U.S. patent application number 15/632139 was filed with the patent office on 2017-12-28 for compound air filters and methods thereof.
This patent application is currently assigned to K&N Engineering, Inc.. The applicant listed for this patent is K&N Engineering, Inc.. Invention is credited to Jere James Wall.
Application Number | 20170368490 15/632139 |
Document ID | / |
Family ID | 60675412 |
Filed Date | 2017-12-28 |
United States Patent
Application |
20170368490 |
Kind Code |
A1 |
Wall; Jere James |
December 28, 2017 |
COMPOUND AIR FILTERS AND METHODS THEREOF
Abstract
Compound air filters and methods thereof are provided for
sequestering airborne contaminants including volatile organic
compounds (VOCs) from air streamed through the air filters. An air
filter can include a support frame having a shape and size suitable
for seating the air filter within an air-filtering system. A
compound filter medium can be retained within the support frame to
remove the airborne contaminants and VOCs from air flowing through
the air filter and the air-filtering system containing one or more
of the air filters. A first media layer of the compound filter
medium can be pleated with pleats and configured to exhibit a
relatively high filtration efficiency and a low air pressure drop
across the filter medium. A second media layer of the filter medium
can be coupled to the first media layer and configured to maintain
a uniform distribution of the pleats with the first media
layer.
Inventors: |
Wall; Jere James;
(Helendale, CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
K&N Engineering, Inc. |
Riverside |
CA |
US |
|
|
Assignee: |
K&N Engineering, Inc.
Riverside
CA
|
Family ID: |
60675412 |
Appl. No.: |
15/632139 |
Filed: |
June 23, 2017 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
62354549 |
Jun 24, 2016 |
|
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B01D 53/02 20130101;
B01D 2259/4566 20130101; B01D 2239/0618 20130101; B01D 46/02
20130101; B01D 2265/06 20130101; B01D 46/10 20130101; F02M 35/024
20130101; B01D 46/00 20130101; B01D 2253/10 20130101; B01D 2258/06
20130101; B01D 2253/102 20130101; B01D 2257/708 20130101; B03C 9/00
20130101; B01D 46/521 20130101; B01D 46/0016 20130101; B01D 27/08
20130101; B01D 46/0036 20130101; B01D 2239/0613 20130101; B01D
46/0005 20130101; B01D 2275/10 20130101; B01D 2279/40 20130101 |
International
Class: |
B01D 46/02 20060101
B01D046/02; B01D 27/08 20060101 B01D027/08; F02M 35/024 20060101
F02M035/024; B01D 53/02 20060101 B01D053/02 |
Claims
1. An air filter, comprising: a compound filter medium configured
to sequester airborne contaminants from air streamed through the
filter medium; a first media layer of the compound filter medium
formed into a pleated configuration including a plurality of
pleats; a second media layer of the compound filter medium; and a
support frame configured to support the compound filter medium,
wherein the first media layer is disposed between the second media
layer and the support frame such that inner-pleat folds of the
plurality of pleats are coupled to the support frame and
outer-pleat folds of the plurality of pleats are coupled to the
second media layer.
2. The air filter of claim 1, wherein each outer-pleat fold of the
outer-pleat folds is coupled to the second media layer along an
entire length of the outer-pleat fold.
3. The air filter of claim 1, wherein each inner-pleat fold of the
inner-pleat folds is coupled to the support frame at both ends of
the inner-pleat fold.
4. The air filter of claim 1, wherein the support frame comprises a
molded rim along a perimeter of the filter medium, the rim
configured for seating the air filter in an air-filtering
system.
5. The air filter of claim 4, wherein the support frame further
comprises a wire mesh fixed in the rim, the wire mesh configured to
provide structural integrity to the support frame without
obstructing air streamed through the air filter.
6. The air filter of claim 4, wherein the air filter is configured
to stream air through the air filter in a direction from the
support frame to the second media layer.
7. The air filter of claim 1, wherein the first media layer
includes a plurality of bosses embossed in the first media layer
between each inner-pleat fold of the inner-pleat folds and an
adjacent outer-pleat fold of the outer-pleat folds.
8. The air filter of claim 7, wherein the plurality of bosses are
configured with a shape and orientation to provide structural
integrity to the first media layer in the pleated configuration
without obstructing air streamed through the air filter.
9. The air filter of claim 1, wherein the compound filter medium is
configured to sequester airborne contaminants selected from
particulate matter, volatile organic compounds (VOCs), and
combinations thereof from air streamed through the filter
medium.
