U.S. patent application number 15/506204 was filed with the patent office on 2017-08-24 for powered window air filter.
The applicant listed for this patent is 3M INNOVATIVE PROPERTIES COMPANY. Invention is credited to Nicolas A. Echeverri, Andrew R. Fox, Weilai Jiang, Jonathan S. Langer, Yu Wen Sun.
Application Number | 20170241656 15/506204 |
Document ID | / |
Family ID | 55400394 |
Filed Date | 2017-08-24 |
United States Patent
Application |
20170241656 |
Kind Code |
A1 |
Fox; Andrew R. ; et
al. |
August 24, 2017 |
POWERED WINDOW AIR FILTER
Abstract
The present disclosure relates to powered window air filters.
More particularly, it relates to air filter systems capable of use
in a window opening. Some embodiments relate to an adjustably sized
air filter. Some embodiments include a filter assembly including
filter media and a fan and/or control unit that forces air through
the filter media in the filter assembly.
Inventors: |
Fox; Andrew R.; (Oakdale,
MN) ; Langer; Jonathan S.; (Westfield, NJ) ;
Jiang; Weilai; (Shanghai, CN) ; Sun; Yu Wen;
(Woodbury, MN) ; Echeverri; Nicolas A.; (Woodbury,
MN) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
3M INNOVATIVE PROPERTIES COMPANY |
St. Paul |
MN |
US |
|
|
Family ID: |
55400394 |
Appl. No.: |
15/506204 |
Filed: |
August 24, 2015 |
PCT Filed: |
August 24, 2015 |
PCT NO: |
PCT/US15/46494 |
371 Date: |
February 23, 2017 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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62041496 |
Aug 25, 2014 |
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62041499 |
Aug 25, 2014 |
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62041500 |
Aug 25, 2014 |
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62041501 |
Aug 25, 2014 |
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62206928 |
Aug 19, 2015 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
F24F 13/18 20130101;
F24F 2003/1657 20130101; B01D 46/448 20130101; F24F 13/28 20130101;
E06B 7/03 20130101; B01D 46/0002 20130101; B01D 2279/35 20130101;
E06B 7/02 20130101; F24F 2003/1635 20130101; B01D 46/521 20130101;
B01D 46/442 20130101; B01D 2279/40 20130101; E06B 2007/023
20130101; B01D 46/0032 20130101; F24F 3/1603 20130101; B01D 46/4227
20130101; B01D 46/46 20130101; B01D 2275/203 20130101; B01D 46/523
20130101; F24F 2221/20 20130101; B01D 2265/04 20130101; B01D 46/10
20130101 |
International
Class: |
F24F 3/16 20060101
F24F003/16; B01D 46/00 20060101 B01D046/00; B01D 46/44 20060101
B01D046/44; F24F 13/28 20060101 F24F013/28; E06B 7/02 20060101
E06B007/02; E06B 7/03 20060101 E06B007/03; F24F 13/18 20060101
F24F013/18; B01D 46/52 20060101 B01D046/52; B01D 46/46 20060101
B01D046/46 |
Claims
1. A window air filter comprising: a filter assembly including
filter media; and a fan and/or control unit that forces air through
the filter media in the filter assembly.
2. The window air filter of claim 1, wherein the fan and/or control
unit comprises: a housing; a control module; a vent; and a
motor.
3. The window air filter of claim 2, wherein the housing is at
least one of u-shaped and/or c-shaped.
4. The window air filter of claim 1, further comprising an end
cap.
5. The window air filter of claim 4, further comprising: an
internal connector between the end cap and the fan and/or control
unit.
6. The window air filter of claim 5, wherein the internal connector
provides an outward pushing force when the window air filter is
installed in a window.
7. The window air filter of claim 5, wherein the internal connector
includes at least one of a spring-loaded feature or a telescoping
feature.
8. The window air filter of claim 1, wherein the filter assembly is
at least one of flexible, adjustable, and/or extendible.
9. The window air filter of claim 1, wherein the filter media is
replaceable within the filter assembly and/or wherein the filter
assembly is replaceable.
