U.S. patent application number 17/192137 was filed with the patent office on 2021-06-24 for air filter devices with gap sealing unit.
The applicant listed for this patent is 3M INNOVATIVE PROPERTIES COMPANY. Invention is credited to Glen O. Gregerson, Thomas J. Herbrand, Judd D. Olson, David J. Prince, Danielle M. Schreppel, Craig D. Thompson.
Application Number | 20210187425 17/192137 |
Document ID | / |
Family ID | 1000005434788 |
Filed Date | 2021-06-24 |
United States Patent
Application |
20210187425 |
Kind Code |
A1 |
Gregerson; Glen O. ; et
al. |
June 24, 2021 |
AIR FILTER DEVICES WITH GAP SEALING UNIT
Abstract
An air filter device including an air filter unit and an
expansion unit. The air filter unit includes a filter media
assembly maintained by an outer frame assembly. The outer frame
assembly defines exterior length, width and depth dimensions of the
air filter device in an initial state. The expansion unit provides
one or more of an expanded length, width or depth in an expanded
state of the air filter device. Portions or an entirety of the
expansion unit can provided apart from the air filter unit in a
deliver condition of the air filter device, or can be assembled to
the air filter unit prior to delivery to a user. The air filter
devices of the present disclosure are useful with a wide variety of
differently size air handling devices, able to readily seal with an
air handling device compartment via the expansion unit.
Inventors: |
Gregerson; Glen O.; (Hudson,
WI) ; Herbrand; Thomas J.; (Eagan, MN) ;
Prince; David J.; (Saint Paul, MN) ; Schreppel;
Danielle M.; (Saint Paul, MN) ; Thompson; Craig
D.; (Inver Grove Heights, MN) ; Olson; Judd D.;
(Deephaven, MN) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
3M INNOVATIVE PROPERTIES COMPANY |
St. Paul |
MN |
US |
|
|
Family ID: |
1000005434788 |
Appl. No.: |
17/192137 |
Filed: |
March 4, 2021 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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15762409 |
Aug 13, 2018 |
10940416 |
|
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PCT/US2016/052047 |
Sep 16, 2016 |
|
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17192137 |
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62222836 |
Sep 24, 2015 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
F24F 8/10 20210101; B01D
46/0002 20130101; B01D 46/0032 20130101; B01D 2271/027 20130101;
B01D 46/521 20130101; B01D 46/0005 20130101; B01D 46/10 20130101;
B01D 2275/203 20130101; F24F 13/28 20130101 |
International
Class: |
B01D 46/00 20060101
B01D046/00; B01D 46/52 20060101 B01D046/52; F24F 13/28 20060101
F24F013/28; B01D 46/10 20060101 B01D046/10; F24F 8/10 20060101
F24F008/10 |
Claims
1. An air filter device comprising: an air filter unit including: a
filter media assembly defining a perimeter, an outer frame assembly
arranged about the perimeter and establishing exterior length,
width and depth dimensions of the air filter device in an initial
state; and an expansion unit configured to effect an expanded state
of the air filter device; wherein at least one of the exterior
length, width and depth dimensions of the air filter device is
greater in the expanded state than in the initial state.
2. The air filter device of claim 1, wherein the at least a portion
of the expansion unit is configured for selective assembly to the
outer frame assembly.
3. The air filter device of claim 1, further comprising packaging
containing the air filter unit and the expansion unit in the
delivery condition.
4. The air filter device of claim 1, wherein an entirety of the
expansion unit is provided apart from the air filter unit in the
delivery condition.
5. The air filter device of claim 1, wherein the expansion unit
includes at least a first standoff configured for selective
mounting to the outer frame assembly, and wherein the first
standoff includes a standoff body and an adhesive disposed on a
face of the standoff body.
6. The air filter device of claim 5, wherein the first standoff is
sized for mounting to an end frame member of the outer frame
assembly in the expanded state, and further wherein upon mounting
of the first standoff to the air filter unit, the length dimension
of the expanded state is greater than the length dimension of the
initial state or the width dimension of the expanded state is
greater than the width dimension of the initial state.
7. The air filter device of claim 1, wherein the outer frame
assembly includes a first frame member covering a first edge of the
perimeter, and further wherein the expansion unit includes a first
flange configured to project from the first frame member in the
expanded state.
8. The air filter device of claim 7, wherein the first side flange
defines a fixed end attached to the first frame member and a free
end opposite the fixed end, and further wherein the expanded state
includes the free end laterally spaced from the first frame
member.
9. The air filter device of claim 7, wherein outer frame assembly
further includes a second frame member covering a second end of the
perimeter, and further wherein the expansion unit further includes
a second flange configured to project from the second frame member
in the expanded state.
10. The air filter device of claim 9, wherein the expansion unit
further includes a deflection device configured to bias the free
end away from the first frame member.
11. The air filter device of claim 10, wherein the deflection
device includes a deflection body configured for placement between
the first frame member and the first flange.
12. The air filter device of claim 11, wherein the deflection
device further includes an adhesive disposed on a face of the
deflection body for selectively securing the deflection body to the
first frame member.
13. The air filter device of claim 8, wherein the first flange
defines a fold line between the fixed and free ends, wherein the
first flange includes a first portion between the fixed end and the
fold line, and a second portion between the fold line and the free
end, and further wherein the expanded state includes second portion
overlapping the first portion.
14. The air filter device of claim 7, wherein the first flange
includes a panel and a first tab, wherein the panel defines a fixed
end pivotably connected to the first frame member, a free end
opposite the fixed end, and opposing, first and second sides,
further wherein the first tab projects from the first side.
15. The air filter device of claim 14, wherein the first tab
terminates at a leading end opposite the first side, the leading
end configured to selectively interface with respective ones of a
plurality of slots.
16. The air filter device of claim 15, wherein the outer frame
assembly includes a second frame member covering a second edge of
the perimeter, the second frame member arranged orthogonal to the
first frame member, and further wherein the plurality of slots are
defined in the second frame member.
17. The air filter device of claim 16, wherein the first tab and
the plurality of slots are configured to selective lock the panel
at a plurality of different angular orientations of the panel
relative to the first frame member.
18. The air filter device of claim 1, wherein the perimeter
includes opposing, first and second side edges and opposing, first
and second end edges, and further wherein the outer frame assembly
includes first and second side frame members covering the first and
second side edges, respectively, and first and second end frame
members covering the first and second end edges, respectively, and
further wherein the expansion unit includes a first flange
configured to project from the first side frame member in the
expanded state, a second flange configured to project from the
second side frame member in the expanded state, a third flange
configured to project from the first end frame member in the
expanded state, and a fourth flange configured to project from the
second end frame member in the expanded state, wherein each of the
flanges includes a fixed end connected to the corresponding frame
member and a free end opposite the fixed end.
19. The air filter device of claim 18, wherein adjacent ones of the
flanges are slidably connected.
20. The air filter device of claim 1, wherein the filter media
assembly includes a pleated filter media defining a plurality of
pleats.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation application of U.S.
application Ser. No. 15/762,409, filed 13 Aug. 2018, which is a
national stage filing under 35 U.S.C. 371 of PCT/US2016/052047,
filed 16 Sep. 2016, which claims the benefit of U.S. Provisional
Application No. 62/222,836, filed 24 Sep. 2015, the disclosures of
which are incorporated by reference in their entireties herein.
BACKGROUND
[0002] The present disclosure relates to air filters. More
particularly, it relates to expandable air filters, such as
expandable HVAC air filters, appropriate for use with multiple,
differently sized air filter compartments.
