Room air treatment system

• US 4,737,173 A
• Filed: 07/03/1986
• Issued: 04/12/1988
• Est. Priority Date: 07/03/1986
• Status: Expired due to Fees

• Current Assignee: Amway Corporation (Alticor Incorporated)
• Original Assignee: Amway Corporation (Alticor Incorporated)
• Inventors: Grochoski, Gregory T., Hamilton, Robert W., Kudirka, Paul J.
• Primary Examiner(s): Prunner, Kathleen J.
• Application Number:
  US06/881,702
• Time in Patent Office: 649 Days
• Field of Search: 55/276, 55/316, 55/350, 55/485, 55/471-473, 55/502, 55/507, 55/511, 55/470
• US Class Current: 96/131
• CPC Class Codes: B01D 2253/102 Carbon
• CPC Class Codes: B01D 2267/40 Different types of filters
• CPC Class Codes: B01D 2273/30 Means for generating a circulation of a fluid in a filtration system, e.g. using a pump or a fan
• CPC Class Codes: B01D 2279/50 for air conditioning
• CPC Class Codes: B01D 46/10 Particle separators, e.g. dust precipitators, using filter plates, sheets or pads having plane surfaces
• CPC Class Codes: B01D 46/44 controlling filtration
• CPC Class Codes: B01D 46/521 using folded, pleated material
• CPC Class Codes: B01D 46/62 connected in series
• CPC Class Codes: F24F 1/0071 with means for purifying supplied air perfuming or deodorising means F24F1/008
• CPC Class Codes: F24F 1/04 Arrangements for portability
• CPC Class Codes: F24F 13/28 Arrangement or mounting of filters
• CPC Class Codes: F24F 2221/12 transportable
• CPC Class Codes: F24F 8/10 by separation, e.g. by filtering
• CPC Class Codes: F24F 8/108 using dry filter elements
• CPC Class Codes: F24F 8/158 using active carbon

Abstract

A room air treatment system in which air is drawn through a large particle prefilter, a first carbon filter, a second dual honeycomb matrix carbon filter in which the honeycomb cells in adjacent matrices are offset relative to one another, a blower mounted on vibration isolation mounts and is expelled by the blower into a plenum from when it exits upwardly through a fine particle HEPA filter and finally out through a final filter which is a combination fine particle filter and carbon filter. A filter change warning system is provided which includes a 3500 hour filter change indicator, an every 7000 hour filter change indictor, a back-up warning indicator, a mute button for muting the warning indicator and a recycle system for restarting the hour count.

Claims

1. A room air treatment system comprising:

a cabinet having an air inlet and an air outlet;

a large particle prefilter located generally at said inlet;

carbon filter means located in said cabinet downstream from said prefilter for absorbing odorous and other chemical gases;

blower means located in said cabinet downstream from said carbon filter means for drawing air through said prefilter and said carbon filter means;

fine particle filter means located in said cabinet downstream from said blower means in air flow communication therewith whereby said blower means forces air through said fine particle filter means; and

a final filter comprising a combination carbon filter and fine particle filter whereby odorous and other chemical gases and particles passing through or escaping earlier entrapment in said fine particle filter means are entrapped by said final filter.

2. The air treatment system of claim 1 in which said carbon filter means comprises at least two separate layers of carbon of different types, whereby different types of contaminants are attracted differentially to said two carbon layers.

3. The air treatment system of claim 2 in which said two carbon layers are arranged serially as an upstream layer and a downstream layer, said downstream layer of carbon being more preferentially attractive to specific contaminants than said upstream layer of carbon, whereby a broader range of contaminants will be absorbed by said upstream carbon layer and will thereby not contaminate said downstream carbon layer and interfere with its preferential absorption of said specific contaminants.

4. The air treatment system of claim 3 in which said upstream layer of carbon comprises a combination of activated carbon and activated carbon impregnated with an aldehyde attracting composition;

said downstream layer comprising a blend of activated carbon treated with an acid attracting substance and activated carbon treated with a base attracting substance.