10. The window air filter of claim 1, wherein the filter media is
at least one of moisture-resistant, moisture-repellant,
electrostatically charged, an electret nonwoven web, and/or not
electrostatically charged.
11. The window air filter of claim 1, wherein the filter media
includes at least one of carbon, activated carbon, a nonwoven, a
thermoplastic, a thermosetting material, a porous foam, fiberglass,
paper, a high loft spunbound web, a low loft spunbound web, a
meltblown web, and/or bi-modal fiber diameter meltblown media.
12. The window air filter of claim 1, wherein the filter media is
pleated.
13. The window air filter of claim 1, wherein the filter media is
at least one of self-supporting and non-self-supporting.
14. The window air filter of claim 1, further including
electronics.
15. The window air filter of claim 1, further comprising: an
anchoring device.
16. A kit, comprising: an air filter of claim 1; and a cutting
device capable of cutting the filter media to a desired size.
17. A kit, comprising: an air filter of claim 1; and an attachment
device capable of permanently or semi-permanently attaching the air
filter to a window.
18. The kit of claim 17, wherein the attachment device is at least
one of a nail, a screw, a hook, an adhesive, and/or an adhesive
backed interlocking strip.
Description
TECHNICAL FIELD
[0001] The present disclosure relates to powered air filters. More
particularly, it relates to powered air filter systems capable of
use in a window opening.
BACKGROUND
[0002] Windows are available in a large variety of sizes and can
include vertically or horizontally operable sashes to provide air
flow between an exterior and an interior of a building structure.
Occupants of a building structure often desire opening windows to
let fresh air into an interior of a home, business, or otherwise
enclosed space. However, in many locations, such as highly
populated areas of China, the outside air is more contaminated than
the indoor air. Novel filtering solutions are needed to let the
fresh aspects of the outdoor air in without letting in the
pollution or contaminants. Outdoor contaminants may include larger
particles such as pollen, dust, and mold spores and smaller
particles such as those forming PM.sub.2.5, bacteria, and viruses.
Gaseous outdoor pollutants such as odors, NO.sub.x, SO.sub.2,
ozone, and others may also be of concern in some locations.
SUMMARY
[0003] The inventors of the present disclosure recognized that, in
light of the above, a need exists for a powered air filter that
protects users from air quality contaminants, allows fresh air get
into the home through windows, can be easily installed and used by
consumers, is versatile to fit in most locations, and/or has
minimal impact on lighting and visibility. In some embodiments, the
powered air filter is a window air filter. Powered air filters have
various benefits, at least one of which is that they provide more
or increased air flow into a room than an unpowered (passive) air
filter.
[0004] The inventors of the present disclosure invented various
embodiments of air filters, methods of making air filters, and
methods of using air filters.
[0005] Some embodiments relate to a window air filter comprising a
filter assembly including filter media; and a fan and/or control
unit that forces air through the filter media in the filter
assembly. In some embodiments, the fan and/or control unit
comprises: a housing; a control module; a vent; and a motor.
[0006] In some embodiments, the housing is at least one of u-shaped
and/or c-shaped. Some embodiments further comprise an end cap. In
some embodiments, the filter assembly is at least one of flexible,
adjustable, and/or extendible.
[0007] Some embodiments further comprise an internal connector
between the end cap and the fan and/or control unit. In some
embodiments, the internal connector provides an outward pushing
force when the window air filter is installed in a window. In some
embodiments, the internal connector includes at least one of a
spring-loaded feature or a telescoping feature. In some
embodiments, the air filter further includes electronics. Some
embodiments further include an anchoring device.
[0008] In some embodiments, the filter media is replaceable within
the filter assembly and/or wherein the filter assembly is
replaceable. In some embodiments, the filter media is at least one
of moisture-resistant, moisture-repellant, electrostatically
charged, an electret nonwoven web, and/or not electrostatically
charged. In some embodiments, the filter media includes at least
one of carbon, activated carbon, a nonwoven, a thermoplastic, a
thermosetting material, a porous foam, fiberglass, paper, a high
loft spunbound web, a low loft spunbound web, a meltblown web,
and/or bi-modal fiber diameter meltblown media. In some
embodiments, the filter media is pleated. In some embodiments, the
filter media is at least one of self-supporting and
non-self-supporting.