[0003] Air filters are commonly used in forced air systems (e.g.,
residential heating, ventilation and air conditioning (HVAC)
systems) in order to remove dust, dirt particles and the like. With
many HVAC installations, a disposable air filter is conventionally
employed. Such air filters typically include a filter media
surrounded and supported by an outer frame. In addition to
supporting the filter media, the outer frame rigidly defines a
perimeter size and shape of the air filter. Other supporting and/or
reinforcing components, such as mesh screens, adhesive beads, etc.,
may also be included. After a period of use, these filters become
dirty or clogged and must be replaced.
[0004] To facilitate air filter replacement, HVAC systems
conventionally house the air filter within a user-accessible
compartment. The air filter is placed into and/or retrieved from
the compartment via an access slot. In some instances, the air
filter alone is inserted through the slot. In other instances, a
separate cabinet is provided into which the air filter is placed,
followed by insertion of the loaded cabinet through the slot. In
all instances, upon final insertion, a seal is desirably
established between the outer frame of the air filter and framework
of the compartment so as to prevent airflow around the air filter
during use (and thus prevent un-filtered airflow from passing
through the HVAC system). Preferred replacement air filters have a
size that corresponds with the expected size (in terms of height,
width and depth) of the HVAC system's air filter compartment.
[0005] A number of "standard" HVAC air filter compartment sizes
have gained industry acceptance over time and are widely employed.
Replacement air filter manufacturers, in turn, attempt to make
available for retail purchase air filters corresponding with these
standard sizes, allowing a customer to select a particular air
filter that should fit their HVAC system's compartment
configuration. The rigid outer frame of conventional air filters
dictates that the replacement air filter has the same size when
shipped to a retailer, when presented to potential purchases, and
when installation to the HVAC system is attempted. Because these
typical HVAC air filters are thus rather bulky, they undesirably
occupy a relatively large volume of space on transportation
vehicles and retailer shelves. Further, where the retailer has
limited available shelf space and/or desires to display for
purchase a large number of differently-sized air filters, only a
small number of larger-sized air filters (e.g., deep pleat air
filters) can reasonably be presented on the retailer's shelving
system. When the small number of a certain air filter size are
subsequently removed from the shelf for purchase and the retailer
does not consistently replenish the display shelf, it may
undesirably appear to the next potential purchaser that the
particular air filter size of interest is out of stock.
[0006] In addition, a potential customer may not immediately recall
with confidence the correct air filter size for their HVAC system
while at the retailer's place of business; this uncertainty can be
exacerbated when a large number of different air filter sizes are
displayed. Rather than purchase a potentially incorrectly-sized air
filter, the consumer will instead decide to delay air filter
replacement to a later date, potentially leading to inefficient
operation of the HVAC system if a new air filter is not actually
purchased for an extended period of time.
[0007] Moreover, the actual air filter compartment size associated
with a particular HVAC system will oftentimes deviate from the
designated "standard" or expected size. For example, the HVAC
system manufacturer's specifications may identify an air filter
size of 16''.times.20''.times.4'', yet the actual air filter
compartment is slightly smaller or slightly larger in one or more
dimensions. Thus, a purchased 16''.times.20''.times.4'' replacement
air filter may not be an optimal fit for the actual HVAC system
compartment (e.g., the purchased air filter may be too large for
straightforward insertion, or may be too small and lead to
suboptimal HVAC system operation). These circumstances can be
frustrating for the user, and can lead to even greater uncertainty
when considering the next replacement air filter purchase.
[0008] The above-described concerns with conventional replacement
HVAC air filters can also arise in other contexts. Many other types
of air handling devices or systems (e.g., room air purifiers,
window air filters, etc.) make use of a replaceable, rigid-frame
air filter, and a plethora of differently-sized replacement air
filters are presented for retail purchase. Once again, the
relatively large number of differently-sized air filters that must
be displayed occupies valuable retail shelf space, and a potential
purchaser will oftentimes be unsure as to which size is a best
"fit" at the time of purchase.
SUMMARY
[0009] The inventors of the present disclosure recognize that a
need exists for an air filter that overcomes one or more of the
above-mentioned problems.
[0010] Some aspects of the present disclosure relate to an air
filter device including an air filter unit and an expansion unit.
The air filter unit includes a filter media assembly maintained by
an outer frame assembly. The outer frame assembly defines exterior
length, width and depth dimensions of the air filter device in an
initial state. The expansion unit provides one or more of an
expanded length, width or depth in an expanded state of the air
filter device. In some embodiments, portions or an entirety of the
expansion unit is provided apart from the air filter unit in a
deliver condition of the air filter device (e.g., the air filter
device can be provided in kit form to a user). In other
embodiments, portions or an entirety of the expansion unit is
assembled to the air filter unit prior to delivery to a user.
Regardless, the air filter devices of the present disclosure are
useful with a wide variety of differently size air handling
devices, able to readily fit and seal with a compartment of the air
handling device via the expansion unit.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 a perspective view of an air filter device in
accordance with principles of the present disclosure, including
portions shown in block form;
[0012] FIG. 2A is a perspective view of the air filter device of
FIG. 1 in an initial state;
[0013] FIGS. 2B-2D are perspective views of the air filter device
of FIG. 1 in various expanded states;
[0014] FIG. 3A is a perspective view of a filter media assembly
useful with the air filter device of FIG. 1A;
[0015] FIG. 3B is a side view of a portion of the filter media
assembly of FIG. 3A;
[0016] FIG. 4A is a perspective view of an air filter device in
accordance with principles of the present disclosure;
[0017] FIG. 4B is an enlarged view of a portion of the air filter
device of FIG. 4A;
[0018] FIG. 5A is a perspective view of an air filter device in
accordance with principles of the present disclosure;
[0019] FIG. 5B is an enlarged view of a portion of the air filter
device of FIG. 5A;
[0020] FIG. 6A is a perspective view of an air filter device in
accordance with principles of the present disclosure;
[0021] FIG. 6B is an enlarged view of a portion of the air filter
device of FIG. 6A;
[0022] FIG. 7A is a perspective view of an air filter device in
accordance with principles of the present disclosure;
[0023] FIG. 7B is an enlarged view of a portion of the air filter
device of FIG. 7A;
[0024] FIG. 8A is a perspective view of an air filter device in
accordance with principles of the present disclosure;
[0025] FIG. 8B is an enlarged view of a portion of the air filter
device of FIG. 8A;
[0026] FIG. 9A is a perspective view of an air filter device in
accordance with principles of the present disclosure;
[0027] FIG. 9B is an enlarged view of a portion of the air filter
device of FIG. 9A;
[0028] FIG. 10A is a perspective view of an air filter device in
accordance with principles of the present disclosure; and
[0029] FIG. 10B is an enlarged view of a portion of the air filter
device of FIG. 10A.