10. An air filter configured for a heating, ventilation, and air
conditioning ("HVAC") system of a vehicle, comprising: a first
media layer of a compound filter medium formed into a pleated
configuration including a plurality of accordion pleats and a
plurality of bosses embossed in the plurality of pleats; a second
media layer of the compound filter medium; and a support frame
configured to support the compound filter medium, wherein: the
first media layer is disposed between the second media layer and
the support frame such that inner-pleat folds of the plurality of
pleats are coupled to the support frame at both ends of each of the
inner-pleat folds and outer-pleat folds of the plurality of pleats
are coupled to the second media layer along an entire length of
each of the outer-pleat folds, the plurality of bosses are set-wise
embossed in the first media layer between each inner-pleat fold of
the inner-pleat folds and an adjacent outer-pleat fold of the
outer-pleat folds, the plurality of bosses are configured with a
common shape and orientation to provide structural integrity to the
first media layer in the pleated configuration, and the air filter
is configured to stream air through the compound air filter in a
direction from the support frame to the second media layer to
sequester airborne contaminants from the air.
11. The air filter of claim 10, wherein at least one layer of the
first media layer and the second media layer is configured to
sequester volatile organic compounds (VOCs) from the air.
12. The air filter of claim 10, wherein at least one layer of the
first media layer and the second media layer includes an
electrostatic component configured to sequester particulate matter
from the air.
13. The air filter of claim 10, wherein the first media layer is a
textile, paper, cotton, spun fiberglass, foam, or a combination
thereof.
14. The air filter of claim 10, wherein the second media layer is a
textile, a woven synthetic material, a woven natural material,
woven cotton, or a combination thereof
15. The air filter of claim 10, wherein the support frame
comprises: a molded rim along a perimeter of the compound filter
medium configured for seating the air filter in an air-filtering
system, and a wire mesh fixed in the rim configured to provide
structural integrity to the support frame without obstructing air
streamed through the air filter.
16. The air filter of claim 15, wherein the rim is silicone rubber,
foam rubber, or integral skin polyurethane foam.
17. A method, comprising: coupling a second media layer to a first
media layer to form a compound filter medium, the first media layer
having a pleated configuration including a plurality of pleats;
molding a rim over a wire mesh to form a support frame for the
compound filter medium; and coupling the compound filter medium to
the support frame to form an air filter configured to sequester
airborne contaminants from air streamed through the air filter,
wherein: the first media layer is disposed between the second media
layer and the support frame such that inner-pleat folds of the
plurality of pleats are coupled to the support frame at both ends
of each of the inner-pleat folds and outer-pleat folds of the
plurality of pleats are coupled to the second media layer along an
entire length of each of the outer-pleat folds.
18. The method of claim 16, wherein: coupling the second media
layer to the first media layer includes adhering the outer-pleat
folds of the plurality of pleats to the second media layer either
continuously or at discrete points along an entire length of each
of the outer-pleat folds, and coupling the compound filter medium
to the support frame includes adhering the inner-pleat folds of the
plurality of pleats to the support frame at both ends of each of
the inner-pleat folds.
19. The method of claim 16, further comprising: embossing the first
media layer with a plurality of bosses configured with a shape and
orientation to provide structural integrity to the first media
layer in the pleated configuration without obstructing air streamed
through the air filter.
20. The method of claim 19, further comprising: pleating the first
media layer into the pleated configuration such that the plurality
of bosses are set-wise embossed in the first media layer between
each inner-pleat fold of the inner-pleat folds and an adjacent
outer-pleat fold of the outer-pleat folds.
Description
CROSS-REFERENCE
[0001] This application claims the benefit of U.S. Provisional
Patent Application No. 62/354,549, filed Jun. 24, 2016, titled,
"COMPOUND AIR FILTER," which is hereby incorporated by reference
herein in its entirety.
BACKGROUND
[0002] An air filter designed to remove particulate matter from an
airstream generally is a device including fibrous materials. These
fibrous materials can remove solid particulates such as dust,
pollen, mold, and bacteria from an airstream. Air filters are used
in applications where air quality is important, notably in
air-filtering systems such as heating, ventilation, and air
conditioning (HVAC) systems of vehicles. Such air-filtering systems
generally operate to provide optimal interior air quality to
occupants within interior spaces of vehicles by removing particle
contaminants by way of filtration of air. As will be appreciated,
the effectiveness of an air-filtering system to provide an optimal
interior air quality depends largely on an ability of an air filter
within the air-filtering system to remove particle contaminants
from the air within the vehicle.
[0003] A drawback to conventional air filters, particularly air
filters including pleats, is that as the number or density of
pleats increases, the ability to maintain a uniform distribution of
the pleats within the air filter generally decreases. Even light
forces applied to a densely pleated air filter, either from
handling during installation of the air filter or from air flow
pressure during use, can dent or bend the pleats out of position.
When pleats are compressed together the surface area of the air
filter is effectively decreased, along with the efficiency of the
filter. This decrease in efficiency can reduce the effective life
of an air filter prompting the air filter to be discarded
prematurely in an effort to increase air-system system airflow and
decrease operation costs. Considering the innumerable number of
vehicles with air-filtering systems throughout the world, the
volume of discarded air filters that could be eliminated from
landfills is staggering.