[0009] Some embodiments relate to a kit including an air filter as
described above or herein and a cutting device capable of cutting
the filter media to a desired size.
[0010] Some embodiments relate to a kit including an air filter as
described above or herein and an attachment device capable of
permanently or semi-permanently attaching the air filter to a
window. In some embodiments, the attachment device is at least one
of a nail, a screw, a hook, an adhesive, and/or an adhesive backed
interlocking strip.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is a front view of an exemplary powered air purifier
or filter in accordance with principles of the present
disclosure;
[0012] FIG. 2A is a cross-sectional view of an exemplary powered
air purifier or filter in accordance with principles of the present
disclosure;
[0013] FIG. 2B is a cross-sectional view of another exemplary
powered air purifier of filter in accordance with principles of the
present disclosure;
[0014] FIG. 3A is a top view of the window air purifier of FIG.
2A;
[0015] FIG. 3B is a top view of the window air purifier of FIG.
2B;
[0016] FIGS. 4A-4C are perspective views of an exemplary window air
purifier or filter for installation in a vertically opening window
in accordance with principles of the present disclosure; and
[0017] FIG. 5A-5B are perspective views of an exemplary window air
purifier or filter for installation in a horizontally opening
window in accordance with principles of the present disclosure.
DETAILED DESCRIPTION
[0018] Various embodiments and implementations will be described in
detail. These embodiments should not be construed as limiting the
scope of the present application in any manner, and changes and
modifications may be made without departing from the spirit and
scope of the embodiments and implementations. For example, many of
the embodiments, implementations, and examples are discussed with
specific reference to window air filters, but these should not be
construed to limit the application scope to this one exemplary
implementation. Further, only some end uses have been discussed
herein, but end uses not specifically described herein are included
within the scope of the present application. As such, the scope of
the present application should be determined by the claims.
[0019] One exemplary embodiment of an air purifier or filter 20, in
accordance with principles of the present disclosure, is
illustrated in FIG. 1. In some embodiments, the air purifier or
filter can be used in a window. The air purifier 20 of FIG. 1
includes a fan/control unit 22, a filter assembly 24, and an end
cap 26. In general terms, the air purifier 20 is capable of fitting
into a window to filter impurities from the outdoor air to make it
cleaner upon its exit from the air purifier into the indoors where
people will breathe the cleaner air. In some embodiments, the fan
22 can be a low profile fan that draws air in through the filter
assembly 24 and discharges the cleaned air to the indoor
environment. In some embodiments, the low profile design delivers
purified outdoor air to the indoors without blocking a significant
portion of the window area. In some embodiments, the low profile
window air purifier 20 can be installed on a window ledge, fill the
entire gap across the ledge, and/or provide a self-sealing
construction to the window frame and sash. In some embodiments, the
window air purifier 20 can be employed in horizontal or vertical
sliding multi-part windows.
[0020] In some embodiments, the fan/control unit 22 includes a
housing 40, control modules 42, a vent 44, a plug 46, and a motor
48. In some embodiments, the fan/control unit 22 and the end cap 26
are rigid structures, although they may include gaskets or other
soft or rubbery materials to provide improved air seals and
gripping to the window structure surfaces. In some embodiments, the
filter assembly 24 is inherently flexible, due to the choice of
materials, the geometry of the filter media 28, or both. In some
embodiments, the filter assembly 24 is an elongated,
adjustable-length assembly, as described in greater detail below.
In some embodiments, an internal connector 30 may be included to
extend between the fan/control unit 22 and the end cap 26. In some
embodiments, the connector 30 is adjustable in a longitudinal
direction between the fan/control unit 22 and the end cap 26. In
some embodiments, the connector 30 can provide structural support
for the window air purifier 20 and may help maintain the
dimensional integrity of the window air purifier 20 in use,
particularly by providing compression strength. In some
embodiments, the connector 30 may use spring-loaded, telescoping
features, which could provide a constant outward pushing force when
the window air purifier 20 is installed in a window. In some
embodiments, an outward pushing force could help the window air
purifier 20 remain installed in a variety of situations.