DETAILED DESCRIPTION
[0030] Aspects of the present disclosure relate to air filter
devices that readily fit, and achieve a desired seal within,
differently-sized air handling compartments. One embodiment of an
air filter device 20 in accordance with principles of the present
disclosure is shown in FIG. 1 and includes an air filter unit 22
and an expansion unit 24 (shown in block form). The air filter unit
22 can be akin to any conventional or known air filter (e.g., HVAC
air filter), and includes a filter media assembly 30 and an outer
frame assembly 32 as described below. The outer frame assembly 32
can establish exterior dimensions of the air filter unit 22,
including exterior dimensions in length L, width W, and depth D
directions. The expansion unit 24 can assume a wide variety of
forms as described below, and generally serves to selectively
increase a footprint or size of the air filter unit 22 in one or
more of the length L, width W and depth D directions. The air
filter device 20 is generally constructed to have an initial state
as initially provided to a user in which some or all of the
expansion unit 24 is separate from the air filter unit 22, or, if
connected to the air filter unit 22 in the initial state, the
expansion unit 24 (or corresponding portions thereof) is retracted
so as to not overtly extend outside the footprint established by
the outer frame assembly 32. FIG. 2A is a non-limiting example of
the initial state of the air filter device 20 in which a portion or
entirety of the expansion unit 24 (FIG. 1) is apart from the air
filter unit 22, and the air filter unit 22 alone (or with the
optional portion of the expansion unit 24 in a retracted
arrangement) serves as the air filter device 20 for installation to
an air handling system (not shown). In the initial state, then, the
air filter device 20 has length L.sub.I, width W.sub.I and depth
D.sub.I dimensions as dictated by the air filter unit 22, for
example by the outer frame assembly 32. Where desired by a user,
the expansion unit 24 can be installed and/or deployed relative to
the air filter unit 22, to generate an expanded state of the air
filter device 20. The air filter device 20 can be installed to an
air handling system in the expanded state (and/or be caused to
transition to the expanded state following installation). As
generally reflected by the non-limiting example expanded states of
FIGS. 2B-2D, the expanded state of the air filter device 20 of the
present disclosure can include an expanded length L.sub.E (FIG.
2B), an expanded width W.sub.E (FIG. 2C) and/or an expanded depth
D.sub.E (FIG. 2D) that is greater than the corresponding dimension
L.sub.I, W.sub.I, D.sub.I in the initial state.
[0031] Returning to FIG. 1, in some embodiments, the air filter
unit 22 is sized for installation to a conventional HVAC system,
with at least the outer frame assembly 32 supporting the filter
media assembly 30 in the presence of HVAC system airflow. With
these non-limiting constructions, depending upon a size of the air
filter compartment provided with the HVAC system, a user can
install the air filter unit 22 alone (i.e., the air filter device
20 in the initial state as described above), or can utilize the
expansion unit 24 to expand the air filter device 20 in one or more
directions to better match an actual size of the air filter
compartment, better ensuring a desired seal is achieved between the
air filter device 20 and framework of the compartment.
[0032] With embodiments in which the initial state of the air
filter device 20 includes a portion or an entirety of the expansion
unit 24 not directly attached or connected to the air filter unit
22, the air filter device 20 can optionally be provided to a user
in kit form. For example, the air filter unit 22 and the expansion
unit 24 can be commonly packaged within a container or other
packaging, optionally with one or more additional items such as
written instructions for use. The packaging can assume any useful
format, for example packaging useful for retail display and
sale.
[0033] Air Filter Unit
[0034] The air filter unit 22 can assume various forms, and can
include the filter media assembly 30 and the outer frame assembly
32. The filter media assembly 30 can assume a wide variety of forms
useful for air filtration, such as HVAC air filtration, presently
known, or in the future developed. In some embodiments, the filter
media assembly 30 is a pleated filter media assembly. By "pleated"
is meant a web at least a portion of which has been folded to form
a configuration comprising rows of generally parallel, oppositely
oriented folds. For example, and as shown in FIGS. 3A and 3B, a
pleated version of the filter media assembly 30 includes a
plurality of pleats 40 each including a fold line 42 defining a
pleat tip 44 and a pair of adjacent panels 46.
[0035] The pleated version of the filter media assembly 30 can
consist of a pleated filter media or web 60 alone (as in the
illustrated embodiment), or can include one or more additional
components or structures applied or assembled to a pleated filter
media 60. The pleated filter media 60 of the assembly 30 can be
self-supporting or non-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. For example, where the pleated
version of the filter media assembly 30 consists of the pleated
filter media 60 alone, the pleated filter media or web 60 can be
self-supporting or non-self-supporting. Where the pleated version
of the filter media assembly 30 consists of the pleated filter
media or web 60 and a support structure, the pleated filter media
60 can be non-self-supporting with the additional supporting
structure rendering the pleated filter media assembly 30, as a
whole, to be self-supporting.
[0036] The particular filter media 60 selected for the pleated
version of the filter media assembly 30 is not critical to the
present disclosure so long as the resultant pleated filter media
assembly 30 (whether consisting solely of the pleated filter media
60 alone or with additional structures applied thereto) has the
desired characteristics described herein. The filter media 60 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. The filter media
assembly 30 can optionally include a highly open wire mesh or
screen, one or more adhesive strands, etc., that is bonded to the
filter media 60 in order to enhance the pleatability thereof and
that is pleated along with the filter media 60 itself. The wire
mesh or screen (or other additional component) may impede
re-collapsing of the pleated version of the filter media assembly
30. In other embodiments, the pleated version of the filter media
assembly 30 can incorporate wire-supported pleats, self-supported
mini-pleats, or other pleat constructions currently available or in
the future developed.
[0037] In some embodiments, the filter media 60 comprises a
nonwoven web that can have random fiber arrangement and generally
isotropic in-plane physical properties (e.g., tensile strength), or
if desired may have aligned fiber construction (e.g., one in which
the fibers are aligned in the machine direction as described in
U.S. Pat. No. 6,858,297 to Shah et al., the teachings of which are
incorporated herein by reference) and anisotropic in-plane physical
properties. Some or all of the fibers comprising the nonwoven webs
useful with the filter media 60 can be multicomponent fibers having
at least a first region and a second region, where the first region
has a melting temperature lower than the second region. Some
suitable multicomponent fibers are described, for example, in U.S.
Pat. Nos. 7,695,660, 6,057,256, 5,597,645, 5,972,808, 5,662,728 and
5,486,410 the teachings of each of which are incorporated herein by
reference in their entireties.
[0038] Other nonwoven webs useful with the filter media 60 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 teachings of which are
incorporated herein by reference. In other embodiments, the filter
media 60 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 teachings of
which are incorporated herein by reference. In yet other
embodiments, nonwoven webs useful with the filter media 60 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. (mentioned above). Other non-limiting
example of useful nonwoven web formats include bi-modal fiber
diameter meltblown media such as that described in U.S. Pat. No.
7,858,163, the entire teaching of which are incorporated herein by
reference.
[0039] In some embodiments, an electrostatic charge is optionally
imparted into or on to material(s) of the filter media 60. Thus,
the filter media 60 can be an electret nonwoven web. Electric
charge can be imparted to the filter media 60 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 60 is
not electrostatically charged.
[0040] The optional pleats can be formed in the filter media 60 (or
in the pleated filter media assembly 30) 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.
[0041] With pleated versions of the filter media assembly 30, a
variety of pleat depths D can be incorporated. In some embodiments,
the pleated filter media assembly 30 has a pleat depth D of at
least about 4 inches, optionally not less than 4 inches (e.g., a
"deep pleat" pleated filter media). Other depths, greater or
smaller, are also acceptable.
[0042] In other embodiments of the present disclosure, portions or
all of the filter media assembly 30 need not have a pleated
construction.
[0043] Regardless of an exact construction, the filter media
assembly 30 defines opposing, first and second major faces 70, 72
(referenced generally in FIGS. 3A and 3B). Further, a perimeter of
the filter media assembly can be defined by opposing, first and
second side edges 80, 82, and opposing, first and second end edges
84, 86. In some embodiments, the perimeter can have the rectangular
shape (that is specifically inclusive of a square shape) shown.
