Replacement filter with cartridge and automatic filter media advance and wireless communications

• US 9,409,114 B2
• Filed: 12/11/2013
• Issued: 08/09/2016
• 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:
  US14/103,764
• Publication Number:
  US 20140305086A1
• Time in Patent Office: 972 Days
• US Class Current: 1/1
• CPC Class Codes: B01D 2273/14 Filters which are moved between two or more positions, e.g. by turning, pushing
• CPC Class Codes: B01D 46/18 Particle separators, e.g. dust precipitators, using filtering belts
• CPC Class Codes: B01D 46/22 the belts travelling during filtering
• CPC Class Codes: B01D 46/4227 Manipulating filters or filter elements, e.g. handles or extracting tools
• CPC Class Codes: B01D 46/521 using folded, pleated material

Abstract

A replacement filter deployed within a flow channel with a housing having a first of two or more frame members and a second of two or more frame members that are detachable with an exposure slot formed within the housing. A filter media storage area is within the housing, having unexposed, folded, pleated filter media stored therein. The unexposed folded, pleated filter media is compactly held within the filter media storage area. A motor is coupled to a power supply and in communication with a controller. The motor moving a movement member that advances an unexposed portion of the stacked pleated filter media into the exposure slot, expanding and exposing the unexposed portion of the media to the flow channel while retaining pleats and creating an exposed portion of the filter media. A containment area is provided where the exposed portion of the pleated filter media is collected folded, restacked and compactly stored and retained.

Claims

1. A replacement filter within a flow channel comprising:

a first frame portion of an at least two frame portions;

an at least one movement device;

an at least one motor coupled to and driving the at least one movement device;

an at least one power source powering the at least one motor;

a controller;

an at least one filter media stack having a filter media, the filter media being pleated and folded and compactly stored in the stack;

a second frame portion of an at least two frame portions that couples with the first frame portion of the at least two frame portions forming a housing with an at least one exposure slot through which the fluid channel passes, the first and second frame portions of the at least two frame portions coupling such that the at least one movement member engages the at least one filter media cartridge stack in one of the at least two frame portions, the at least one member moves the filter media upon instruction from the controller from a pleated, folded and compact state to extend across the at least one exposure slot to expose the pleated and extended filter media to the flow and through the movement of the at least one movement member to remove exposed filter media and restack and store the exposed filter media in a media cartridge stack.

2. The filter of claim 1, wherein the movement member further comprises at least one of a cord, wire, string, track, puller or pinch rollers, star, toothed, or pin roller, screw drive, threaded rod, or a take-up roller.

3. The filter of claim 1, wherein the movement member comprises an at least one threaded rod and further comprises an at least one sweep bar, wherein the threaded rod engages the sweep bar and moves the filter media and each of the at least one sweep bars, where each of the at least one sweep bars is spaced such that each bar separates a length of filter media that fills the space across the exposure slot.

4. The filter of claim 1, wherein the pleated and folded and compactly stored filter media further comprises an adhesive element wherein the adhesive bond strength of the at least one adhesive element permits removal of the pleats from the folded, pleated filter media stack by a selective removal device such that an at least one portion of the pleats at the point of contact with the adhesive element may remain adhered.

5. The filter of claim 1, wherein the at least one movement device and the at least one motor are contained within the first frame portion.

6. The filter of claim 5, wherein the at least one filter media stack is contained in the second frame portion.

7. The filter of claim 1, wherein the filter media stack is at one end of the housing in a storage area.

8. The filter of claim 1, wherein the exposed filter media is stored in a containment area.

9. The filter of claim 1, wherein the media cartridge stack is sealed.

10. The filter of claim 1, wherein the media cartridge stack is at a further end of the housing.

11. The filter of claim 1, wherein the filter media is drawn from the filter media stack into a storage area and stored in a compact, pleated, and folded fashion.

12. The filter of claim 11, wherein a containment area is within the filter media cartridge stack, such that the filter material is drawn back into the filter media cartridge stack after exposure.

13. The filter of claim 1, wherein the first and second of the at least two frame portions are of uniform thickness.

14. The filter of claim 1, wherein the first of the at least two frame portions has channel portions.

15. The filter of claim 14, wherein the second of the at least two frame portions has leg portions that sliding engage the channel portions to couple the first frame portion and second frame portion of the at least two frame portions.

16. The filter of claim 1, wherein the filter media stack comprises an at least one portion of filter media of sufficient length to provide sufficient unexposed filter to cross the exposure slot and become exposed filter media.

17. The filter of claim 16, wherein the sensor reports a condition of the exposed portion of the filter media to the controller and the controller upon receipt of the condition determines if movement of the movement member moves an amount of unexposed media into the exposure slot to cover the exposure slot.

18. The filter of claim 17, further comprising several spacers or sweep bars which divide several lengths of unexposed media which are stored and moved into the exposure slot based on commands from the controller.

19. The filter of claim 1, wherein the first frame portion of the at least two frame portions is a cartridge with the filter media stack therein and the second frame portion of the at least two frame portions is a frame, wherein the filter cartridge is placed within the frame and engaged by the movement member.

20. The filter of claim 19, wherein the frame is constructed of stiffened cardboard or plastic or metal.

21. The filter of claim 19, wherein the frame contains the at least one motor with the at least one power source and the controller.

