Direct replacement air handler filter with automatic filter media advance

• US 8,313,567 B2
• Filed: 09/16/2009
• Issued: 11/20/2012
• Est. Priority Date: 09/16/2009
• Status: Expired due to Fees

• Current Assignee: Smart Air Filter LLC
• Original Assignee: Smart Air Filter LLC
• Inventors: Sullivan, Challen
• Primary Examiner(s): CLEMENTE, ROBERT ARTHUR
• Application Number:
  US12/585,514
• Publication Number:
  US 20110061537A1
• Time in Patent Office: 1,161 Days
• Field of Search: 553/51, 553/52, 553/54, 952/73, 952/77, 964/29
• US Class Current: 95/277
• CPC Class Codes: B01D 2273/14 Filters which are moved between two or more positions, e.g. by turning, pushing
• CPC Class Codes: B01D 46/16 arranged on non-filtering conveyors or supports
• CPC Class Codes: B01D 46/18 Particle separators, e.g. dust precipitators, using filtering belts
• CPC Class Codes: B01D 46/185 Construction of filtering belts or supporting belts including devices for centering, mounting or sealing thereof
• CPC Class Codes: B01D 46/22 the belts travelling during filtering
• CPC Class Codes: B01D 46/521 using folded, pleated material
• CPC Class Codes: B01D 46/88 Replacing filter elements
• CPC Class Codes: B01D 46/90 Devices for taking out of action one or more units of multi-unit filters, e.g. for regeneration or maintenance

Abstract

The invention is directed to a direct replacement air handler filter placed within an air flow channel having a housing. The housing having a motor coupled to a power source. The motor being in communication with a controller having an at least one sensor input or a timer. With a filter media storage area located on one end of the housing, having a folded filter media compactly stored inside the filter media storage area, and an exposed filter media containment area located on an opposed end. The filter media extending there between. The filter media is paid out from the filter media storage area across the housing where it is exposed to air within an exposure area and removes contaminants from the air. It is further passed through a seal that seals the containment area where the filter media is re-folded, collected, and compactly stored with the filtered contaminants.

Claims

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

a unitary housing having a uniform thickness throughout the length and width of the unitary housing and an at least one exposure slot;

an at least one filter media storage area, 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 an independent power supply and in communication with a controller, the at least one motor moving an at least one cord, wire, or string, and the at least one cord, wire, or string is further attached to the pleated filter media via reinforcement tabs 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, the exposed portion being paid out across an at least one supporting member with the at least one supporting member forcing the at least one filter media to fold at its pleats into a zig-zag pattern when placed into an air flow in the air flow channel and the paying out the at least one filter media being based on output from the controller; 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 direct replacement filter of claim 1, wherein the at least one cord, wire, or string is rolled up on a take-up roller for a pre-determined time or length and the exposed filter media is moved to the collection area and the exposed media is folded at its pleats and stored in a compacted state.

3. The direct replacement filter of claim 1, wherein the containment area is sealed within the housing by a separate sealing element.

4. The direct replacement filter of claim 1, further comprising a sealing member sealing the containment area, wherein the movement member re-folds the at least one pleated filter media after its exposure and moves it past the sealing member and stores it compactly in the containment area.

5. The direct replacement filter of claim 1, wherein when the at least one filter media is moved to the collection area and the exposed pleated media is refolded at the pleats and stored in a compacted state.

6. The direct replacement air handler filter of claim 1, wherein the unitary housing is comprised of at least one of an environmentally friendly cellulose, an environmentally friendly cardboard, an environmentally friendly paper, and an environmentally friendly organic plastic compound or plastic and the power source further comprises a battery.

7. The direct replacement air handler filter of claim 1, wherein the controller further comprises a clock or a programmed advancement profile, wherein the the at least one cord, wire, or string is engaged based on the clock or the programmed advancement profile.

8. The direct replacement filter of claim 1, wherein the at least one independent power supply is a battery or battery pack.

9. The direct replacement filter of claim 1, wherein the unitary housing is sealed throughout to prevent opening of the unitary housing.

10. A direct replacement air handler filter system within an air flow channel within an air handler unit comprising:

a housing having a uniform thickness throughout its length and width and having an exposure slot there through;

a motor coupled to a battery power source and in communication with a controller having an at least one sensor input or a timer; and

a filter media storage area located on one end of the housing, with a filter media folded and compactly stored inside the filter media storage area, and an exposed filter media containment area located on an opposed end within the housing with the filter media extending therebetween, the filter media being paid out from said filter media storage area across the housing and the exposure slot while being supported by an at least one support member where it is exposed to air within the air flow channel and folds into a zig-zag pattern and removes contaminants from the air and is further passed through to the containment area where the filter media is re-folded, collected, and compactly stored with the filtered contaminants, the motor being activated by said controller in response to input from the at least one sensor or based on a timed input from said timer and moving an at least one cord, wire, or string engaged to move the filter media across the exposure area.