[0021] In some embodiments, the air filter and/or fan/control unit
includes electronics of a type generally known. Some exemplary
electronics that can be used in the air filters described herein
include, for example, sensors for temperature, humidity,
particulate matter (e.g. PM2.5), VOC's, other gases or pollutants
(e.g., ozone, etc.). In some embodiments, the onboard electronic
controls could turn the air filter and/or fan on or off and/or
could adjust the fan speed depending on input from any of these
sensors. Some embodiments could additionally or alternatively
include wireless communication (e.g. wi-fi) so that the product
could be remotely monitored or controlled. In some embodiments, the
air filter could interact with other devices. In one exemplary
embodiments, the air filter could communicate with a user's smart
phone. In another exemplary embodiment, the air filter could
incorporate or access data from other sources (e.g. obtain local
air quality measurement data and modify its operation based on the
received data).
[0022] The window air purifier 20 of FIG. 1 can include various
filter assemblies. In some embodiments, the filter media 28 is
exposed to the "dirty" air outside the window and is sealed to the
air inside of the window. With additional reference to FIGS. 3A and
3B, in some embodiments, air flows from outside the window, through
the filter media 28, into the fan/control unit 22, and into the
room through the vents 44. As illustrated in FIGS. 2A-2B, in some
embodiments, the filter media 28a, 28b can be formed as a flat
sheet. In some embodiments, the filter media 28a, 28b can extend
along the entire length of the filter assembly 24. In some
embodiments, the filter media 28 is replaceable. In some
embodiments, the entire filter assembly 24 is sold as a single
replaceable unit. In some embodiments, only the filter media 28 of
the filter assembly 24 is sold as the replaceable item, and the
filter housing 32 is considered permanent.
[0023] With reference to FIGS. 2A and 2B, in some embodiments, the
filter assembly 24 includes a filter housing 32. In some
embodiments, the filter housing 32 can be C-shaped or U-shaped in
cross section. In some embodiments, the shape, along with the
internal open cavity formed by the filter housing 32, provides some
flexibility to the filter assembly 24. In some embodiments, the
filter housing 32 can be made of plastic, for example. Even a
moderately thick plastic filter housing 32, in a C- or U-shaped
geometry, will provide some flexibility. In some embodiments, the
flexibility of the filter housing 32 can be useful in helping to
seal the filter assembly 24 to the window "W" when the filter is
pinched between the window sash and the window frame during use. In
some embodiments, the filter housing 32 can include an outer cover
34 and an inner shell 36. In some embodiments, flexibility may also
be imparted through the selection of materials for the filter
assembly 24, for example the use of thick (e.g. 5-25 mm) expanded
polyethylene foam, or the inclusion of other gasket or
weather-stripping materials can be used. In some embodiments, the
outer shell 34 may be rigid or non-rigid. In some embodiments, the
particular filter media 28 selected for the window air purifier 20
can be particularly suited have particular desired characteristics
described herein. In some embodiments, the filter media 28 is
preferably constructed from moisture-resistant materials and may
optionally include additional layers or features to specifically
block or repel water, such as rain. In some embodiments, an
electrostatic charge is optionally imparted into or on to
material(s) of the filter media 28. An electrostatically charged
media 28 may be used, of which many grades are available, and many
of which offer high efficiency with low pressure drop. In some
embodiments, the filter media 28 can be an electret nonwoven web.
Electrostatic charge can be imparted to the filter media 28 in a
variety of ways as is well known in the art, for example by
hydrocharging, corona charging, etc. (e.g., as described in U.S.
Pat. No. 7,947,142 (mentioned above)). In other embodiments, the
filter media 28 is not electrostatically charged. Additional
multi-functional media grades, which incorporate activated carbon
or other materials for purifying gas-phase pollutants, may also be
incorporated into the filter structure.