[0004] What is needed, therefore, is a compound air filter that is
configured to maintain a uniform distribution of pleats, during
installation and use, in order to maximize surface area and overall
efficiency of the filter.
SUMMARY
[0005] Provided herein, in some embodiments, is an air filter
including a compound filter medium configured to sequester airborne
contaminants from air streamed through the filter medium and a
support frame configured to support the filter medium. The compound
filter medium can include a first media layer and a second media
layer. The first media layer can be formed into a pleated
configuration including a plurality of pleats. The first media
layer can be disposed between the second media layer and the
support frame, wherein inner-pleat folds of the plurality of pleats
can be coupled to the support frame, and wherein outer-pleat folds
of the plurality of pleats can be coupled to the second media
layer.
[0006] In such embodiments, each outer-pleat fold of the
outer-pleat folds can be coupled to the second media layer along an
entire length of the outer-pleat fold.
[0007] In such embodiments, each inner-pleat fold of the
inner-pleat folds can be coupled to the support frame at both ends
of the inner-pleat fold.
[0008] In such embodiments, the support frame includes a molded rim
along a perimeter of the filter medium. The rim can be configured
for seating the air filter in an air-filtering system.
[0009] In such embodiments, the support frame can further include a
wire mesh fixed in the rim. The wire mesh can be configured to
provide structural integrity to the support frame without
obstructing air streamed through the air filter.
[0010] In such embodiments, the air filter can be configured to
stream air through the air filter in a direction from the support
frame to the second media layer.
[0011] In such embodiments, the first media layer can include a
plurality of bosses embossed in the first media layer between each
inner-pleat fold of the inner-pleat folds and an adjacent
outer-pleat fold of the outer-pleat folds.
[0012] In such embodiments, the plurality of bosses can be
configured with a shape and orientation to provide structural
integrity to the first media layer in the pleated configuration
without obstructing air streamed through the air filter.
[0013] In such embodiments, the compound filter medium can be
configured to sequester airborne contaminants selected from
particulate matter, volatile organic compounds, and combinations
thereof from air streamed through the filter medium.
[0014] Also provided herein, in some embodiments, is an air filter
configured for a HVAC system of a vehicle including a compound
filter medium and a support frame configured to support the
compound filter medium. The compound filter medium can include a
first media layer and a second media layer. The first media layer
can be formed into a pleated configuration including a plurality of
accordion pleats and a plurality of bosses embossed in the
plurality of pleats. The first media layer can be disposed between
the second media layer and the support frame, wherein inner-pleat
folds of the plurality of pleats can be coupled to the support
frame at both ends of each of the inner-pleat folds, and wherein
outer-pleat folds of the plurality of pleats can be coupled to the
second media layer along an entire length of each of the
outer-pleat folds. The plurality of bosses can be set-wise embossed
in the first media layer between each inner-pleat fold of the
inner-pleat folds and an adjacent outer-pleat fold of the
outer-pleat folds. The plurality of bosses can also be configured
with a common shape and orientation to provide structural integrity
to the first media layer in the pleated configuration. The air
filter can be configured to stream air through the air filter in a
direction from the support frame to the second media layer to
sequester airborne contaminants from the air.
[0015] In such embodiments, at least one layer of the first media
layer and the second media layer can be configured to sequester
volatile organic compounds from the air.
[0016] In such embodiments, at least one layer of the first media
layer and the second media layer can include an electrostatic
component configured to sequester particulate matter from the
air.
[0017] In such embodiments, the first media layer can be a textile,
paper, cotton, spun fiberglass, foam, or a combination thereof.
[0018] In such embodiments, the second media layer can be a
textile, a woven synthetic material, a woven natural material,
woven cotton, or a combination thereof.
[0019] In such embodiments, the support frame includes a molded rim
along a perimeter of the compound filter medium and a wire mesh.
The molded rim can be configured for seating the air filter in an
air-filtering system. The wire mesh can be fixed in the rim to
provide structural integrity to the support frame without
obstructing air streamed through the air filter.
[0020] In such embodiments, the rim can be silicone rubber, foam
rubber, or integral skin polyurethane foam.
[0021] Also provided herein, in some embodiments, is a method
including forming a compound air filter configured to sequester
airborne contaminants from air streamed through the air filter.
Forming the compound air filter can include coupling a second media
layer to a first media layer to form a compound filter medium,
molding a rim over a wire mesh to form a support frame for the
compound filter medium, and coupling the compound filter medium to
the support frame to form the compound air filter. Coupling the
second media layer to the first media layer can include coupling
the second media layer to the first media layer having a pleated
configuration including a plurality of pleats to form the compound
filter medium. Coupling the compound filter medium to the support
frame can include disposing the compound filter medium such that
the first media layer is between the second media layer and the
support frame. Inner-pleat folds of the plurality of pleats can be
coupled to the support frame at both ends of each of the
inner-pleat folds. Outer-pleat folds of the plurality of pleats can
be coupled to the second media layer along an entire length of each
of the outer-pleat folds.
