DIRECT REPLACEMENT AIR FILTER WITH AUTOMATIC FILTER MEDIA ADVANCE AND WIRELESS COMMUNICATIONS

• US 20110061527A1
• Filed: 11/23/2010
• Published: 03/17/2011
• Est. Priority Date: 09/16/2009
• Status: Active Grant

• Current Assignee: Challen Sullivan
• Original Assignee: Challen Sullivan
• Inventors: Sullivan, Challen
• Granted Patent: US 8,657,936 B2
• Time in Patent Office: Days
• US Class Current: 95/1
• CPC Class Codes: B01D 46/18 Particle separators, e.g. dust precipitators, using filtering belts
• CPC Class Codes: B01D 46/42 Auxiliary equipment or operation thereof
• CPC Class Codes: B01D 46/429 Means for wireless communication
• CPC Class Codes: B01D 46/521 using folded, pleated material
• CPC Class Codes: B01D 46/88 Replacing filter elements
• CPC Class Codes: G06Q 10/20 Administration of product repair or maintenance
• CPC Class Codes: Y02P 90/845 Inventory and reporting systems for greenhouse gases [GHG]

Abstract

The invention is directed to a direct replacement air filtration or handler filter that is placed within an air flow channel within an air handler unit having a housing. A motor in communication with a controller and having an at least one sensor input or a timer or a transceiver and processing module. A filter media storage area is located on one end of the housing, with a pleated, folded filter media folded and compactly stored inside the filter media storage area. An exposed filter media containment area is located on an opposed end within the housing with the filter media extending therebetween. The filter media being paid out or advanced from the filter media storage area across the housing where it is exposed to air within the air flow channel as it removes contaminants from the air. The motor can be activated by said controller in response to input from the at least one sensor or based on a timed input from said timer and rotate an at least one movement member to move the filter media across the exposure area. This allows for higher efficiency operation and reduces maintenance and energy costs. The sensors and communications capability allow for the use of the filter in providing Air Quality Management (AQM). AQM allows the filter to monitor the quality of the air as it passes through the filter and interact with a network system to monitor the air quality at the point of filtration.

Claims

1. A direct replacement air handler filter within an air flow channel comprising:

a housing with an at least one exposure slot;

an at least one filter media storage area within the housing, having unexposed filter media stored therein, the unexposed filter media being pleated, folded, and stacked to be compactly held within the at least one filter media storage area;

an at least one motor coupled to a power supply and in communication with a controller, the at least one motor moving an at least one movement member that pays out an unexposed portion of the at least one filter media into the at least one exposure slot and exposes the unexposed portion of the at least one filter media to the air flow channel creating an exposed portion of the at least one filter media;

an at least one processing module and an at least one transceiver module on the controller and an at least one sensor, the controller communicating with the at least one sensor, the at least one sensor communicating data to the processing module and the controller, and the transceiver module transmitting data from the filter to a network or a storage device; and

a containment area, wherein the exposed portion of the at least one filter media is collected and retained within the containment area.

2. The air handler filter of claim 1, wherein the at least one sensor measures temperature, mold count, carbon monoxide, carbon dioxide, Volatile Organic Compounds (VOCs), smoke, fire, noxious gases, and air particle concentrations.

3. The air handler filter of claim 1, wherein the at least one sensor measures air flow and reports estimated energy consumption to the network or storage device.

4. The air handler filter of claim 1, wherein the controller communicates through the transceiver module with a further network interface device.

5. The air handler filter of claim 4, wherein the network interface device is a wi-fi enabled device or an internet gateway.

6. The air handler filter of claim 1, wherein the filter communicates through the controller and transceiver module as a wi-fi enabled device to the network

7. The air handler filter of claim 1, wherein the filter communicates through the controller and transceiver module communicate data from the at least one sensor to a network which in turn reports it to an alert device.

8. The air handler filter of claim 7, wherein the alert device is a cell phone, computer, or network enabled interface device.

9. The air handler filter of claim 8, wherein the alert device is a Network Operations Center or control center.

10. A method of reporting a status of an at least one air handler filter to a computer network, the method comprising:

activating and registering a network enabled air filter with a network;

starting operation of the at least one air filter within the air handler;

monitoring the operation and performance of the at least one air filter through an onboard controller in communication with an at least one sensor in the air filter sending data to a controller;

processing and comparing the data sent to the controller and comparing data against a set of parameters;

reporting when the processed data is outside the set of parameters; and

sending an alert to an alert device in communication with the network.

11. The method of claim 10, wherein monitoring step includes monitoring an amount of filter media through the at least one sensor and the method further comprises the method step of sending a further alert when the amount of filter media remaining reaches a preset minimum.

12. The method of claim 11, wherein the step of sending a further alert also activates a dispensing step, the dispensing step comprising the mailing of a replacement filter to a specified address for the registered air filter.

13. The method of claim 10, wherein the sending of an alert sends the alert to an end user and communicates the status of the air filter to a user through the alert device.

14. The method of claim 10, wherein the sending of an alert sends an alert to a security responder for an emergency response.

15. The method of claim 10, wherein the data from the at least one sensor measures and reports estimated energy consumption to the alert device.

16. An air filtration direct replacement filter deployed within an air flow channel comprising:

a housing with an at least one exposure slot;

an at least one filter media storage area within the housing, having unexposed filter media stored therein, the unexposed filter media being pleated, folded, and stacked to be compactly held within the at least one filter media storage area;

an at least one motor coupled to a power supply and in communication with a controller, the at least one motor moving an at least one movement member that advances an unexposed portion of the at least one filter media into the at least one exposure slot and exposes the unexposed portion of the at least one filter media to the air flow channel creating an exposed portion of the at least one filter media;

an at least one processing module and an at least one transceiver module on the controller and an at least one sensor, the controller communicating with the at least one sensor, the at least one sensor communicating data to the processing module and the controller, and the transceiver module transmitting data from the filter to a network or a storage device; and

a containment area, wherein the exposed portion of the at least one filter media is collected and retained within the containment area.

17. The air filtration direct replacement filter of claim 16, wherein the at least one movement member comprises a first roller containing the unexposed filter media with pleats contained thereon and a second roller collecting the exposed, pleated filter media and further comprising an at least one support assisting in supporting the filter media on the pleats and assisting in producing a zig-zag pattern.