[0024] FIGS. 2A and 3A illustrate one exemplary embodiment of a
filter media 28a including a nonwoven web media. In some
embodiments, the filter media 28a can be constructed, for example,
from nonwoven fibrous media formed of thermoplastics or
thermosetting materials such as polypropylene, linear polyethylene
and polyvinyl chloride. Other suitable, non-limiting materials for
the filter media include porous foams, nonwovens, papers,
fiberglass, or the like. In some embodiments, the filter media 28
comprises a filter media that attracts and captures dust, allergens
such as pollen and mold spores, and fine particle pollution from
the outdoor air.
[0025] In some embodiments, other nonwoven webs useful with the
filter media 28a can be a high loft spunbond web, such as
described, for example, in U.S. Pat. No. 8,162,153 to Fox et al.,
the entire teaching of which is incorporated herein by reference.
In other embodiments, the filter media 28a can be a low loft
spunbond web, such as those described in U.S. Pat. No. 7,947,142 to
Fox et al., the entire teaching of which is incorporated herein by
reference. In yet other embodiments, nonwoven webs useful with the
filter media 28a are generated by other techniques and/or have
other characteristics, such as the meltblown nonwoven webs
disclosed in U.S. Pat. No. 6,858,297 to Shah et al., the entire
teaching of which is incorporated herein by reference). Other
non-limiting examples of useful nonwoven web formats include
bi-modal fiber diameter meltblown media such as those described in
U.S. Pat. No. 7,858,163, the entire teaching of which is
incorporated herein by reference.
[0026] In some embodiments, the filter media 28 can alternatively
be a pleated filter media 28b, as illustrated in FIGS. 2B and 3B,
including at least a portion that has been folded to form a
configuration comprising rows of generally parallel, oppositely
oriented folds. In some embodiments, pleats can be formed in the
filter media 28b using various methods and components as are well
known in the art, e.g., to form a pleated filter for use in
applications such as air filtration., for example those described
in U.S. Pat. No. 6,740,137 to Kubokawa et al. and U.S. Pat. No.
7,622,063 to Sundet et al., the entire teachings of both of which
are incorporated herein by reference. FIGS. 2B and 3B illustrate an
exemplary pleated filter media 28b. In one embodiment, the pleated
filter media 28b extends only partially along the filter assembly
24, as illustrated in FIG. 3B. In some embodiments, the pleated
filter media 28b may be difficult to cut linearly to fit an entire
length of the filter assembly 24. In some embodiments, the filter
assembly 24 may be sealed at the point where the filter media 28b
terminates, and the rest of the filter assembly 24 length may be
cut to the desired length for installation: it is essentially dead
space. In some embodiments, the filter media 28 can consist of the
filter media or web alone or can include one or more additional
components or structures applied or assembled to the filter media
28. The filter media 28 of the assembly 24 can be self-supporting
or non-self-supporting. Where the filter media 28 consists of the
filter media or web and a support structure, the filter media 28
can be non-self-supporting with the addition supporting structure
rendering the filter media 28, as a whole, to be self-supporting.
As used herein, the term "self-supporting filter media or web" can
describe at least one of the following conditions: (1) a filter
media or web that is deformation resistant without requiring
stiffening layers, adhesive or other reinforcement in the filter
media web; or (2) the filter media generally maintains its shape
when subjected to an airstream as described, for example, in U.S.
Pat. No. 7,169,202 to Kubokawa, the entire teachings of which are
incorporated herein by reference; or (3) a web or media having
sufficient coherency and strength so as to be drapable and
handleable without substantial tearing or rupture. As used herein,
the term "non-self-supporting" can denote an air filter media that
is not capable, in the absence of a support frame and/or a support
grill, of withstanding the forces encountered due to typical air
flow.
[0027] The present window air purifiers or filters 20 can be useful
in protecting users from outside air quality contaminants As
discussed above, an electrostatically charged filter media 28 may
be used. Additional multi-functional media grades, which may
incorporate activated carbon or other materials for purifying
gas-phase pollutants, may also be incorporated into the filter
assembly 24. The use of a powered fan unit 22 should provide more
airflow into a room than any unpowered (passive) window filter. It
will also likely provide more airflow than an open window under
calm wind conditions. By further using a low pressure drop web
enabled by the electrostatic charging, additional airflow
improvements and reductions in fan power consumption can be
achieved.