22. The filter of claim 19, wherein the at least one cartridge contains the at least one movement member.

23. The filter of claim 22, wherein the at least one motor is coupled to the at least one movement member through a coupling that penetrates through the exterior of the filter cartridge.

24. The filter of claim 19, further comprising an at least one securement coupling wherein with the insertion of the filter cartridge into the frame the at least one securement coupling secures the filter cartridge and engages the coupling.

25. The filter of claim 1, wherein the first frame portion of the at least two frame portions further comprises a supply cartridge and the second frame portion of an at least two frame portions further comprises a collection cartridge and a third frame portion of an at least two frame portions couples to the first and second portions to form the housing with the first and second portions of the at least two portions extending from the housing.

26. The filter of claim 25, further comprising an at least one securement coupling the supply cartridge and the collection cartridge to the housing.

27. The filter of claim 26, wherein the at least one securement coupling is an at least one of an at least one releasable straps, snaps, buckles, interlocking parts slidingly engaged, clasps, and friction fit elements.

28. The filter of claim 27, wherein the filter media stack extends in the supply cartridge in the same plane as the housing with a movement bar dividing the pleated, folded and stacked filter media stack.

29. The filter of claim 28, wherein the media stack is advanced and a further media stack having a sweep bar is pulled down from the supply cartridge.

30. The filter of claim 29, further comprising an at least one guide member to assist in advancing the exposed folded, pleated media into the collection cartridge.

31. The filter of claim 30, wherein the media stack is withdrawn into the collection cartridge and the sweep bar is driven along a single threaded shaft as a movement member in the middle of the housing and then upward onto a further guide member into the collection cartridge.

32. The filter of claim 1, wherein the media cartridge stack is collected in a collection cartridge, and wherein the collection cartridge is at least one of a U-shaped, straight horizontal, vertically stacked, or s-shaped.

33. The filter of claim 1, wherein the media cartridge stack is collected in a collection cartridge which is an angled collection cartridge.

34. The filter of claim 1, further comprising an at least one guide rail within the media cartridge stack which is collected in a collection cartridge.

35. The filter of claim 34, wherein the guide rail is a turning screw mechanism and assists in driving an at least one sweep bar.

36. The filter of claim 25, wherein the movement member is an auger screw on the collection cartridge side of the exposure slot and a star wheel indexer on the supply cartridge side of the exposure slot.

37. The filter of claim 1, wherein the controller further comprises 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.

38. The filter of claim 37, wherein the at least one sensor is coupled to the controller and sensing an at least one operating parameter for the filter.

39. The filter of claim 38, 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 or the at least one sensor measures air flow and reports estimated energy consumption to the network or storage device.

40. The filter of claim 38, wherein the controller communicates through the transceiver module with a further network interface device.

41. The filter of claim 40, wherein the network interface device is a Wi-Fi enabled device or an internet gateway to a network which in turn reports it to an alert device or a Network Operations Center or control center.

42. The filter of claim 1, wherein the at least one movement member is an at least one screw drive or threaded rod.

43. A replacement filter deployed within a flow channel comprising:

a housing having a first frame member of an at least two frame members and a second frame member of an at least two frame members that are detachable with an at least one exposure slot formed within the housing by the at least two frame members;

an at least one filter media storage area within the housing, having unexposed, folded, pleated filter media stored therein, the unexposed folded, pleated 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 compactly held pleated, folded, and stacked pleated filter media into the at least one exposure slot, expanding and exposing the unexposed portion of the pleated filter media to the flow channel while retaining the pleats and creating an exposed portion of the at least one pleated filter media; and

a containment area, wherein the exposed portion of the pleated filter media is collected folded, restacked and compactly stored and retained within the containment area.

44. The filter of claim 43, wherein the containment area is a filter media cartridge, the filter media cartridge containing a folded pleated filter media stacked and stored so as to be in a compact state and, after being engaged by the at least one movement member, the folded pleated filter media is selectively removed from the compact state.

45. The filter of claim 43, wherein the stacked filter media is held with an at least one adhesive element having a separation force such that the separation force allows for separation of the folded, pleated filter media such that an element of the pleat remains adhered so as to prevent air flow around an edge of the unexposed portion of the filter media when it is in the exposure slot.

46. The filter of claim 43, wherein 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.

47. The filter of claim 43, wherein the at least one movement member comprises a star wheel moving the material from a portion containing the unexposed filter media with pleats contained thereon and an at least one auger screw drive assisting in 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 pleated pattern.

48. The filter of claim 43, wherein the first frame member is a housing frame and the second frame member is a filter.

49. The filter of claim 48, further comprising an at least one motor coupling, the at least one motor coupling engaging the at least one motor to the at least one movement member wherein the first frame member contains the at least one motor, the at least one controller, and the at least one power source and the second frame member contains the filter media stack and the at least one movement member.

50. The filter of claim 48, further comprising an at least one motor coupling, the at least one motor coupling engaging the at least one motor to the at least one movement member wherein the first frame member contains the at least one motor and the at least one controller and the second frame member contains the filter media stack, the at least one movement member, and the at least one power source.

51. The filter of claim 43, wherein the at least one movement member is at least one of at least one of a cord, wire, string;

track, puller or pinch rollers, star, toothed, or pin roller, screw drive, threaded rod, or a take-up roller.

52. The filter of claim 43, wherein the at least one movement member is at least one screw drive or threaded rod.