[0044] Returning to FIG. 1, the outer frame assembly 32 can assume
a variety of forms and is generally configured to surround the
perimeter of the filter media assembly 30. Further, the outer frame
assembly 32 is constructed to robustly support the filter media
assembly 30 in the initial state as well as in any of the expanded
states described below, including the outer frame assembly 32
rigidly maintaining the established length L.sub.I, width W.sub.I,
and depth D.sub.I (FIG. 2A) dimensions when subjected to expected
forces of a designated end-use environment (e.g., the outer frame
assembly 32 will maintain its structural integrity with
installation to an HVAC system air filter compartment and
subjecting the air filter device 20 to normal HVAC system airflow).
With this in mind, the outer frame assembly 32 includes or defines
opposing, first and second side frame structures 100 (one of which
is visible in FIG. 1) and opposing, first and second end frame
structures 104 (one of which is visible in FIG. 1). The side frame
structures 100 are generally configured to cover a respective one
of the first and second side edges 80, 82 (FIG. 3A) of the filter
media assembly 30, whereas the end frame structures 104 are
generally configured to cover a respective one of the first and
second end edges 84, 68 (FIG. 3A).
[0045] The frame structures 100, 104 can have any format conducive
to use as part of the outer frame assembly 32, and in some
embodiments can be substantially identical. For example, in some
embodiments, one or more or all of the frame structures 100, 104
can consist of a single frame member or body. In other embodiments,
one or more or all of the frame structures 100, 104 can include two
or more frame members that connected to another (e.g., slidably
connected).
[0046] The outer frame assembly 32 can be formed from a variety of
materials capable of maintaining their structural integrity in the
presence of expected forces. For example, the outer frame assembly
32 can be constructed of cardboard, paperboard, plastic, metal,
etc. In some embodiments, the outer frame assembly 32 integrally
forms the side and end frame structures 100, 104. Thus, in some
embodiments a major portion of the outer frame assembly 32 may be
conveniently formed by the folding of a suitable precursor material
(e.g., paperboard) along fold lines so as to provide the side and
end frame structures 100, 104. However, any suitable frame
construction may be used; i.e. any major portion of the outer frame
assembly 32 may be made of any suitable material (whether
paperboard, plastic, etc.) and may be formed e.g. by folding of a
single frame piece, by the assembling of multiple pieces to each
other, and so on. In many embodiments, all four major frame
structures 100, 104 may each comprise upstream and downstream
flanges and inner and outer sidewalls/panels and foldable
connections there between.
[0047] In some embodiments, the air filter unit 22 can further
include one or more grid or grill structures extending over a
corresponding one of the major faces 70, 72 (FIGS. 3A and 3B) of
the filter media assembly 30. For example, FIG. 1 illustrates a
grid or grill 120 projecting from the outer frame assembly 32 and
extending over the first major face 70 (best identified in FIG. 3B)
of the filter media assembly 30. The pattern reflected by FIG. 1
for the grid or grill 120 is but one acceptable configuration. The
air filter unit 22 can optionally include an additional grill or
grid structure (not shown) overlying the second major face 72
(hidden in FIG. 1, but identified, for example, in FIG. 3B) of the
filter media assembly 30. Regardless, the grill(s) or grid(s) 120
can be formed of a material similar to that of the outer frame
assembly 32. In some embodiments, the grill(s) or grid(s) 120 can
be integrally formed with, and folded relative to, the outer frame
assembly 32. In other embodiments, the grill(s) or grid(s) (or
sub-components thereof) can be separately formed and subsequently
attached to the outer frame assembly 32.
[0048] Expansion Unit
[0049] The expansion unit 24 can assume a variety of forms
compatible with the particular format of the air filter unit 22.
One or more portions of, or an entirety of, the expansion unit 24
can be provided as component of (e.g., pre-assembled to) the air
filter unit 22; in other embodiments, an entirety of the expansion
unit 24 can be provided apart from the air filter unit 22 and
subsequently assembled thereto by a user. Various examples of
expansion units in accordance with principles of the present
disclosure are described below. While described separately,
portions or an entirety of one example expansion unit can be
combined with portions or an entirety of another example expansion
unit.
[0050] An air filter device 220 including an example expansion unit
224 (referenced generally) in accordance with principles of the
present disclosure applied to the air filter unit 22 is shown in
FIGS. 4A and 4B. As a point of reference, FIGS. 4A and 4B reflect a
possible installation condition of the air filter device 220 in
which the expansion unit 224 (or portions thereof) has been mounted
to the air filter unit 22. Conversely, a possible delivery
condition (not shown) of the air filter device 220 includes the
expansion unit 224 not yet mounted to the air filter unit 22 (e.g.,
a user can receive the air filter device 220 in the delivery
condition, and then mount the expansion unit 224 (or portions
thereof) to the air filter unit 22 in achieving the possible
installation condition).
[0051] The expansion unit 224 includes one or more standoffs 230.
The standoffs 230 are generally sized and shaped for mounting to a
designated region of the air filter unit 22, and can include one or
more of a length standoff 230A, a width standoff 230B, and a depth
standoff 230C. The length standoff 230A is generally sized and
shaped for mounting to one of the end frame structures 104 to
effectuate an expanded state length L.sub.E that is greater than
the initial state length L.sub.I (FIG. 1). The width standoff 230B
is generally sized and shaped for mounting to one of the side frame
structures 100 to effectuate an expanded state width W.sub.E in the
air filter device that is greater than the initial state width
W.sub.I (FIG. 1). Finally, the depth standoff 230C is generally
sized and shaped for mounting to outer frame assembly 32 or other
component of the air filter unit 22 at a location that does not
overtly impede airflow through the air filter unit 22 (e.g., at a
corner formed by two of the frame structures 100, 104, on the grill
or grid 120, etc.) to effectuate an expanded state depth D.sub.E
that is greater than the initial state depth D.sub.I (FIG. 1). In
some embodiments, the expansion unit 224 as provided to a user in
the delivery condition mentioned above can include one (or more) of
the length standoff 230A, one (or more) of the width standoff 230B,
and a plurality of the depth standoffs 230C. In other embodiments,
the expansion unit 224 as provided to a user in the delivery
condition can include less than all of the length standoff 230A,
the width standoff 230B and/or the depth standoffs 230C (e.g., the
expansion unit can include only the depth standoffs 230C).
[0052] Each of the standoffs 230 can have a similar construction,
for example including a standoff body 240 (identified, for example,
for the length standoff 230A in FIG. 4B). In some embodiments, the
standoff body 240 can be formed of a light weight, resilient, at
least slightly compressible material capable of maintaining a
designated shape when subjected to compression. For example, the
standoff body 240 can be a foam material (e.g., open or closed cell
foams, natural foams, synthetic foams, etc.). Other materials, such
as rubber, plastic, etc., are also envisioned. In some embodiments,
the standoff body 240 associated with each of the standoffs
230A-230C is a pre-cut foam strip (e.g., as with the standoffs
230A, 230B) or block (e.g., a cylindrical block as with the
standoffs 230C), sized and shaped in accordance with geometries of
the corresponding air filter unit 22 as described above.
[0053] Each of the standoffs 230 can further be configured to
promote mounting thereof to the air filter unit 22 by a user. For
example, a face of the standoff body 240 can carry (e.g., be coated
with) an adhesive formulated to achieve a bond between the standoff
body 240 and a corresponding portion of the air filter unit 22
(e.g., where the outer frame assembly 32 is a paperboard material,
the selected adhesive can be formulated to achieve a bond with
paperboard). As initially provided to a user (e.g., as part of a
kit in which the standoff(s) 230 are provided to a user apart from
the air filter unit 22), a release liner can further be included,
temporarily covering the adhesive. When the user is ready to mount
the standoff 230 to the air filter unit 22, the release liner is
removed thereby exposing the adhesive. In other embodiments, one or
more adhesive strips (not shown) can be provided on the outer frame
assembly 32 (or other exterior components of the air filter unit
22) at location(s) corresponding with potential application of a
standoff 230; under these circumstances, the adhesive strip(s) can
be temporarily covered by a release liner that is removed prior to
mounting of the corresponding standoff 230. In yet other
embodiments, a strip of double sided tape (that may be provided to
the user as part of the expansion unit 224) can be employed to
secure the standoff(s) 230 to the air filter unit 22. Other
configurations that facilitate mounting of the standoff 230 to the
air filter unit 22 are also acceptable (e.g., a mechanical
fastener, hook-and-loop fasteners, etc.).