[0028] FIGS. 4A-4C illustrate an exemplary installation process of
the window air purifier or filter 20 in a vertically opening window
80. First, the filter media 28 is cut to length using a cutting
utensil 82 such as a knife, heavy duty scissors, or similar object.
The cut does not have to be perfectly straight, because the end cap
26 attachment provides some room for a non-straight cut. The filter
media 28 is attached to the filter assembly 24 between the
fan/control unit 22 and the end cap 26, and then the entire window
air purifier 20 is placed in a partially open window. For a
vertical sliding window 80, as illustrated in FIGS. 4A-4C, the
window air purifier 20 is positioned on the lower sill.
[0029] For a horizontal sliding window 180, as illustrated in FIGS.
5A-5B, the window air purifier 20 is positioned in a vertical
orientation with the fan housing 30 on the bottom. In some
embodiments, a pushing force from internal rods or spring-loaded
product 30 (see, e.g., FIG.1) provides a holding force to the
window frame in either orientation. The window is closed the rest
of the way onto the window air purifier 20, and the contact between
the window sash and the window air purifier 20 provides a seal to
close any gaps that might allow leakage from the outside to the
inside. In some embodiments, remaining small gaps may be avoided by
the use of a piece of foam, weather-stripping, etc. In addition, a
restraining strap or other component (not shown) may be optionally
included and attached to prevent the window air purifier 20 from
dislodging and falling out of the window 80, 180 opening.
[0030] In some embodiments, the air filters of the present
disclosure include an anchoring device that ensures that the air
filter does not fall out of the window. The anchoring device can be
any known such device including, for example, a strap that connects
the air filter to a wall or other permanent or stable structure in
a building, room, home, or office. The anchoring device is optional
and present in some embodiments that would benefit from this
enhanced security feature. For example, in the US, most users of
window air filters live in single family homes. In most instances,
if the window air filter falls out of the window, it will probably
land in a bush, and it is extremely unlikely to hurt someone. In
contrast, in urban environments or highly populated countries, like
China, for example, many people live in high rise apartments. If
the window air filter falls out of a window, the problem could be
more significant. In some instances, the window air filter could
harm people or property.
[0031] The air filters of the present disclosure can be placed in
any desired frame or housing. Some exemplary frames are described
in, for example, U.S. Patent Application No. 62/041496 and
62/041,499, both of which are incorporated in their entirety
herein. The air filter media can come in roll form, such as, for
example, that described in U.S. Patent Application No. 62/041,500,
the entirety of which is incorporated herein. The air filter
assembly or media of U.S. Pat. No. 62/206,928 can be used in the
air filters of the present disclosure.
[0032] The terms first, second, third and the like in the
description and in the claims, are used for distinguishing between
similar elements and not necessarily for describing a sequential or
chronological order. It is to be understood that the terms so used
are interchangeable under appropriate circumstances and that the
embodiments of the invention described herein are capable of
operation in other sequences than described or illustrated
herein.
[0033] All of the references mentioned herein are incorporated by
reference in their entirety. Moreover, the terms top, bottom, over,
under and the like in the description and the claims are used for
descriptive purposes and not necessarily for describing relative
positions. It is to be understood that the terms so used are
interchangeable under appropriate circumstances and that the
embodiments of the invention described herein are capable of
operation in other orientations than described or illustrated
herein.
[0034] The recitation of all numerical ranges by endpoint is meant
to include all numbers subsumed within the range (i.e., the range 1
to 10 includes, for example, 1, 1.5, 3.33, and 10).
[0035] Those having skill in the art will appreciate that many
changes may be made to the details of the above-described
embodiments and implementations without departing from the
underlying principles thereof. Further, various modifications and
alterations of the present invention will become apparent to those
skilled in the art without departing from the spirit and scope of
the invention. The scope of the present application should,
therefore, be determined only by the following claims and
equivalents thereof.
* * * * *