Attachment components 609 may be incorporated at various locations, such as by being attached at or proximate to the corners of second housing portion 612, as shown. Attachment components 609 are intended to mate with magnets of a corresponding frame, e.g., magnets 205 of frame 201. The magnetic force generated between the magnets and attachment components 609 should be sufficient to maintain filter-grille device 601 against the frame throughout the filter's life of one to six months, while magnets 205 should maintain their magnetism for many years such that they can survive through many exchanges of filter-grille devices every one to six months over those years. Likewise, because frames 201 and 401 have slanted surfaces that conform with slanted surfaces 619 of second housing portion 612, kits may be sold comprising one or more (preferably more) filter-grille devices and one or more (preferably one) frame. With reference to FIG. 34, a kit 1800 may comprise a filter-grille device (e.g., 601) and a frame (e.g., 201). As shown, the filter-grille device is disposed in the frame, which may simplify packaging a commercial version of the kit in a package 1801 in more compact fashion than not disposing the filter-grille device in the frame. Moreover, because the filter-grille device is disposed in the frame, the slanted surfaces (e.g., 619 and 213) conform to each other and, likewise one or more of the attachment components (e.g., 609) may be magnetically coupled to a corresponding magnet (e.g., 205). Irrespective of whether a filter-grille device is disposed in a frame, a kit may additionally comprise a plurality of additional filter-grille devices 1819 that can be used to replace expired filter-grille devices. As depicted, four additional filter-grille devices are provided such that a total of five filter-grille devices are provided in the kit.
Although it is conceivable that the side surfaces of second housing portion are oriented vertically, such that they are aligned perpendicularly to the airflow region of first housing portion, the inventor has discovered that it is preferable to have the side surfaces be slanted to facilitate installation of the filter-grille device in a frame. With conforming slanted surfaces on the filter-grille device and on the frame, the conformance operates to guide the filter-grille device to a position in the frame where, all of the attachment devices on the second housing portion, e.g., attachment devices 609, are aligned with all frame magnets, e.g., magnets 205, before any magnetic forces generated between a single one of the attachment devices and a single one of the magnets might interfere with establishing such alignment and cause a premature attachment, i.e., magnetic coupling, therebetween. Moreover, once the attachment features are brought sufficiently close to the magnets for magnetic attachment to occur, the conforming slanted surfaces ensure that each attachment feature attaches to each magnet. In contrast, the inventor has discovered that if conforming slanted surfaces were not used but instead the side surfaces of the second housing portion were oriented perpendicularly to the plane defined by the first housing portion when attached to the first housing portion, there is a high risk that one of the attachment features would attach to one of the magnets before any of the other attachment attach to corresponding magnets. Because the premature attachment happens overhead because the frame is in the ceiling, undoing this premature attachment undermines a key purpose of the filter-grille device, which is to reduce or eliminate awkward or difficult overhead tasks. Furthermore, due to the lightweight nature and the thinness of the materials of the filter-grille device and the overhead manipulation required to undo a premature magnetic attachment undoing the premature attachment invites damage to the filter-grille device, such as ripping or cracking it. The slanted surfaces thus facilitate installations of a filter-grille device in the frame by ensuring alignment of all of the attachment components 609 with all of the magnets 205, thus resulting in a secure and proper placement of the filter-grille device in the frame.
To assist with removing an expired filter-grille device 601 from a corresponding frame, e.g., frame 201, and to also assist with installing a new filter-grille device 601 into the corresponding frame, device 601 includes cutouts 611 and a loop 605. Installation and removal techniques are described further below.
FIG. 7 shows another embodiment of a filter-grille device 701, which is similar to device 601 except as described here. Device 701 comprises an off-the-shelf air filter 102 that includes a filter element 107 and a housing 108. As depicted, second housing portion 712 includes a single opening 703 for air to pass through, although, as with second housing portion 612, various airflow holes may be provided. Air filter 102 may be attached to housing 702 using any suitable method such as an adhesive, hook and loop fasteners, staples, etc.