5. The air treatment system of claim 4 in which said carbon filter means comprises first and second adjacent honeycomb support matrices, each comprising a plurality of cells;

carbon particles of said upstream carbon layer being contained in said cells in the upstream one of said honeycomb support matrices and carbon particles of said downstream carbon layer being contained in the downstream one of said honeycomb support matrices;

said cells in said first honeycomb matrix being offset from said cells in said second honeycomb matrix whereby air passing over carbon particles settled in a cell in one of said honeycomb matrices will pass through the carbon in an adjacent but offset cell in the other of said honeycomb matrices.

6. The air treatment system of claim 1 in which said carbon filter means comprises two separate filters, the first comprising a honeycomb support matrix including a plurality of cells, each containing activated carbon particles;

said second filter comprising first and second adjacent honeycomb support matrices, each comprising a plurality of cells containing activated carbon particles;

said first filter containing a first type of activated carbon, said first honeycomb support matrix of said second filter containing a second type of activated carbon and said second honeycomb support matrix of said second filter containing yet a third type of activated carbon.

7. The air treatment system of claim 6 in which said first type of activated carbon in said first filter comprises a blend of approximately 50% by weight activated carbon and 50% by weight activated carbon impregnated with a material attractive to aldehydes;

said second type of activated carbon comprising a blend of approximately 60% by weight activated carbon and 40% by weight activated carbon impregnated with a material attractive to aldehydes;

said third type of activated carbon comprising a blend of approximately 20% by weight activated carbon, 40% by weight activated carbon impregnated with a base attractant material and 40% by weight activated carbon impregnated with an acid attractant material.

8. The air treatment system of claim 7 in which said cells in said first honeycomb support matrix of said second filter are offset from said cells in said second honeycomb matrix of said second filter whereby air passing over carbon particles settled in a cell in one of said matrices will pass through the carbon in an adjacent but offset cell in the other of said honeycomb matrices.

9. The air treatment system of claim 6 in which said air inlet of said air treatment system is framed by at least two stepped, recessed ledges, recessed inwardly away from the exterior of said cabinet, the first of said ledges being recessed a distance approximately equal to the thickness of said first carbon filter, said first carbon filter being seated against said first ledge;

said second recessed ledge being recessed from said first ledge a distance approximately equal to the thickness of said second carbon filter and being stepped inwardly to narrow said inlet opening relative to said first ledge, said second carbon filter being smaller in perimeter dimensions than said first carbon filter and being seated on said second ledge.

10. The air treatment system of claim 9 in which each of said first and second carbon filters includes a foam gasket perimeter seal which seats against its respective one of said first and second ledges.

11. The air treatment system of claim 10 in which said first type of activated carbon in said first filter comprises a blend of approximately 50% by weight activated carbon and 50% by weight activated carbon impregnated with a material attractive to aldehydes;

said second type of activated carbon comprising a blend of approximately 60% by weight activated carbon and 40% by weight activated carbon impregnated with a material attractive to aldehydes;

said third type of activated carbon comprising a blend of approximately 20% by weight activated carbon, 40% by weight activated carbon impregnated with a base attractant material and 40% by weight activated carbon impregnated with an acid attractant material.

12. The air treatment system of claim 11 in which said cells in said first honeycomb support matrix of said second filter are offset from said cells in said second honeycomb matrix of said second filter whereby air passing over carbon particles settled in a cell in one of said matrices will pass through the carbon in an adjacent but offset cell in the other of said honeycomb matrices.

13. The air treatment system of claim 1 in which said carbon filter means comprises at least two separate carbon filters, one containing a first type of carbon and the other containing a different type of carbon whereby different types of contaminants are differentially attracted to said different types of carbon.

14. The air treatment system of claim 13 in which said air inlet of said air treatment system is framed by at least two stepped, recessed ledges, recessed inwardly away from the exterior of said cabinet, the first of said ledges being recessed a distance approximately equal to the thickness of said first carbon filter, said first carbon filter being seated against said first ledge;

said second recessed ledge being recessed from said first ledge a distance approximately equal to the thickness of said second carbon filter and being stepped inwardly to narrow said inlet opening relative to said first ledge, said second carbon filter being smaller in perimeter dimensions than said first carbon filter and being seated on said second ledge.