[0022] In such embodiments, coupling the second media layer to the
first media layer can include adhering the outer-pleat folds of the
plurality of pleats to the second media layer either continuously
or at discrete points along an entire length of each of the
outer-pleat folds. Coupling the compound filter medium to the
support frame can include adhering the inner-pleat folds of the
plurality of pleats to the support frame at both ends of each of
the inner-pleat folds.
[0023] In such embodiments, the method can further include
embossing the first media layer with a plurality of bosses
configured with a shape and orientation to provide structural
integrity to the first media layer in the pleated configuration
without obstructing air streamed through the air filter.
[0024] In such embodiments, the method can further include pleating
the first media layer into the pleated configuration such that the
plurality of bosses are set-wise embossed in the first media layer
between each inner-pleat fold of the inner-pleat folds and an
adjacent outer-pleat fold of the outer-pleat folds.
[0025] These and other features of the concepts provided herein
might be better understood with reference to the drawings,
description, and appended claims.
DRAWINGS
[0026] FIG. 1 illustrates a downstream perspective view of an air
filter configured for use in an air-filtering system of a vehicle
in accordance with some embodiments.
[0027] FIG. 2 illustrates an upstream perspective view of an air
filter configured for use in an air-filtering system of a vehicle
in accordance with some embodiments.
[0028] FIG. 3 is a side view of the air filter shown in FIGS. 1 and
2, illustrating a direction of airflow through the air filter in
accordance with some embodiments.
[0029] FIG. 4 is a side view of the air filter shown in FIGS. 1 and
2, illustrating a direction of airflow through the air filter in
accordance with some embodiments.
[0030] FIG. 5 illustrates a close-up view of a plurality of pleats
of the air filter of FIGS. 1 and 2 in accordance with some
embodiments.
[0031] FIG. 6 illustrates an air filter in an air-filtering system
of a vehicle in accordance with some embodiments.
[0032] While the concepts provided herein are subject to various
modifications and alternative forms, specific embodiments thereof
have been shown by way of example in the drawings and will be
described herein in detail. It should be understood the concepts
provided herein are not limited to the particular embodiments
disclosed, but, on the contrary, the intention is to cover all
modifications, equivalents, and alternatives of such with the
particular embodiments provided as examples thereof.
DESCRIPTION
[0033] In the following description, numerous specific details are
set forth in order to provide a thorough understanding of the
concepts provided herein. It will be apparent, however, to one of
ordinary skill in the art that the concepts provided herein can be
practiced without these specific details. In other instances,
specific numeric references such as "a first media layer," can be
made. However, the specific numeric reference should not be
interpreted as a literal sequential order but rather interpreted
that the "first media layer" is different than a "second media
layer." Thus, the specific details set forth are merely examples.
The specific details can be varied from and still be within the
spirit and scope of the concepts presented herein. The term
"coupled" is defined as meaning connected either directly to the
component or indirectly to the component through another component.
Further, as used herein, the terms "about," "approximately," or
"substantially" for any numerical values or ranges indicate a
suitable dimensional tolerance that allows the part or collection
of components to function for its intended purpose as described
herein.
[0034] In accordance with that set forth above, a compound air
filter is needed that is configured to maintain a uniform
distribution of pleats, during installation and use, in order to
maximize surface area and overall efficiency of the filter. As
such, a compound air filter is provided herein including, in some
embodiments, a compound filter medium configured to sequester
airborne contaminants from air streamed through the filter medium
and a support frame configured to support the filter medium. The
compound filter medium can include a first media layer and a second
media layer. The first media layer can be formed into a pleated
configuration including a plurality of pleats. The first media
layer can be disposed between the second media layer and the
support frame, wherein inner-pleat folds of the plurality of pleats
can be coupled to the support frame, and wherein outer-pleat folds
of the plurality of pleats can be coupled to the second media
layer.
[0035] Such a compound air filter is described for sequestering
airborne contaminants from air within, for example, residential or
commercial spaces, as well as within any of various types of
vehicle. The air filter can include a support frame having a shape
and size suitable to orient the air filter within an air-filtering
system. A filter medium can be retained within the support frame
and configured to remove the airborne contaminants from air flowing
through the air filtering. The support frame can include a single
molded rim disposed along a perimeter of the filter medium and can
be configured to orient the filter medium within an air-filtering
system, such that air flowing through the air-filtering system is
passed through the filter medium. The air filter can include a wire
support incorporated into the air filter and configured to provide
strength and durability to the air filter. The filter medium can
include a combination of one or more media layers configured to
exhibit a relatively high filtration efficiency and a relatively
low air pressure drop across the filter medium. The filter medium
can include a plurality of pleats so as to increase the surface
area of the filter medium. The air filter can also include a
support layer configured to maintain a uniform distribution of the
pleats.