[0054] During use, the air filter device 220 is initially provided
to a user in an initial state in which the air filter unit 22 is
separated from the expansion unit 224. For example, the air filter
unit 22 and the expansion unit 224 can be provided to a user in a
common packaging, with none of the standoffs 230 mounted to the air
filter unit 22. Alternatively, a user can obtain (e.g., purchase)
the air filter unit 22 and the expansion unit 224 separately.
Regardless, the user then evaluates (e.g., visually estimates)
dimensions of the air filter compartment (not shown) to which the
air filter device 220 will be installed. In some instances,
dimensions of the air filter unit 22 will closely correspond to the
dimensions of the air filter compartment. Under these
circumstances, the air filter unit 22 alone can be installed to the
air filter compartment (e.g., the air filter unit 22 serves as the
installed air filter device 220). In other instances, the user may
determine that one or more of the length L.sub.I, width W.sub.I
and/or depth D.sub.I (FIG. 2A) dimension of the air filter unit 22
is appreciably less (e.g., 10% less) than the corresponding
dimension of the air filter compartment. Under these circumstances,
the user can select and mount one or more of the standoffs 230 to
air filter unit 22, effectuating a desired increase in the
corresponding dimension. For example, if it is determined that the
depth D.sub.I of the air filter unit 22 is appreciable less than
the depth dimension of the air filter compartment, one or more of
the depth standoffs 230C can be mounted to the air filter unit 22
as shown, for example, in FIG. 4A. Additionally or alternatively,
the length standoff 230A can be selected and mounted to the air
filter unit 22 to effectuate an increased or expanded length
L.sub.E, and the width standoff 230B can be selected to the air
filter unit 22 to effectuate an increased or expanded width
W.sub.E. It will be understood that for a particular air filter
compartment installation, less than all of the standoffs 230A-230C
may be required. Once the selected standoff(s) 230 have been
mounted to the air filter unit 22 so as to transition the air
filter device 220 to an expanded state, the air filter device 220
can be installed to the air filter compartment, with the mounted
standoff(s) 230 bearing against framework of the air filter
compartment and promoting a seal between the air filter device 220
and the air filter compartment.
[0055] Another air filter device 320 including an example expansion
unit 324 (referenced generally) in accordance with principles of
the present disclosure applied to the air filter unit 22 is shown
in FIGS. 5A and 5B. As a point of reference, FIGS. 5A and 5B
reflect a possible installation condition of the air filter device
320 in which the expansion unit 324 (or portions thereof) has been
mounted to the air filter unit 22. Conversely, a possible delivery
condition (not shown) of the air filter device 320 includes the
expansion unit 324 not yet mounted to the air filter unit 22 (e.g.,
a user can receive the air filter device 320 in the delivery
condition, and then mount the expansion unit 324 (or portions
thereof) to the air filter unit 22 in achieving the possible
installation condition). In yet other embodiments, the delivery
condition of the air filter device 320 includes the expansion unit
324 (or portions thereof) pre-assembled to (or integrally formed
by) the air filter unit 22. With some of these embodiments, the
pre-assembled expansion unit 324 (or portions thereof) is
configured to self-deploy to the expanded condition reflected by
FIGS. 5A and 5B in the presence of airflow as described below.
[0056] The expansion unit 324 includes one or more flanges 330. The
flanges 330 are generally sized and shaped in accordance with a
designated region of the air filter unit 22, and can include one or
more of a length flange 330A and one or more of a width flange
330B. The length flange 330A is generally sized and shaped in
accordance with dimensions of one of the end frame structures 104
to effectuate an expanded state length L.sub.E that is greater than
the initial state length L.sub.I (FIG. 1). The width flange 330B is
generally sized and shaped in accordance with dimensions of one of
the side frame structures 100, 102 to effectuate an expanded state
width W.sub.E that is greater than the initial state width W.sub.I
(FIG. 1). In some embodiments, the expansion unit 324 can include
both of the length and width flanges 330A, 330B; in other
embodiments, the expansion unit 324 includes only the length flange
330A or only the width flange 330B.
[0057] Apart from dimensions, each of the flanges 330 can have a
similar construction. For example, and as identified for the length
flange 330A in FIG. 5B, each of the flanges 330 can be a
lightweight yet relative stiff material defining a fixed end 340
opposite a free end 342. The fixed end 340 can be connected to, or
is configured for connection to by a user, the corresponding frame
structure of the air filter unit 22 (e.g., the fixed end 340 of the
length flange 330A is connected to the fend frame structure 104) in
a manner permitting pivoting movement at the point or line of
connection. The flange 330 projects away from the fixed end 340,
terminating at the free end 342 that is otherwise free of direct
connection or attachment to the air filter unit 22. For example, in
some embodiments the flange 330 is a paperboard body integrally
formed with the outer frame assembly 32, with a fold line being
formed at the line of interface between the flange 330 and the
corresponding frame structure 100, 104 of the outer frame assembly
32 to define the fixed end 340.
[0058] With embodiments in which the air filter device 320 is
provided to a user with the flange(s) 330 pre-assembled to (e.g.,
integrally formed with) the air filter unit 22, the user installs
the air filter device 320 (including the flange(s) 330) to the air
filter compartment (not shown). With embodiments in which the air
filter device 320 is provided to a user with the flange(s) 330
uncoupled from the air filter unit 22, the user can first compare
an estimated size of the air filter compartment with the length and
width L.sub.I, W.sub.I dimensions of the air filter unit 22. Based
on this comparison, one or both of the flanges 330A, 330B can be
mounted to the air filter unit 22 as described above, with the
so-configured air filter device 320 then being installed to the air
filter compartment. In either instance, the air filter device 320
can be installed such that the free end 342 of the flange(s) 330
faces the upstream direction of airflow through the air filter
compartment. During operation of the air handling device, airflow
(designated by arrow F in FIG. 5A) will interface between the
flange(s) 330 and the outer frame assembly 32, forcing the
flange(s) 330 to extend outwardly relative to the outer frame
assembly 32 (e.g., the flange(s) 330 is caused to pivot relative to
the outer frame assembly 32 at the fixed end 340, with the
corresponding free end 342 moving outwardly away from the outer
frame assembly 32). In this expanded state, the flange(s) 330 can
be brought into contact with framework of the air filter
compartment, promoting a seal between the air filter device 320 and
the air filter compartment.
[0059] Another air filter device 420 including an example expansion
unit 424 (referenced generally) in accordance with principles of
the present disclosure applied to the air filter unit 22 is shown
in FIGS. 6A and 6B. As a point of reference, FIGS. 6A and 6B
reflect a possible installation condition of the air filter device
420 in which the expansion unit 424 (or portions thereof) has been
mounted to the air filter unit 22. Conversely, a possible delivery
condition (not shown) of the air filter device 420 includes the
expansion unit 424 (or portions thereof) not yet mounted to the air
filter unit 22 (e.g., a user can receive the air filter device 420
in the delivery condition, and then mount the expansion unit 424
(or portions thereof) to the air filter unit 22 in achieving the
possible installation condition). In yet other embodiments, the
delivery condition of the air filter device 420 includes the
expansion unit 424 (or portions thereof) pre-assembled to (or
integrally formed by) the air filter unit 22. With some of these
embodiments, the pre-assembled expansion unit 424 (or portions
thereof) is configured to self-deploy to the expanded condition
reflected by FIGS. 6A and 6B, optionally in the presence of airflow
as described below.