FIGS. 8 and 9 depict an embodiment of a filter-grille device 801 in which housing 802 is reusable. Except for the differences described here, filter-grille device 801 is similar to filter-grilled assembly 601 A filter, such as an off-the-shelf filter 102, may be inserted into and removed from housing 802. Upon removal of an expired filter from housing 802, a new filter may be introduced into filter 802. Filter-grille device 801 may be attached and detached from its corresponding frame, e.g., frame 201, in the same manner as filter-grille device 801, such as by use of attachment components 809. Second housing portion 812 includes a slot 804 disposed through one of the slanted surfaces 819 to allow insertion of the filter. First housing portion or grille 810 includes guides 808 that ensure proper positioning of the filter within housing 802 and maintain the filter's position therein throughout its use. As seen in FIG. 9, there are three guides 808, two horizontal guides and one vertical guide that is disposed opposite to the slot.
FIG. 10 depicts a positioning tool 1000 that can assist with overhead installations of the filter-grille device. Positioning tool 1000 includes a rod 1002, which may have telescoping capability to extend to have a maximum length of between four and twenty feet, depending on the user and the height of the ceiling in which the integrated-filter-grille assembly is used. For most residential purposes and users, a maximum length of about six feet may be optimal. Head 1004 comprises various protrusions, which may have different shapes. For example, as depicted, head 1004 includes two round protrusions 1006 and two stadium-shape protrusions 1008. Yet the shape of the protrusions can be of any shape, such as triangle or square, so long as they mate with corresponding cutouts and perhaps airflow holes on the first portion of the filter-grille device, e.g., cutouts 611 and airflow holes 617, which are also, respectively round and stadium shaped. Accordingly, the protrusions 1003 and 1005 may be inserted into the corresponding cutouts and airflow holes, as seen in FIG. 11. Such helps prevent rotation of the filter-grille device on head 1004 of positioning tool 1000 as the filter-grille device is raised toward its frame atop head 1004, as seen in FIG. 12, which depicts frame 201 and integrate filter-grille assembly 601. The slanted surfaces 213 on frame 201 and slanted surfaces 619 on the second housing portion 612 of housing 602 of filter-grille device 610 guide the filter-grille device into the correct position inside the frame. As attachment components 609 are brought proximate to magnets 205, the magnetic forces between them become sufficiently strong to support the weight of the filter-grill assembly and to also maintain its position in the frame as shown in FIG. 13. Once the filter-grille device is positioned, positioning tool 1000 can be lowered and thus removed from the filter-grille device.
FIG. 14 depicts an alternate design for head 1004 in which permanent magnets 1010 are attached or embedded to the head. FIG. 15 shows a version of grille 610 that has magnetic or ferromagnetic head-attachment components 1012 embedded or attached therein. Thus, magnets 1010 can mate with head-attachment components 1012. Once the attachment components 609 and magnets 205 establish magnetic attraction between them as depicted in FIG. 13, the installation head can be rotated to reduce attraction force between magnets 1010 and head-attachment components 1012 such that head 1004 can be lowered away from grille 610.
FIG. 16 depicts another embodiment of installation head 1004 that has protrusions 1006 and 1008 and magnets 1010. FIG. 17 illustrates grille 610 having head-attachment components 1012 positioned to allow coupling of the installation head to grille 610. The attraction force between magnets 1010 and head-attachment components 1012 should be less that the total attraction force between attachment components 609 and magnets 205 to allow lowering the head 1004 away from the filter-grille device 601 while it remains in place within frame 201.
FIG. 18 depicts a removal tool 1100 comprising a telescoping rod 1102 and a removal head 1104. Removal head 1104 includes hook 1106 and post 1108. Hook 1106 can hook onto a feature of grille 610, such as loop 605, as shown in FIG. 19, or alternatively, onto a portion of grille 610 between two adjacent airflow holes 617. Once hook 1106 is hooked onto loop 605, the removal head 1104 can be lowered to pull the filter-grille device away from frame 201. Post 1108 helps prevent loop 605 from slipping around removal head 1104 and sliding down rod 1102.
Installation head 1004 may be connected to rod 1002 using a swiveling joint 1020, which assists with installations in vertical walls or slanted ceilings. A locking mechanism 1021, e.g., a set screw, can be loosened and tightened to position head 1004 at a desired angle relative to rod 1002 for the installation. Additionally, hooks 1022 may be incorporated directly into head 1004, which may mate with loop 605 and thus provide an alternative to removal tool 1100.