[0036] Although embodiments of the compound air filters can be
described and illustrated herein in terms of a rectangular air
filter, it should be understood that the compound air filters are
not limited to the exact embodiments or shapes illustrated, but
rather the compound air filters can include a wide variety of
generally rectangular shapes, generally square, circular, oval,
round, curved, conical, or other closed perimeter shape that will
become apparent.
[0037] FIGS. 1 and 2 illustrate an embodiment of an air filter 100
that is configured for use in embodiments of the air-filtering
system incorporated into a vehicle. The air filter 100 includes a
support frame 110 having a shape and size suitable to support a
filter medium 120 and seat the air filter within an air-filtering
system. A filter medium 120 is retained within the support frame
110 and configured to remove airborne contaminants from air flowing
through the air filter. The support frame 110 can include a single
molded rim 112 that is disposed along a perimeter of the filter
medium 120, wherein the rim is configured for seating the air
filter in an air-filtering system. It is understood that the molded
rim 112 can be formed from molded foam rubber, silicone rubber,
integral skin polyurethane foam rubber; or any of various similar
materials that are known in the art.
[0038] In some embodiments, the support frame 110 include a
plurality of elongate sections and corner sections suitably
assembled along a perimeter of the filter medium to orient the air
filter 100 within an air-filtering system.
[0039] As best shown in FIG. 2, the air filter 100 can include a
wire mesh 214 that is incorporated (e.g., molded such as by
overmolding) into the air filter 100 and configured to provide
strength, structural integrity, durability, or a combination
thereof to the support frame 110 and the air filter 100 itself
without obstructing air streamed through the air filter 10.
Although the wire mesh 214 shown in FIG. 2 is molded into the
support frame 110, it should be understood that the wire mesh 214
can be fixed or coupled with the support frame 110 by way of any of
various techniques that are known in the art. Further, it should be
recognized that the size of mesh of the wire mesh 214 can be varied
from that shown in FIG. 2, based on design choice.
[0040] In some embodiments two or more layers of wire mesh can be
used to provide relatively greater support to the air filter 100.
For example, one or more layers of wire mesh can be disposed in
front of, behind, or within the filter medium 120 with respect to
the direction of airflow. It is contemplated that situating one or
more layers of wire mesh 214 in front of the filter medium 120;
with respect to the direction of airflow, can operate to catch
larger particulate matter, thereby removing this particulate matter
from the airstream prior to passing into filter medium 120.
[0041] It is contemplated that any of a variety of fasteners or
structures can be implemented so as to retain the filter medium 120
within the support frame 110. In some embodiments, for example, the
support frame 110 can include a grate, or a similar structure,
which encloses the filter medium 120 within the support frame 110
without restricting airflow through the filter medium 120, In some
embodiments, the filter medium 120 can be coupled with a wire
support, for example the wire mesh 214, that is configured to
resist bowing of the filter medium due to the airstream passing
therethrough. For example, the filter medium 120 can be disposed
between a first wire support and a second wire support. The first
and second wire supports can include a rigid material, such as, by
way of non-limiting example, any of various suitable plastics or
metals.
[0042] In some embodiments, the molded rim 112 can be molded
directly onto the edges of the filter medium 120 so as to retain
the filter medium within the support frame 110. In some
embodiments, the molded rim 112 can be molded onto a first support
layer, such as the wire mesh 214, a second support layer, the
filter medium 120, or any combination thereof. For example, in
those certain embodiments wherein the filter medium 120 is disposed
between a first support layer and a second support layer, the
molded rim 112 can be molded onto the first and second support
layers to retain the filter medium 120 within the support frame
110. Further, in some embodiments, the support frame 110 can
include a crimped portion that folds onto and retains the first and
second support layers and this retains the filter medium 120 within
the support frame 110.
[0043] As discussed above, a first support layer, such as the wire
mesh 214, can be coupled with the filter medium 120 so as to
provide additional strength and durability to the air filter 100.
It is envisioned that in some embodiments, the wire mesh 214 can be
positioned on an outer surface and an inner surface of the filter
medium 120. In some embodiments, the wire mesh 214 can include of
powder-coated aluminum screen wire that is co-pleated along with
the filter medium 120 so as to reinforce the air filter 100. In
some embodiments, the inner surface of the filter medium 120 can
also include a wire mesh reinforcement. It is contemplated that the
wire mesh supports can vary in rigidity. In some embodiments,
additional or alternative reinforcements can be provided, as will
be apparent to those skilled in the art.