11. A method of moving a pleated filter media within a uniform length and width, direct replacement air handler filter frame comprising the method steps of:

storing an unexposed folded filter media compactly within an at least one filter media storage area storage;

engaging an at least one motor coupled to an independent power supply in communication with a controller and the at least one motor moving an at least one cord, wire, or string;

paying out through the movement of the at least one cord, wire, or string by the at least one motor an unexposed portion of the at least one filter media into an at least one exposure slot and exposing 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, the exposed portion being paid out across an at least one supporting member with the at least one supporting member forced to fold into a zig-zag pattern when placed into an air flow in the air flow channel and the paying out of the at least one filter media being based on output from the controller; and

collecting in a containment area the exposed portion of the at least one filter media and retaining it within the containment area.

12. A direct replacement automatic media advancing air handler filter within an air flow channel comprising:

a housing having a uniform thickness throughout the length and width of the housing and an at least one exposure slot;

an at least one filter media storage area, 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 an independent power supply and in communication with a controller, the at least one motor moving an at least one screw drive 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 and the at least one filter media being folded at its pleats into a zig-zag pattern when in the air flow channel and the paying out the at least one filter media being based on output from the controller; and

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

13. The direct replacement filter of claim 12, wherein the controller moves the at least one screw drive is for a pre-determined time or length and the exposed filter media is moved to the collection area and the exposed media is folded at its pleats and stored in a compacted state.

14. The direct replacement filter of claim 12, wherein the at least one screw drive moves an at least one supporting spanning member, the at least one screw drive being moved by the motor and in turn moving the at least one spanning supporting member which engages the unexposed filter media at a pleat and carries the unexposed filter media from the at least one filter media storage area to the slot and then, upon a signal from the controller the motor further moves the at least one screw drive and the at least one supporting member to move the now exposed filter media to the containment area.

15. The direct replacement filter of claim 14, wherein the at least one screw drive re-folds the exposed portion of the pleated filter media after its exposure and the movement of the at least one screw drive stores the exposed pleated compactly in the containment area.

16. The direct replacement filter of claim 12, wherein the containment area is sealed within the housing by a separate sealing element.

17. The direct replacement filter of claim 12, wherein when the at least one filter media is moved to remove unexposed portion of the filter media, the movement also moves the exposed portion of the filter media to the collection area and the exposed media is folded at its pleats and stored in a compacted state.

18. The direct replacement air handler filter of claim 12, wherein the housing is comprised of at least one of an environmentally friendly cellulose, an environmentally friendly cardboard, an environmentally friendly paper, and an environmentally friendly organic plastic compound or plastic and the power source further comprises a battery.

19. The direct replacement air handler filter of claim 12, wherein the controller further comprises a clock or a programmed advancement profile, wherein the at least one screw drive is engaged based on the clock or the programmed advancement profile.

20. The direct replacement filter of claim 12, further comprises an at least one roller , the roller assisting in paying out the filter media from the pleated, folded storage area and taking up the exposed filter material and rolling it about the roller in the containment area.

21. The direct replacement filter of claim 12, further comprising an at least one set of pinch rollers or an at least one cord, wire, or string, the at least one set of pinch rollers or the at least one cord, wire, or string assisting in moving the filter media from the storage area and feeding the exposed filter portion of the filter media into the containment area.

22. The direct replacement filter of claim 12, wherein the at least one independent power supply is a battery or battery pack.

23. The direct replacement filter of claim 12, further comprising an at least one support member, wherein at least one support member assists in moving the filter media from the storage area to the exposure slot and from the exposure slot to the containment area.

24. The direct replacement filter of claim 12, wherein the housing is a unitary housing that is sealed throughout to prevent opening of the unitary housing.

25. A direct replacement air handler filter system within an air flow channel within an air handler unit comprising:

a housing having a uniform thickness and an exposure slot there through;

a motor coupled to a power source and in communication with a controller having an at least one sensor input or a timer; and

a filter media storage area located on one end of the housing, with a pleated, folded filter media folded and compactly stored inside the filter media storage area, and an exposed filter media containment area located on an opposed end within the housing with the filter media extending therebetween, the filter media being paid out from said filter media storage area across the housing and the exposure slot while being supported by an at least one support member where it is exposed to air to become an exposed filter media portion within the air flow channel and being folded along its pleats into a zig-zag pattern to remove contaminants from the air flow channel, the exposed filter media being further passed through to a containment area where the exposed filter media is re-folded, collected, and compactly stored with the filtered contaminants, the motor being activated by said controller in response to input from the at least one sensor or based on a timed input from said timer and moving an at least one screw drive-to move the filter media from the storage area, across the exposure area, and into the containment area.