[0060] The expansion unit 424 can be akin to the expansion unit 324
(FIGS. 5A and 5B) described above, and includes one or more the
flanges 330 (e.g., the length flange 330A and the width flange
330B). In addition, the expansion unit 424 includes one or more
deflection bodies 430 associated with a corresponding one of the
flanges 330 (e.g., with the non-limiting example of FIGS. 6A and
6B, the expansion unit 424 includes a first deflection body 430A
corresponding with the length flange 330A and a second deflection
body 430B corresponding with the width flange 330B). Apart from
dimensions, each of the deflection bodies 430 can have a similar
construction. For example, each of the deflection bodies 430 can be
formed of a light weight, resilient, at least slightly compressible
material capable of maintaining a designated shape when subjected
to compression. In some embodiments, the deflection bodies 430 can
be a foam material (e.g., open or closed cell foams, natural foams,
synthetic foams, etc.). Other materials, such as rubber, plastic,
etc., are also envisioned. In some embodiments, the deflection
bodies 430 can each be a pre-cut foam strip, sized and shaped in
accordance with geometries of the corresponding air filter unit 22
components (e.g., the first deflection body 430A is pre-cut to a
size and shape corresponding with dimensions of one of the end
frame structures 104; the second deflection body 430B is pre-cut to
a size and shape corresponding with dimensions of one of the side
frame structures 100).
[0061] In some embodiments, the air filter device 420 is provided
to a user with the deflection bodies 430 pre-assembled to the air
filter unit 22. In other embodiments, the delivery condition of the
air filter device 420 can include the deflection bodies 430 apart
from the air filter unit 22 (it being recalled that the flanges 330
may or may not be assembled to the air filter unit 22 in the
delivery condition). With these configurations, the expansion unit
424 can further include one or more strips of double-sided adhesive
tape or other fastening devices (e.g., complimentary strips of
hook-and-loop fasteners) that are employed by a user to secure the
deflection bodies 430 at the locations shown. Alternatively, the
deflection bodies 430 can be coated with an adhesive that is
temporarily covered by a release liner, the air filter unit 22 can
be coated with an adhesive at desired locations and that are
temporarily covered by a release liner, etc.
[0062] With embodiments in which the air filter device 420 is
provided to a user with the flange(s) 330 and the deflection
body/bodies 430 pre-assembled to the air filter unit 22, the user
installs the air filter device 420 to the air filter compartment
(not shown). With embodiments in which the air filter device 320 is
provided to a user with the deflection body/bodies 430 uncoupled
from the air filter unit 22, the user can first compare an
estimated size of the air filter compartment with the length and
width L.sub.I, W.sub.I dimensions of the air filter unit 22. Based
on this comparison, one or both of the deflection bodies 430A, 430B
can be mounted to the air filter unit 22 as described above, with
the so-configured air filter device 420 then being installed to the
air filter compartment. In either instance, the air filter device
420 can be installed such that the free end 342 of the flange(s)
330A, 330B faces the upstream direction of airflow through the air
filter compartment. During operation of the air handling device,
airflow (designated by arrow F in FIG. 6A) will progress between
each of the flanges 330A, 330B and the outer frame assembly 32,
forcing the flange(s) 330 to extend outwardly relative to the outer
frame assembly 32 as described above. The deflection body (where
provided) 430 biases the corresponding flange 330 such that the
free end 342 projects away from the outer frame assembly 32, and
prevents the corresponding flange 330A, 330B from collapsing on to
the outer frame assembly 32. Once again, in this expanded state,
the flange(s) 330A, 330B can be brought into contact with framework
of the air filter compartment, promoting a seal between the air
filter device 420 and the air filter compartment.
[0063] Another air filter device 520 including an example expansion
unit 524 (referenced generally) in accordance with principles of
the present disclosure applied to the air filter unit 22 is shown
in FIGS. 7A and 7B. As a point of reference, FIGS. 7A and 7B
reflect a possible installation condition of the air filter device
520 in which the expansion unit 524 (or portions thereof) has been
mounted to the air filter unit 22. Conversely, a possible delivery
condition (not shown) of the air filter device 520 includes the
expansion unit 524 not yet mounted to the air filter unit 22 (e.g.,
a user can receive the air filter device 520 in the delivery
condition, and then mount the expansion unit 524 (or portions
thereof) to the air filter unit 22 in achieving the possible
installation condition). In yet other embodiments, the delivery
condition of the air filter device 520 includes the expansion unit
524 (or portions thereof) pre-assembled to (or integrally formed
by) the air filter unit 22. With some of these embodiments, the
pre-assembled expansion unit 524 (or portions thereof) is
configured to self-deploy to the expanded condition reflected by
FIGS. 7A and 7B in the presence of airflow as described below.
[0064] The expansion unit 524 includes one or more flanges 530 that
can be akin to the flanges 330 (FIG. 5A) described above. The
flanges 530 are generally sized and shaped in accordance with a
designated region of the air filter unit 22, and can include one or
more of a length flange 530A and one or more of a width flange
530B. The length flange 530A is generally sized and shaped in
accordance with dimensions of one of the end frame structures 104
to effectuate an expanded state length L.sub.E (not specifically
identified in FIGS. 7A and 7B for ease of illustration) that is
greater than the initial state length L.sub.I (FIG. 1). The width
flange 530B is generally sized and shaped in accordance with
dimensions of one of the side frame structures 100 to effectuate an
expanded state width W.sub.E (not specifically identified in FIGS.
7A and 7B for ease of illustration) that is greater than the
initial state width W.sub.I (FIG. 1). In some embodiments, the
expansion unit 524 can include both of the length and width flanges
530A, 530B; in other embodiments, the expansion unit 524 includes
only the length flange 530A or only the width flange 530B.
[0065] Apart from dimensions, each of the flanges 530 can have a
similar construction. For example, each of the flanges 530 can be a
lightweight yet relative stiff material. As identified in FIG. 7B
for the width flange 530B, each of the flanges 530 can define a
fixed end 540 opposite a free end 542. Further, a fold line 544 can
be formed intermediate the ends 540, 542. With this construction,
the flange 530 can be viewed has having or defining a first portion
546 between the fixed end and the fold line 544, and a second
portion 548 between the fold line 544 and the free end 542. The
fixed end 540 can be connected to, or is configured for connection
to be a user, the corresponding frame structure of the air filter
unit 22 (e.g., the fixed end 540 of the width flange 530B is
connected to the side frame structure 100) in a manner permitting
pivoting movement at the point or line of connection. For example,
in some embodiments the flange 530 is a paperboard body integrally
formed with the outer frame assembly 32, with a fold line being
formed at the line of interface between the flange 530 and the
corresponding frame structure 100, 104 of the outer frame assembly
32 to define the fixed end 540 as described above. The fold line
544 arranges the first and second portions 546, 548 in differing
spatial orientations. For example, with the non-limiting example of
FIGS. 7A and 7B, the second portion 548 extends over or overlaps
the first portion 546. Other spatial arrangements are also
envisioned, and in other embodiments, two or more fold lines can be
formed along the corresponding flange 530.