FIG. 21 illustrates a filter-replacement indicator 1200 attached to the grille of the filter-grille device, e.g, first housing component 610 of device 601. The indicator 1200 is an electronic unit, which may be powered by any suitable means, such as a battery 1204. It additionally includes light indicator 1202, which may be an LED, a reset button 1210. It may also include a speaker 1212 and a clip 1214 suitable for attaching filter-replacement indicator 1200 to the grille. Components of the indicator 1200 can have any shapes and forms, and they can be arranged in any configuration. At installation, the user can activate the indicator and an internal clock will trigger the indicator to provide visual and/or audible signals at programmed time intervals after activation, e.g. 90 days, to let the user know the filter needs to be replaced. Alternatively, the indicator 1200 could be activated automatically when the filter is fully seated via a mechanical or magnetic switch. The visual signal could be a changing color of the LED from green to red, or a flashing LED color. The audible signal could be any pattern of sound. The indicator can be designed as a built-in feature for each filter or a reusable accessory that the user can attach to the filter at installation and reuse when replacing a used filter.
FIGS. 22 to 32 concern positioning devices having that may be used to assist with removing a used air filter and installing a new air filter. These positioning devices are maintained in or on the ceiling, proximate to a duct's port therethrough. As such, the positioning devices operate to lower a filter from the ceiling to a level a few feet up from the ground, e.g., about two to about five feet above the ground. Accordingly, the positioning device functions to position the grille and filter at a level where a user can replace the filter without having to use a ladder. As described below, these positioning devices may include a motorized mechanism, which can be powered by direct wiring to home electricity or by batteries. The level of the positioning system relative to ceiling and ground may be controlled with a remote-control device. The positioning system may also be connected to a smart-home system, such as AMAZON ALEXA, and thus may also be controlled via a computer application, a smartphone application, or voice commands.
FIGS. 22 and 23 depict a positioning device 1300 in a closed configuration before and after it has been installed against ceiling 1302. As shown, the installation may be considered a retrofit installation because the duct's port 1303 through the ceiling includes a frame 1304 for attaching a standard metal grille. In new installations, frame 1304 need not be installed and attachment features of positioning device 1300 may be attached directly to the ceiling or additional attachment features mated to the ceiling. Likewise, for retrofit installations, frame 1304 can be removed and positioning device 1300 may be attached to the ceiling similar to a new installation. Positioning device 1300 comprises a housing 1307 including a first housing portion 1308 and a second housing portion 1310. Because positioning device is intended to be used for many years, through the use of many filter exchanges, the materials used to build it should be robust, e.g., plastic or metal.
As shown in FIG. 22, a filter-grille device 1306 is disposed in housing 1306 and viewable through a port 1309 of first housing portion 1308. FIG. 23 shows positioning device 1300 in an open or lowered configuration in which first housing portion 1308 has been lowered down away from ceiling 1302 while second housing portion 1310 remains attached to ceiling 1302. Guide features 1312 are provided on an inner surface 1304 of first housing portion 1308, alongside port 1309 and extending toward the second portion of the housing, to maintain the position of filter-grille device 1306 over port 1309. As such, the filter-grille device contacts the first housing portion and also contacts at least one of the guide features. FIG. 24 depicts an exemplary filter-grille device 1306 that may be used with positioning device 1300. Filter-grille device 1306 includes a face or grille 1318 and a filter 1320 attached thereto, similar to, e.g., filter-grille device 601 and made from the same materials.
FIG. 25 depicts an elevator mechanism 1321 comprising linkages 1322, which are visible when housing 1307 is in the open or lowered configuration. Elevator mechanism 1321 is positioned in an interior of second housing portion 1310 and connected to first housing portion 1308 and second housing portion 1310. Elevator mechanism 1321 includes wheels 1324 that are disposed along tracks 1326 which are attached to the inside of second housing portion 1312. Elevator mechanism 1321 also includes cross bar 1328 that is moveable and extends between opposing tracks 1326 and wheels 1324 of opposing linkages 1322. A lead screw 1330 is disposed through cross bar 1328 and connected on one end to a stabilizer bar 1329 and on its other end to a motor unit 1332. As lead screw 1330 is turned by the motor, it drives cross bar 1328 to translate along tracks 1326, which, depending on the direction that lead screw 1330 is turned, causes linkages 1322 to change configurations from the open configuration to the closed configuration and vice versa.
