DEEP FILTER ELEMENT SUITABLE FOR REPLACING A SHALLOW FILTER ELEMENT AND HAVING A SUPPORT FRAME MADE FROM THIN STOCK

• US 20060236667A1
• Filed: 06/22/2006
• Published: 10/26/2006
• Est. Priority Date: 05/06/2002
• Status: Active Grant

• Current Assignee: Ademco Inc. (Resideo Technologies, Inc.)
• Original Assignee: Honeywell International Inc.
• Inventors: Terlson, Brad A.
• Granted Patent: US 7,435,278 B2
• Time in Patent Office: Days
• US Class Current: 55/498
• CPC Class Codes: B01D 2271/02 Gaskets, sealings
• CPC Class Codes: B01D 46/0002 Casings; Housings; Frame constructions
• CPC Class Codes: B01D 46/0005 Mounting of filtering elements within casings, housings or frames B01D46/2422 takes precedence
• 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 46/521 using folded, pleated material
• CPC Class Codes: Y10S 55/05 Methods of making filter
• CPC Class Codes: Y10S 55/31 Filter frame

Abstract

A deep format filter element has a peripheral frame with outwardly protruding mounting flanges. The mounting flanges simulate the periphery of a shallow format filter element to allow the deep format filter element to replace the shallow format filter element in many situations. The frame design allows the entire frame to be formed of cardboard and still provide adequate rigidity and strength. The frame includes at least a first cardboard sheet forming individual sides of the frame and panels of the mounting flange. The first cardboard sheet includes for each mounting flange at least two inside folds defining edges of the mounting flange'"'"'s end panel and first and second side panels An outside fold defines the second side panel of the mounting flange.

Claims

1. A deep format filter element having i) a filter medium with a plurality of edge planes defining a medium periphery and first and second opposite facing face planes through which air to be filtered can pass, and ii) a frame enclosing the medium periphery, said frame having a plurality of body sections, each body section having a wall in generally facing relationship to one of the medium edge planes, at least first and second body sections each having a mounting flange, each of said mounting flanges having a generally rectangular cross section defined by first and second side panels and an end panel, each of said mounting flanges simulating a part of the periphery of a shallow filter element, said frame comprising at least a first cardboard sheet forming an individual body section of the frame and the panels of the mounting flange, said first cardboard sheet including for each mounting flange at least two inside folds defining edges of the mounting flange'"'"'s end panel and first and second side panels, and at least one outside fold defining an edge of the second side panel of the mounting flange.

2. The filter element of claim 1, wherein each of the body sections has a flange projecting therefrom, and where the first side panels of the flanges are generally coplanar and where the second side panels of the flanges are generally coplanar.

3. The filter element of claim 2, wherein at least the first body section'"'"'s first cardboard sheet has a first fastening tab defined by the outside fold and an end edge.

4. The filter element of claim 3, wherein at least the first body section has a mounting flange whose first side panel extends from the end panel of the mounting flange to overlap the first face plane of the filter element, thereby forming a first frame flange.

5. The filter element of claim 4, wherein at least the first body section includes a second cardboard sheet having a second fastening tab for attaching to the first cardboard sheet and a second frame flange integral with the tab surface and projecting along the filter element second face plane, said second cardboard sheet having an inside fold defining the second frame flange and the second fastening tab.

6. The filter element of claim 3, wherein at least the body section includes a second cardboard sheet having a second fastening tab for attaching to the first cardboard sheet and a second frame flange integral with the tab surface and projecting along the filter element second face plane, said second cardboard sheet having an inside fold defining the second frame flange and the second fastening tab.

7. The filter element of claim 6, wherein the filter element is a pleated filter element.

8. The filter element of claim 7, wherein at least the first body section includes a glue layer bonding the first fastening tab to the second cardboard sheet and a glue layer bonding the second fastening tab to the first cardboard sheet.

9. The filter element of claim 7, wherein at least the first body section'"'"'s first fastening tab extends from a fold defining a side panel of the mounting flange.

10. The filter element of claim 4, wherein each body section has a generally U-shaped cross section excluding the mounting flange, and including a wall facing the medium'"'"'s edge plane, and a second frame flange attached to the wall and extending along and substantially parallel to the filter element second face plane.

11. The filter element of claim 10, wherein at least the first body section includes a second cardboard sheet having for each filter element edge plane, a second fastening tab attached to the first cardboard sheet and a second frame flange panel integral with the fastening tab said second cardboard sheet having an inside fold defining the second frame flange panel and the second fastening tab, said second frame flange panel comprising the second frame flange.

12. The filter element of claim 2, wherein at least the first body section includes a second cardboard sheet, said first and second cardboard sheets collectively having first and second fastening tabs for attaching the first cardboard sheet to the second cardboard sheet and collectively forming the body section wall.

13. The filter element of claim 12, wherein the first body section'"'"'s second cardboard sheet includes the first and second fastening tabs.