15. The air treatment system of claim 14 in which each of said first and second carbon filters includes a foam gasket perimeter seal which seats against its respective one of said first and second ledges.

16. The air treatment system of claim 13 in which said inlet opening is defined by first, second and third stepped, recessed ledges, each being recessed further towards the inside of said cabinet and each being stepped inwardly to successively narrow the dimensions of said inlet opening as one proceeds from said first ledge to said third ledge;

said first ledge being recessed a distance approximately equal to the thickness of said prefilter, said prefilter including at least top and bottom connection means engaging mating connection means on said first ledge;

said second ledge being recessed from said first ledge a distance approximately equal to the thickness of said first carbon filter, said first carbon filter being seated on said second ledge;

said third ledge being recessed from said second ledge a distance approximately equal to the thickness of said second carbon filter, said second carbon filter being smaller in lateral and longitudinal dimensions than said first carbon filter whereby it seats on said third ledge.

17. The air treatment system of claim 16 in which said first and second carbon filters include foam gasket seals engaging and seating on said second and third ledges respectively to minimize air bypassing said first and second carbon filters.

18. The air treatment system of claim 17 in which said mating connection means on said prefilter and said first ledge comprise a fabric securing strip on one of said ledge and prefilter having a plurality of projecting loops and a fabric securing strip on the other thereof having a plurality of loop engaging projections whereby said prefilter can be readily attached to and removed from said air treatment system by engaging or disengaging said loops and loop engaging projections.

19. The air treatment system of claim 16 in which said mating connection means on said prefilter and said first ledge comprise a fabric securing strip on one of said ledge and prefilter having a plurality of projecting loops and a fabric securing strip on the other thereof having a plurality of loop engaging projections whereby said prefilter can be readily attached to and removed from said air treatment system by engaging or disengaging said loops and loop engaging projections.

20. The air treatment system of claim 1 in which said carbon filter means comprises first and second adjacent honeycomb support matrices, each comprising a plurality of cells containing carbon particles;

said cells in said first honeycomb matrix being offset from said cells in said second honeycomb matrix whereby air passing over carbon particles settled in a cell in one of said honeycomb matrices will pass through the carbon in an adjacent but offset cell in the other of said honeycomb matrices.

21. The air treatment system of claim 1 in which said carbon filter means is seated within said air inlet in said air treatment system and said prefilter means is seated over said air inlet, said prefilter means including connecting means cooperating with connecting means on said cabinet whereby said prefilter can be removably mounted on said cabinet, said prefilter holding said carbon filter means in position within said inlet opening when said prefilter is secured to said cabinet.

22. The air treatment system of claim 21 in which said mating connecting means on said cabinet and said prefilter comprise:

a fabric securing strip on one of said cabinet and prefilter having a plurality of projecting loops and a fabric securing strip on the other thereof having a plurality of loop engaging projections whereby said prefilter can be readily attached to and removed from said cabinet by engaging or disengaging said loops and loop engaging projections.

23. The air treatment system of claim 1 in which said blower means is secured to a plurality of vibration absorbing mounts, which in turn are secured to said cabinet and which maintain a separation between said cabinet and said blower means whereby transmission of vibrations from said blower means to said cabinet is minimized.

24. The air treatment system of claim 1 in which said cabinet is divided into a front compartment and a rear compartment, said air inlet opening into said rear compartment and said air outlet opening out of said front compartment;

said prefilter, said carbon filter means and said blower means being mounted in said rear compartment, said blower means located generally at the bottom of said rear compartment;

said blower means opening into and communicating with a plenum located in the bottom of said front compartment;

said fine filter means being positioned above said plenum and above the level of said blower means opening into said plenum whereby air exiting said blower means is forced to turn upwardly in said plenum before entering said fine particle filter.

25. The air treatment system of claim 24 in which said carbon filter means comprises at least two separate carbon filters, one containing a first type of carbon and the other containing a different type of carbon whereby different types of contaminants are differentially attracted to said different types of carbon.