A light 1332 can be added to the vent assembly 101 for purposes of general illumination or to provide a visual alert that it is time to replace the filter. A switch may be included in housing 1307 that is triggered whenever the configuration of housing 1307 is changed, the triggering resetting a timer that controls the visual alert. A UV light 1334 may also be provided inside housing 1307 to kill bacteria and viruses. Hollow standoffs 1338 may be provided that mate with corresponding posts 1340 (FIG. 23) on first housing portion 1308. Such assists with aligning first housing portion 1308 and second housing portion 1310, and a tight fit therebetween, when housing 1307 is in a closed configuration
FIG. 26 depicts a positioning device 1400 that is similar to positioning device 1300 except as described here. Instead of a port 1309 through first housing portion 1308, first housing portion 1408 includes a grille portion 1440. As such, a standard filter instead of a filter-grille device may be used with positioning device 1400.
FIG. 27 depicts an elevator mechanism 1521 comprising a set of cables 1522 wrapped around wheels 1524 disposed in second housing portion 1510. Cables 1522 and wheels 1524 may be used instead of linkages 1322 yet provide similar functionality of changing the configuration of the positioning device. One or more motor units 1532 may be coupled to wheels 1524. As wheels 1524 are turned by the motor, depending on the direction that the wheels 1524 are turned, the cables can be wound or unwound about the wheels, and thus raise or lower first housing portion 1510. FIG. 28 depicts a positioning device with both linkages 1322 (and associated componentry, e.g., wheels 1324, tracks 1326 and lead screw 1330) and cables 1522 (and associated componentry, e.g., wheels 1524).
FIG. 29 depicts a positioning device 1600 that is similar to positioning device 1400 except as described here. First housing portion 1608 has a through-hole 1660 that permits for coupling first housing portion 1608 to a mating feature 1662 of a positioning tool 1664, which may be a rod, e.g., a telescoping rod as depicted in FIG. 30. FIG. 31 reflects mating feature 1662 mated to first housing portion 1508 by way of having been inserted through through-hole 1660 and then rotated. As such, upwards or downwards force exerted on positioning tool 1664 permits for changing the configuration of positioning device 1600 from an open configuration to a closed configuration and vice versa. To decouple head 155, rotate it 90 degree and pull it through the hole 151.
As depicted in FIG. 32, retaining posts 1668 may be mounted to first housing portion 1608 and latches 1670 may be mounted at corresponding locations on second housing portion 1610. When positioning device 1600 is in the closed configuration, posts 168 and latches 1670 engage to hold tray 149 in closed position while positioning tool 1664 is being removed from through-hole 1660. Yet the engagement force between posts 1668 and latches 1670 can be overcome when sufficient downward force is exerted on position tool 1664 while it is mated to first housing portion 1608. Such decouples posts 1668 from latches 1670, allowing first housing portion 1608 and the configuration of positioning device 1600 to be changed to the open configuration. Furthermore, as described above, linkages (and associated components), cables (and associated components), or both, may also be used.
Any of the examples or embodiments described herein may include various other features in addition to or in lieu of those described above. The teachings, expressions, embodiments, examples, etc., described herein should not be viewed in isolation relative to each other. Various suitable ways in which the teachings herein may be combined should be clear to those skilled in the art in view of the teachings herein.
Having shown and described exemplary embodiments of the subject matter contained herein, further adaptations of the methods and systems described herein may be accomplished by appropriate modifications without departing from the scope of the claims. In addition, where methods and steps described above indicate certain events occurring in certain order, it is intended that certain steps do not have to be performed in the order described but in any order as long as the steps allow the embodiments to function for their intended purposes. Therefore, to the extent there are variations of the invention, which are within the spirit of the disclosure or equivalent to the inventions found in the claims, it is the intent that this patent will cover those variations as well. Some such modifications should be apparent to those skilled in the art. For instance, the examples, embodiments, geometrics, materials, dimensions, ratios, steps, and the like discussed above are illustrative. Accordingly, the claims should not be limited to the specific details of structure and operation set forth in the written description and drawings.
Patent Application
20250216117