[0044] FIGS. 3 and 4 illustrate side views of the air filter 100,
indicating a direction of airflow 301 passing through the air
filter 100 from the support frame 110 (e.g., inlet side of the air
filter 100) through the filter medium 120 (e.g., outlet side of the
air filter 100). The air filter 100 generally includes a
combination of two or more filter media layers forming a compound
filter medium 120 configured to exhibit a relatively high
filtration efficiency and a relatively low air pressure drop across
the filter medium 120. In the embodiments illustrated in FIGS. 1-5,
the air filter 100 includes a first media layer 122 and a second
media layer 128 forming the compound filter medium 120, in which at
least one of the foregoing media layers (or both) is configured to
sequester airborne contaminants selected from at least particulate
matter, volatile organic compounds (VOCs), and combinations thereof
from air streamed through the compound filter medium 120. As such,
the direction of airflow 301 passing through the air filter 100 of
FIGS. 3 and 4 is from the support frame 110, through the first
media layer 122, and, ultimately, through the second media layer
128.
[0045] The first media layer 122 can be formed into a pleated
configuration including a multiplicity of pleats 124 (e.g.,
accordion pleats) so as to increase the surface area of the filter
medium 120. It will be appreciated that an increase in the number
or density of the pleats 124 increases the surface area of the
filter medium 120. As best shown in FIGS. 1 and 3, the first media
layer 122 can be disposed between the second media layer 128 and
the support frame 110 such that inner-pleat folds (e.g., pleat fold
lines or creases on the inlet side of the air filter 100) of the
plurality of pleats 124 are coupled (e.g., adhered) to the support
frame 110 and outer-pleat folds (e.g., pleat fold lines or creases
on the outlet side of the air filter 100) of the plurality of
pleats 124 are coupled (e.g., adhered) to the second media layer
128. Each outer-pleat fold of the outer-pleat folds can be coupled
to the second media layer 128 along an entire length of the
outer-pleat fold. For example, each outer-pleat fold of the
outer-pleat folds can be adhered to the second media layer 128
along an entire length of the outer-pleat fold either continuously
(e.g., line of adhesive along the length of the outer-pleat fold)
or at discrete points (e.g., points of adhesive along the length of
the outer-pleat fold) along an entire length of each of the
outer-pleat folds. Each inner-pleat fold of the inner-pleat folds
can be coupled to the support frame 110 at both ends of the
inner-pleat fold. For example, each inner-pleat fold of the
inner-pleat folds can be adhered to the support frame 110 at both
ends of the inner-pleat fold while leaving the center free.
[0046] It is contemplated that the first media layer 122 can be
constructed of a natural material (i.e., a material sourced from
nature), a synthetic material, or a combination thereof. The
natural material can include, but is not limited to, cotton, wool,
flax, hemp, or the like, optionally formed into fibers, a paper
product thereof, or a woven or felted textile thereof. The
synthetic material can include, but is not limited to, polyester,
aramid, acrylic, nylon, polyurethane, olefin, polylactide, carbon,
or the like, optionally formed into fibers or a woven or felted
textile thereof. Combinations of the natural material and the
synthetic material can include woven or felted textiles of at least
one of the foregoing natural-material fibers and at least one of
the foregoing synthetic-material fibers. Other filter materials
known in the art can also be used. As such, the first media layer
122 can be constructed of paper, foam, cotton, spun fiberglass, or
other filter materials known in the art, woven or non-woven
material, synthetic or natural, or any combination thereof. In some
embodiments the first media layer 122 can be configured to remove
VOCs from the airstream. For example, in some embodiments, the
first media layer 122 can include a portion capable of removing
VOCs from the airstream. It is envisioned that embodiments of the
first media layer 122 can include components capable of removing
VOCs from the airstream such as activated charcoal or similar
materials known in the art.
[0047] In some embodiments, the first media layer 122, the second
media layer 128, or both media layers can include an electrostatic
portion that is configured to electrostatically attract and
agglomerate particle contaminants within the air flowing through
the air filter. It is contemplated that the electrostatic portion
can include at least some fibers that are treated with a coating of
antimicrobial molecules configured to destroy microbes. In some
embodiments, the antimicrobial molecules can include positively
charged molecules distributed around a circumference some fibers of
the first media layer 122 and configured to cooperate with
polarized fibers disposed within the filter medium 120.
[0048] In some embodiments, the first media layer 122 can include a
combination of one or more media layers, each having a unique
appearance. The combination of one or more media layers can be
configured to exhibit a relatively high filtration efficiency and a
relatively low air pressure drop across the filter medium 120, and
the unique appearance can be configured to indicate a preferred
direction of airflow 301 through the filter medium 120. In one
embodiment, the combination of one or more media layers includes a
first media layer and a second media. The first media layer
includes a first color (e.g., cream color) and the second media
layer includes a second color (e.g., grey color). As will be
appreciated, the first color indicates an air entry side of the
filter medium 120, and the second color indicates an air exit side
of the filter medium. It will be recognized that a variety of
colors, shapes, symbols, logos, written instructions or the like
can be used, without limitation, to indicate a preferred air entry
side of the filter medium 120.