26. The air treatment system of claim 25 in which said air inlet of said air treatment system is framed by at least two stepped, recessed ledges, recessed inwardly away from the exterior of said cabinet, the first of said ledges being recessed a distance approximately equal to the thickness of said first carbon filter, said first carbon filter being seated against said first ledge;

said second recessed ledge being recessed from said first ledge a distance approximately equal to the thickness of said second carbon filter and being stepped inwardly to narrow said inlet opening relative to said first ledge, said second carbon filter being smaller in perimeter dimensions than said first carbon filter and being seated on said second ledge.

27. The air treatment system of claim 26 in which each of said first and second carbon filters includes a foam gasket perimeter seal which seats against its respective one of said first and second ledges.

28. The air treatment system of claim 25 in which said inlet opening is defined by first, second and third stepped, recessed ledges, each being recessed further towards the inside of said cabinet and each being stepped inwardly to successively narrow the dimensions of said inlet opening as one proceeds from said first ledge to said third ledge;

said first ledge being recessed a distance approximately equal to the thickness of said prefilter, said prefilter including at least top and bottom connection means engaging mating connection means on said first ledge;

said second ledge being recessed from said first ledge a distance approximately equal to the thickness of said first carbon filter, said first carbon filter being seated on said second ledge;

said third ledge being recessed from said second ledge a distance approximately equal to the thickness of said second carbon filter, said second carbon filter being smaller in lateral and longitudinal dimensions than said first carbon filter whereby it seats on said third ledge.

29. The air treatment system of claim 28 in which said first and second carbon filters include foam gasket seals engaging and seating on said second and third ledges respectively to minimize air bypassing said first and second carbon filters.

30. The air treatment system of claim 29 in which said mating connection means on said prefilter and said first ledge comprise a fabric securing strip on one of said ledge and prefilter having a plurality of projecting loops and a fabric securing strip on the other thereof having a plurality of loop engaging projections whereby said prefilter can be readily attached to and removed from said air treatment system by engaging or disengaging said loops and loop engaging projections.

31. The air treatment system of claim 28 in which said mating connection means on said prefilter and said first ledge comprise a fabric securing strip on one of said ledge and prefilter having a plurality of projecting loops and a fabric securing strip on the other thereof having a plurality of loop engaging projections whereby said prefilter can be readily attached to and removed from said air treatment system by engaging or disengaging said loops and loop engaging projections.

32. The air treatment system of claim 28 in which said blower means is secured to a plurality of vibration absorbing mounts, which in turn are secured to said cabinet and which maintain a separation between said cabinet and said blower means whereby transmission of vibrations from said blower means to said cabinet is minimized.

33. The air treatment system of claim 24 in which said blower means is secured to a plurality of vibration absorbing mounts, which in turn are secured to said cabinet and which maintain a separation between said cabinet and said blower means whereby transmission of vibrations from said blower means to said cabinet is minimized.

34. A room air treatment system comprising:

a cabinet;

air filter means;

blower means, said blower means being mounted in said cabinet through vibration absorbing isolation mounts, said blower means being secured to said mounts and said mounts engaging said cabinet but holding said blower means spaced from said cabinet whereby vibration generated by said blower means tend to be absorbed by said mounts rather than transmitted to said cabinet;

said cabinet being divided into a front compartment and a rear compartment;

said cabinet including an air inlet opening into said rear compartment and an air outlet opening out of said front compartment;

said air filter means including a large particle prefilter, and carbon filter means, located along with said blower means in said rear compartment, said blower means being located generally at the bottom of said rear compartment;

said blower means opening into and communicating with a plenum located in the bottom of said front compartment; and

said air filter means including a fine particle filter means positioned above said plenum whereby air exiting said blower means is forced to turn upwardly in said plenum before entering said fine particle filter means.

35. A room air treatment system comprising:

a cabinet including an air inlet and an air outlet;

carbon filter means seated within said air inlet and prefilter means located over said air inlet;

a fabric securing strip on one of said cabinet and prefilter having a plurality of projecting loops and a fabric securing strip on the other thereof having a plurality of loop engaging projections whereby said prefilter can be readily attached to and removed from said air treatment system by engaging or disengaging said loops and loop engaging projections, said prefilter holding said carbon filter means in position within said air inlet when said prefilter is secured to said cabinet.