[0066] With embodiments in which the air filter device 520 is
provided to a user with the flange(s) 530 pre-assembled to (e.g.,
integrally formed with) the air filter unit 22 and pre-folded to
arrangement shown in FIGS. 7A and 7B, the user installs the air
filter device 520 (including the flange(s) 530) to the air filter
compartment (not shown). With embodiments in which the air filter
device 520 is provided to a user with the flange(s) 530 either
uncoupled from the air filter unit 22 or pre-assembled to the air
filter unit 22 but not fully folded (e.g., the fold line 544 can be
imparted into the flange 530, but the second portion 548 is not
completely folded relative to the first portion 546), the user can
first compare an estimated size of the air filter compartment with
the length and width L.sub.I, W.sub.I dimensions of the air filter
unit 22. Based on this comparison, one or both of the flanges 530A,
530B can be mounted to the air filter unit 22 as described above
and then folded at the corresponding fold line 544 (or, if
pre-assembled but not yet folded, the selected flange(s) 530A, 530B
can then be folded), with the so-configured air filter device 520
then being installed to the air filter compartment. In either
instance, the air filter device 520 can be installed such that the
fixed end 540 of the flange(s) 530 is opposite of the upstream
direction of airflow through the air filter compartment. During
operation of the air handling device, airflow (designated by arrow
F in FIG. 7A) will interface between the flange(s) 530 and the
outer frame assembly 32, forcing the flange(s) 530 to extend
outwardly relative to the outer frame assembly 32 (e.g., the
flange(s) 530 is caused to pivot relative to the outer frame
assembly 32 at the fixed end 540, with the corresponding free end
542 moving outwardly away from the outer frame assembly 32). In
this expanded state, the flange(s) 530 can be forced into contact
with framework of the air filter compartment, promoting a seal
between the air filter device 520 and the air filter compartment.
The folded arrangement of the flange(s) 530 better ensures contact
between the free end 542 (and other regions of the flange 530) and
the air filter compartment framework.
[0067] Another air filter device 620 including an example expansion
unit 624 (referenced generally) in accordance with principles of
the present disclosure applied to the air filter unit 22 is shown
in FIGS. 8A and 8B. As a point of reference, the expansion unit 624
can be pre-assembled to the air filter unit 22 in a delivery
condition of the air filter device 620. FIGS. 8A and 8B reflect a
possible expanded state of the air filter device 620.
[0068] The expansion unit 624 includes at least one flange 630 that
can be generally akin to the flanges 330 (FIG. 5A) described above.
The flange 630 is generally sized and shaped in accordance with a
designated region of the air filter unit 22, such as dimensions of
one of the end frame structures 104 or one of the side frame
structures 100. For example, FIGS. 8A and 8B illustrate the flange
630 as being associated with the end frame structure 104.
Alternatively, the flange 630 can be associated with one of the
side frame structures 100. In yet other embodiments, the expansion
unit 624 can include two (or more of flanges 630), such as a flange
at each of the side frame structures 100, a flange at each of the
end frame structures 104, a first flange at one of the side frame
structures 100 and a second flange at one of the end frame
structures 104, etc.
[0069] The flange 630 can include a main panel 640 and locking tabs
642, 644. The main panel 640 is sized and shaped in accordance with
dimensions of the corresponding frame structure 100, 104. The
locking tabs 642, 644 extend from opposing side edges of the main
panel 640. In other embodiments, a single one of the tabs 642 or
644 is included. The main panel 640 defines a fixed end 650
opposite a free end 652. The fixed end 650 can be connected to, or
is configured for connection to by a user, the corresponding frame
structure of the air filter unit 22 (e.g., the fixed end 650 is
connected to the end frame structure 104) in a manner permitting
pivoting movement at the point or line of connection. The panel 640
projects away from the fixed end 650, terminating at the free end
652 that is otherwise free of direct connection or attachment to
the air filter unit 22. For example, in some embodiments the flange
630 is a paperboard body integrally formed with the outer frame
assembly 32, with a fold line being formed at the line of interface
between the main panel 640 and the corresponding frame structure
100. 104 of the outer frame assembly 32 to define the fixed end
650, and additional fold lines defining the locking tabs 642, 644
relative to the main panel 640.
[0070] The locking tabs 642, 644 are configured to selectively lock
the flange 630 relative to the air filter unit 22 at a desired
spatial orientation. For example, each of the locking tabs 642, 644
can form or define a tab end 660 projecting from a shoulder 662 as
identified for the locking tab 642 in FIG. 8B. The tab end 660 is
sized for insertion within one or more locking slots 664 formed in
the outer frame assembly 32. Upon insertion, the shoulder 662 bears
against a structure of the outer frame assembly 32, with this
interface preventing the flange 630 from collapsing on to the outer
frame assembly 32. In some embodiments, a plurality of the locking
slots 664 are provided, with the locking slots 664 being arranged
in a spaced apart manner to provide differing spatial orientations
of the flange 630 relative to the outer frame assembly 32, and thus
a range of available including spacings between the free end 652
and the outer frame assembly 32. The locking slots 664 can be
formed in various manners (e.g., slits, cuts, perforations, etc.
through a thickness of the corresponding frame structure of the
outer frame assembly 32), and may or may not be complete cuts in
the initial state (e.g., to the extent a user desires to employ a
selected one of the locking slots 664, the selected locking slot
664 can first be "completed" by the user). Other locking mechanisms
or techniques are also acceptable that may or may not entail the
locking slots 664; for example, an adhesive can be provided along a
face of the locking tabs 642, 644.
[0071] Use of the air filter device 620 can include the first
comparing an estimated size of the air filter compartment with the
length and width L.sub.I, W.sub.I (FIG. 2A) dimensions of the air
filter unit 22 for which one of the flanges 630 is available (e.g.,
with the non-limiting example of FIGS. 8A and 8B, the flange 630 is
available to affect an expansion in the length direction). Based on
this comparison, the flange 630 can be arranged to an expanded
state corresponding with the estimated dimension by coupling the
locking tabs 642, 644 to the outer frame assembly 32 at a desired
location (e.g., the locking tabs 642, 644 are connected to the
locking slot 664 appropriate for locating the free end 652 at a
spatial position that effectuates an expanded length L.sub.E
corresponding with the estimated length of the air filter
compartment). The so-configured air filter device 620 can then be
installed to the air filter compartment, with the free end 652
contacting framework of the air filter compartment to promote a
seal between the air filter device 620 and the framework. In other
instances, the comparison may indicate that the air filter unit 22
is appropriately sized for installation to the air filter
compartment, in which case the flange 630 is not transitioned to an
expanded stated. Instead, the flange 630 can remain collapsed
against the outer frame assembly 32 with installation of the air
filter device 620 to the air filter compartment.
[0072] Another air filter device 720 including an example expansion
unit 724 (referenced generally) in accordance with principles of
the present disclosure applied to the air filter unit 22 is shown
in FIGS. 9A and 9B. As a point of reference, the expansion unit 724
can be pre-assembled to the air filter unit 22 in a delivery
condition of the air filter device 720. The expansion unit 724 can
be configured to self-deploy to the expanded state reflected by
FIGS. 9A and 9B in the presence of airflow as described below.
[0073] The expansion unit 724 includes first-fourth flanges
730A-730D. The flanges 730A-730D can be akin to the flanges 330
(FIG. 5A) described above, and are generally sized and shaped in
accordance with a designated region of the air filter unit 22. For
example, the first and second flanges 730A, 730B are each generally
sized and shaped in accordance with dimensions of one of the end
frame structures 104 to effectuate an expanded state length L.sub.E
(not specifically identified in FIGS. 9A and 9B for ease of
illustration) that is greater than the initial state length L.sub.I
(FIG. 1). The third and fourth flanges 730C, 730D are each
generally sized and shaped in accordance with dimensions of one of
the side frame structures 100 to effectuate an expanded state width
W.sub.E (not specifically identified in FIGS. 9A and 9B for ease of
illustration) that is greater than the initial state width W.sub.I
(FIG. 1).