[0049] As best shown in FIGS. 4 and 5, the first media layer 122
can include a plurality of bosses or embossed shapes 426. The
embossed shapes 426 can be positioned between the fold lines or
creases of the pleats 124 such that they are disposed substantially
on the sides of the pleats when the first media layer 122 is in the
pleated configuration. In other words, the first media layer 122
can include the plurality of bosses 426 embossed (in sets) in the
first media layer 122 between each inner-pleat fold of the
inner-pleat folds (e.g., pleat fold lines or creases on the inlet
side of the air filter 100) and an adjacent outer-pleat fold of the
outer-pleat folds (e.g., pleat fold lines or creases on the outlet
side of the air filter 100). The plurality of bosses 426 can be
configured with a common or shared shape (e.g., line, triangle,
etc.) and orientation (e.g., in direction of air flow through the
air filter 100) to provide structural integrity to the first media
layer 426 in the pleated configuration without obstructing air
streamed through the air filter 100. The embossed shapes 426 of
adjacent pleats 124 are longitudinally aligned such that apices of
opposing embossed shapes 426 sharing a pleat fold line are in
contact when the first media layer 122 is in the folded
configuration. These embossed shapes 426 aide in maintaining a
fold-to-fold pitch of the pleats in the spaced configuration while
maintaining a minimal loss in surface area as well as operating to
impart structural integrity to the first media layer 122, thereby
mitigating deformation of the plurality of pleats and preserving
filtration efficiency of the air filter. In some embodiments, the
embossed shapes 426 include adhesive beads or strips configured to
advantageously maintain a majority of their original shape while
adhering adjacent pleats 124. The adhesive beads or strips can
advantageously direct air through the first media layer 122 as
shown in FIGS. 3 and 4 instead of allowing the air to escape
through sides of the air filter 100. While the embossed shapes 426
in the present embodiment are disclosed as longitudinal and
orientated substantially parallel with the direction of airflow
301, it should be understood that any orientation, shape and number
of the embossed shapes 426 can be used that provide structural
integrity with suitable air flow.
[0050] As described above, the filter medium 120 includes a second
media layer 128 which can be incorporated into or coupled (e.g.,
adhered) to the first media layer 122. The second media layer 128
is configured to maintain a uniform distribution of the pleats 124
as best shown in FIG. 3. Preferably, the second media layer 128
includes a woven, fibrous material adhered to a down-stream side of
the first media layer 122, with respect to the direction of airflow
301.
[0051] It should be understood that the second media layer 128 can
include materials other than the above mentioned woven, fibrous
material, such as any of the natural materials, synthetic
materials, or the combinations thereof described for the first
media layer 122. The material including the second media layer 128
can be any material that is suitable for maintaining a uniform
distribution of the pleats 124 while providing little or no
resistance to airflow. For example, the second media layer 128 can
include synthetic or natural materials, organic or inorganic
materials, rigid or flexible materials, woven cotton or cotton
fabric, a woven synthetic material such as nylon fabric, wire mesh,
perforated plastic sheet, and the like.
[0052] It is contemplated that the second media layer 128 can be
adhered to the first media layer 122 by way of any suitable
fixation means known in the art, such as by way of non-limiting
examples any of adhesive (e.g., glue), clips, staples, sewing, pins
and the like. It is contemplated that the second media layer 128
can be affixed to the first media layer 122 by way of any one, or a
combination of, the suitable fixation configurations. In one
embodiment, the second media layer 128 is adhered to the first
media layer 122 by way of one or more lines of a suitable adhesive
disposed perpendicular to the pleats 124 and extends along a width
of the first media layer 122. It is contemplated that any suitable
adhesive can be used to adhere the first and second media layers
122, 128, without limitation. In some embodiments, the first and
second media layers can be mechanically fastened together by way of
, for example, a multiplicity of staples, one or more lines of
thread, or a combination thereof.
[0053] In some embodiments, at least some of the fibers including
the second media layer 128 can be treated with a coating of
antimicrobial molecules configured to destroy microbes on contact.
Preferably, the coating of antimicrobial molecules surrounds
substantially the entire circumference of each fiber strand that is
treated. In some embodiments, substances configured to release a
fragrance can be incorporated into the second media layer 128
including the antimicrobial molecules. It is contemplated that the
fragrance can be any natural substance, synthetic material,
(incorporating aldehydes, ketones, esters, and other chemical
constituents), or combinations thereof, which is known in the art
and suitable for use in candles for imparting an odor, aroma, or
fragrance. In some embodiments, suitable natural and synthetic
fragrance/flavor substances can include those compiled by the U.S.
