Direct replacement air filter with automatic pleated filter media advance

• US 8,657,906 B2
• Filed: 11/14/2012
• Issued: 02/25/2014
• Est. Priority Date: 09/16/2009
• Status: Active Grant

• Current Assignee: Challen Sullivan
• Original Assignee: Challen Sullivan
• Inventors: Sullivan, Challen
• Primary Examiner(s): CLEMENTE, ROBERT ARTHUR
• Application Number:
  US13/677,285
• Publication Number:
  US 20130068099A1
• Time in Patent Office: 468 Days
• Field of Search: 553/51, 553/52, 553/54, 952/73, 952/77, 964/29
• US Class Current: 55/354
• 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 replacement media advancing air filter in air handling units with a flow channel. The filter having a housing and an exposure slot with filter media storage area that has an unexposed pleated, folded filter media portion stored therein. The filter media portion being folded and stacked in and compactly held at least in part within the storage area. A motor is coupled to a power supply and in communication with a controller. The motor moves a movement member that moves a portion of the filter media from a stored state in the storage area into the exposure slot and is exposed to the air in the air flow channel creating an exposed portion of the filter media. The exposed portion is collected within a containment area as a further portion of media is moved into the exposure slot to replace the exposed portion therein.

Claims

1. A replacement media advancing air filter in an air handling unit with an air flow channel comprising:

a housing having a substantially 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 an at least one media with an at least one unexposed pleated, folded filter media portion stored therein, the at least one unexposed pleated, folded filter media portion being pleated, folded, and stacked in and compactly held at least in part 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 moves a portion of the at least one unexposed, pleated, folded filter media portion from a stored state in the at least one filter media storage area unfolding the unexposed pleated, filter, pleated filter media into the at least one exposure slot and exposing the unexposed pleated filter media portion of the at least one filter media to the air in the air flow channel creating an exposed pleated filter media portion of the at least one filter media, the exposed portion being moved in conjunction with an at least one supporting member and the movement of the exposed portion of 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 as a further portion of the unexposed, pleated, folded filter media from the at least one filter media is moved into the exposure slot to replace the exposed portion therein.

2. The replacement filter of claim 1, wherein the at least one movement member is 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, 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 replacement filter of claim 1, wherein the at least one movement member is an at least track with an at least one supporting spanning member, the at least one track member being moved by the motor and in turn moving the at least one support member which engages the unexposed, folded, pleated filter media portion.

4. The replacement filter of claim 3, wherein the at least one track member engages the at least one filter media at a pleat and carries the unexposed filter media from the at least one filter media storage area to the exposure slot and then, upon a signal from the controller the motor further moves the track member and the at least one supporting and at least one support member to move the exposed filter media to the containment area.

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

6. The replacement filter of claim 1, wherein the movement member re-folds the at least one pleated filter media after its exposure and stores it compactly in the containment area.

7. The replacement filter of claim 1, wherein when the at least one filter media is moved to the containment area and the exposed media is folded at its pleats and stored in a compacted state.

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

9. The replacement filter of claim 1, wherein the at least one movement member is an at least one roller, the roller moving the filter media from the pleated, folded storage area and taking up the exposed filter material and rolling it about the roller in a containment area.

10. The replacement filter of claim 1, wherein the at least one movement member is an at least one set of pinch rollers, the pinch rollers pulling the filter to pay out the filter media from the pleated, folded storage area and feeding the exposed filter media into a containment area.

11. The replacement filter of claim 1, wherein the at least one movement member is an at least one screw drive.

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

13. The replacement filter of claim 1, wherein the at least one power supply is a commercial power supply supplied from a utility grid.

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

15. The replacement filter of claim 1, wherein the at least one movement member is an at least one chain drive.

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

a housing having a substantially uniform thickness of between about one inch and three inches throughout its length and width and having an exposure slot there through and the housing being sealed throughout to prevent opening of the housing;

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, having a pleated, folded filter media folded and compactly stored substantially 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 in an operational state, the filter media being unstacked and an unexposed portion of the filter media being pleated and moved from said filter media storage area while being supported by an at least one support member with a fixed pleat spacing, across the housing and the exposure slot where it is exposed to air within the air flow channel which removes contaminants from the air and is then folded along its pleats into an exposed folded and pleated filter media portion and is further passed through to a 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 the at least one movement member to move the filter media across the exposure area.

17. 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;

engaging an at least one motor coupled to a power supply in communication with a controller and the at least one motor moving an at least one movement member;

moving with the at least one movement member moved by the at least one motor, an unexposed portion of the at least one filter media from an unexposed, pleated state 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 pleated portion of the at least one filter media, the exposed pleated 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 of the at least one filter media being based on output from the controller; and

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