26. A method of moving a pleated filter media within a uniform length and width, direct replacement air handler filter frame comprising the method steps of:

storing an unexposed folded, pleated filter media compactly within an at least one filter media storage area storage;

engaging an at least one motor coupled to an independent power supply in communication with a controller and the at least one motor moving an at least one screw drive;

paying out through the movement of the at least one screw drive by the at least one motor an unexposed portion of the at least one filter media into an at least one exposure slot with an at least one support member and exposing 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, the exposed portion being folded at its pleats into a zig-zag pattern when placed into an air flow in the air flow channel and the paying out of the at least one filter media being based on output from the controller; and

collecting in a containment area the exposed portion of the at least one filter media and retaining it within the containment area.

27. A direct replacement automatic media advancing air handler filter within an air flow channel comprising:

a unitary housing having a uniform thickness throughout the length and width of the unitary housing and an at least one exposure slot;

an at least one filter media storage area, 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 an independent power supply and in communication with a controller, the at least one motor moving an at least one set of pinch rollers that pays out an unexposed portion of the at least one filter media from the pleated, folded storage area 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, the exposed portion being paid out across an at least one supporting member with the at least one supporting member forcing the at least one filter media to fold at its pleats into a zig-zag pattern when placed into an air flow in the air flow channel and the paying out the at least one filter media being based on output from the controller; and

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

28. The direct replacement filter of claim 27, wherein the at least one set of pinch rollers moves the exposed media and the exposed media is rolled up on a take-up roller for a pre-determined time or length and the exposed filter media is moved to the collection area.

29. The direct replacement filter of claim 27, further comprising an at least track with an at least one supporting spanning member cooperating with the at least one set of pinch rollers, the at least one track member being moved by the motor and in turn moving the at least one spanning supporting member which engages the unexposed filter media at a pleat and carries the unexposed filter media from the at least one filter media storage area to the slot and then, upon a signal from the controller the motor further moves the at least one track member and the at least one supporting and spanning member to move the now exposed filter media to the containment area in conjunction with the at least one set of pinch rollers.

30. The direct replacement filter of claim 27, wherein the containment area is sealed within the housing by a separate sealing element.

31. The direct replacement filter of claim 27, further comprising an at least one screw drive or an at least one string, wire or cord, wherein the at least one screw drive or the at least one string, wire, or cord assists in moving the filter media.

32. The direct replacement filter of claim 27, wherein when the at least one filter media is moved to the collection area and the exposed media is folded at its pleats and stored in a compacted state.

33. The direct replacement air handler filter of claim 27, wherein the unitary housing is comprised of at least one of an environmentally friendly cellulose, an environmentally friendly cardboard, an environmentally friendly paper, and an environmentally friendly organic plastic compound or plastic and the power source further comprises a battery.

34. The direct replacement air handler filter of claim 27, wherein the controller further comprises a clock or a programmed advancement profile, wherein the at least one set of pinch rollers is engaged based on the clock or the programmed advancement profile.

35. The direct replacement filter of claim 27, wherein the at least one independent power supply is a battery or battery pack.

36. The direct replacement filter of claim 27, wherein the unitary housing is sealed throughout to prevent opening of the unitary housing.

37. A direct replacement air handler filter system within an air flow channel within an air handler unit comprising:

a housing having a uniform thickness throughout its length and width and having an exposure slot there through;

a motor coupled to a battery power source and in communication with a controller having an at least one sensor input or a timer; and

a filter media storage area located on one end of the housing, with a filter media folded and compactly stored inside the filter media storage area, and an exposed filter media containment area located on an opposed end within the housing with the filter media extending there between, the filter media being paid out from said filter media storage area across the housing and the exposure slot while being supported by an at least one support member where it is exposed to air within the air flow channel and folds into a zig-zag pattern and removes contaminants from the air and is further passed through to the containment area where the filter media is re-folded, collected, and compactly stored with the filtered contaminants, the motor being activated by said controller in response to input from the at least one sensor or based on a timed input from said timer and moving an at least one set of pinch rollers is engaged to move the filter media across the exposure area.

38. A method of moving a pleated filter media within a uniform length and width, direct replacement air handler filter frame comprising the method steps of:

storing an unexposed folded, pleated filter media compactly within an at least one filter media storage area storage;

engaging an at least one motor coupled to an independent power supply in communication with a controller and the at least one motor moving an at least one set of pinch rollers;

paying out through the movement of the least one set of pinch rollers by the at least one motor an unexposed portion of the at least one filter media into an at least one exposure slot and exposing 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, the exposed portion being paid forcing the at least one filter media to fold at its pleats into a zig-zag pattern when placed into an air flow in the air flow channel and the paying out of the at least one filter media being based on output from the controller; and

collecting in a containment area the exposed portion of the at least one filter media and retaining it within the containment area.