Food and Drug Administration in Title 21 of the Code of Federal
Regulations, Sections 172.510 and 172.515 respectively. In some
embodiments, suitable fragrances include spice oil, flower oil,
fruit oil, and the like. In some embodiments, suitable fragrances
include fragrance components, such as for example benzaldehydes,
phenols, cinnamic aldehydes and esters, octadienes, dienes,
cyclohexadienes, terpenes, and the like. Further details regarding
dispersion of aromas by way of air filters and fragrance
compositions are disclosed in U.S. patent application Ser. No.
10/544,157, entitled "Vehicle cabin air filter freshener," filed on
Aug. 13, 2003, the entirety of each of which is incorporated herein
by reference.
[0054] It should be understood that the air filter 100 described
herein is not to be construed as limited solely to HVAC systems for
treating air within vehicle cabins where passengers and drivers
reside. Rather the air filter 100 can be used for internal
combustion engine intakes or the like requiring filtered air.
Vehicles, by way of non-limiting example, include automobiles,
trucks, recreational vehicles, buses, earthmoving equipment and
tractors with enclosed cabins, crane operator cabins, various cargo
moving vehicles, locomotives, rail passenger cars, airplanes,
helicopters, ship cabins, airship cabins, military vehicles, and
the like. Moreover, the air filter 100 can be incorporated into
other HVAC systems such as portable HVAC systems for treating air
volumes commensurate with, for example, those of vehicle
cabins.
[0055] FIG. 6 illustrates an air filter in an air-filtering system
of a vehicle in accordance with some embodiments. As shown, the
compound air filter 100 is incorporated into a ventilation system
602 of a vehicle 600 so as to clean outside air drawn through the
air filter 100 for a passenger compartment 604. The ventilation
system 602 includes a fan configured to draw a stream of outside
air through the compound air filter 100, wherein particulate
matter, volatile organic compounds (VOCs), and other airborne
contaminants are removed from the air. The fan then pushes a stream
of clean air into a heater core or an air conditioning system
before the passenger compartment 604.
Methods
[0056] Methods for forming the compound air filter 100 configured
to sequester airborne contaminants from air streamed through the
air filter 100 can include coupling the second media layer 128 to
the first media layer 122 to form the compound filter medium 120,
molding the rim over the wire mesh 214 to form the support frame
110 for the compound filter medium 120, and coupling the compound
filter medium 120 to the support frame 110 to form the compound air
filter 100.
[0057] Coupling the second media layer 128 to the first media layer
122 can include coupling the second media layer 128 to the first
media layer 122 having the pleated configuration including a
plurality of pleats 124 to form the compound filter medium 120.
Such coupling can include adhering the outer-pleat folds of the
plurality of pleats 124 to the second media layer 128 either
continuously or at discrete points along an entire length of each
of the outer-pleat folds. As such, outer-pleat folds of the
plurality of pleats 124 can be coupled or adhered to the second
media layer 128 along an entire length of each of the outer-pleat
folds.
[0058] Coupling the compound filter medium 120 to the support frame
110 can include disposing the compound filter medium 120 such that
the first media layer 122 is between the second media layer 128 and
the support frame 110. Such coupling can include adhering the
inner-pleat folds of the plurality of pleats 124 to the support
frame 110 at both ends of each of the inner-pleat folds. As such,
inner-pleat folds of the plurality of pleats 124 can be coupled or
adhered to the support frame 110 at both ends of each of the
inner-pleat folds.
[0059] Methods for forming the compound air filter 100 can further
include embossing the first media layer 122 with a plurality of
bosses 426 configured with a shape and orientation to provide
structural integrity to the first media layer 122 in the pleated
configuration without obstructing air streamed through the air
filter 100.
[0060] Methods for forming the compound air filter 100 can further
include pleating the first media layer 122 into the pleated
configuration such that the plurality of bosses 426 are set-wise
embossed in the first media layer 122 between each inner-pleat fold
of the inner-pleat folds and an adjacent outer-pleat fold of the
outer-pleat folds.
[0061] While the concepts provided herein have been described in
terms of particular variations and illustrative figures, those of
ordinary skill in the art will recognize that the concepts are not
limited to the variations or figures described. In addition, where
methods and steps described above indicate certain events occurring
in certain order, those of ordinary skill in the art will recognize
that the ordering of certain steps can be modified and that such
modifications are in accordance with the concepts provided herein.
Additionally, certain of the steps can be performed concurrently in
a parallel process when possible, as well as performed sequentially
as described above. To the extent there are variations, it is the
intent that this patent will cover those variations as well.
Therefore, it should be understood the concepts presented herein
are not limited by the specific embodiments described herein, but
only by scope of the appended claims.
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