[0074] Apart from dimensions, each of the flanges 730A-730D can
have a similar construction. For example, each of the flanges
730A-730D can be a lightweight yet relative stiff material defining
a fixed end 740 opposite a free end 742 (identified in FIG. 9B for
the third flange 730C). The fixed end 340 can be connected to the
corresponding frame structure of the air filter unit 22 (e.g., the
fixed end 740 of the third flange 730C is connected to the side
frame structure 100) in a manner permitting pivoting movement at
the point or line of connection. The free end 742 of each of the
flanges 730A-730D is free of direct connection or attachment to the
air filter unit 22. Finally, a continuous connection feature 744
(drawn generally in FIGS. 9A and 9B) is established or provided
between orthogonally adjacent ones of the flanges 730A-730D that
permits pivoting movement of the corresponding flanges while
maintaining a continuous obstruction to airflow. For example, the
first flange 730A and the third flange 730C are orthogonal to one
another, and are connected to one another at the connection feature
744. The connection feature 744 is configured such that the flanges
730A, 730C can readily transition from a collapsed arrangement (not
shown), in which the flanges 730A, 730C are collapsed on to the
outer frame assembly 32, to the expanded state shown. The
connection feature 744 remains intact throughout this transition,
presenting a continuous structure or obstruction to airflow. For
example, the connection feature 744 can include the flanges 730A,
730C providing complimentary engagement features, such as a
tab-and-slot type connection, that permits sliding movement of the
flanges 730A, 730C relative to one another. Alternatively, a series
of folds can be imparted into a material defining an interface
between the flanges 730A, 730C (e.g., akin to origami). In yet
other embodiments, a separate corner piece (not shown) can be
assembled to the flanges 730A, 730C in defining the connection
feature 744.
[0075] In some embodiments the flanges 730A-730D are each a
paperboard body integrally formed with the outer frame assembly 32,
with a fold line being formed at the line of interface between each
of the flanges 730A-730D and the corresponding frame structure 100,
104 of the outer frame assembly 32 to define the fixed end 740.
[0076] During use, the air filter device 720 can be installed such
that the free end 742 of each of the flanges 730A-730D faces the
upstream direction of airflow through the air filter compartment.
During operation of the air handling device, airflow (designated by
arrow F in FIG. 9A) will interface between the flanges 730A-73D and
the outer frame assembly 32, forcing the flanges 730A-730D to
extend outwardly relative to the outer frame assembly 32 (e.g., the
flanges 730A-730D are caused to pivot relative to the outer frame
assembly 32 at the corresponding fixed end 740, with the
corresponding free end 742 moving outwardly away from the outer
frame assembly 32). The expansion unit 724 can optionally be viewed
as self-energizing to the expanded state. In the expanded state,
the flanges 730A-730D can be brought into contact with framework of
the air filter compartment, promoting a seal between the air filter
device 720 and the air filter compartment.
[0077] Another air filter device 820 including an example expansion
unit 824 (referenced generally) in accordance with principles of
the present disclosure applied to the air filter unit 22 is shown
in FIGS. 10A and 10B. As a point of reference, FIGS. 10A and 10B
reflect a possible expanded state of the air filter device 820 in
which the expansion unit 824 has been mounted to the air filter
unit 22. Conversely, a possible delivery condition (not shown) of
the air filter device 820 includes the expansion unit 824 not yet
mounted to the air filter unit 22 (e.g., a user can receive the air
filter device 820 in the delivery condition, and then mount the
expansion unit 824 (or portions thereof) to the air filter unit 22
in achieving the possible expanded state).
[0078] The expansion unit 824 includes one or more seal bodies 830.
The seal bodies 830 are generally sized and shaped in accordance
with a designated region of the air filter unit 22, and can include
first-fourth seal bodies 830A-830D. The first and second seal
bodies 830A, 830B can each be generally sized and shaped in
accordance with dimensions of one of the end frame structures 104
to effectuate an expanded state length L.sub.E (not specifically
identified in FIGS. 10A and 10B for ease of illustration) that is
greater than the initial state length L.sub.I (FIG. 1). The third
and fourth seal bodies 830C, 830D can each be generally sized and
shaped in accordance with dimensions of one of the side frame
structures 100 to effectuate an expanded state width W.sub.E (not
specifically identified in FIGS. 10A and 10B for ease of
illustration) that is greater than the initial state width W.sub.I
(FIG. 1). In other embodiments, the expansion unit 824 can include
less than all of the first-fourth seal bodies 830A-830D.
[0079] Apart from dimensions, each of the seal bodies 830 can have
a similar construction. For example, each of the seal bodies 830
can be formed of a light weight, resilient, at least slightly
compressible material capable of maintaining a designated shape
when subjected to compression. In some embodiments, the seal bodies
830 can be a foam material (e.g., open or closed cell foams,
natural foams, synthetic foams, etc.). In related embodiments, the
seal bodies 830 can be hollow structures. Other materials, such as
rubber, plastic, etc., are also envisioned. In some embodiments,
the seal bodies 830 associated can each be a pre-cut, hollow foam
strip, sized and shaped in accordance with geometries of the
corresponding air filter unit 22 components (e.g., the first and
second seal bodies 830A, 830B are both pre-cut to a size and shape
corresponding with dimensions of one of the end frame structures
104; the third and fourth seal bodies 830C, 830D are pre-cut to a
size and shape corresponding with dimensions of one of the side
frame structures 100).
[0080] In some embodiments, the air filter device 820 is initially
provided to a user with the seal bodies 830A-830D mounted to the
air filter unit 22 (e.g., via an adhesive or other fastener). In
related embodiments, one or more of the seal bodies 830A-830D are
pre-assembled to the air filter unit 22 in a releasable fashion
(e.g., a pressure sensitive adhesive) that permits a user to
selectively remove one or more of the pre-applied seal bodies
830A-830D. In yet other embodiments, the delivery condition of the
air filter device 820 can include the seal bodies 830A-830D apart
from the air filter unit 22. With these configurations, the
expansion unit 824 can further include one or more strips of
double-sided adhesive tape or other fastening devices (e.g.,
complimentary strips of hook-and-loop fasteners) that are employed
by a user to secure the seal bodies 830A-830C at the locations
shown. Alternatively, the seal bodies 830A-830D can be coated with
an adhesive that is temporarily covered by a release liner, the air
filter unit 22 can be coated with an adhesive at desired locations
and that are temporarily covered by a release liner, etc.
[0081] With embodiments in which the air filter device 820 is
provided to a user with the seal bodies 830A-830D permanently
assembled to the air filter unit 22, the user installs the air
filter device 820 to the air filter compartment (not shown). With
embodiments in which the air filter device 820 is provided to a
user with the seal bodies 830A-830D uncoupled from the air filter
unit 22 or with the seal bodies 830A-830D removably pre-mounted to
the air filter unit 22, the user can first compare an estimated
size of the air filter compartment with the length and width
L.sub.I, W.sub.I dimensions of the air filter unit 22. Based on
this comparison, one or more of the seal bodies 830A-830D can be
mounted to (or removed from) the air filter unit 22 as described
above, with the so-configured air filter device 820 then being
installed to the air filter compartment. With circumstances in
which at least one of the seal bodies 830A-830D is mounted to the
air filter unit 22 upon installation, the seal body/bodies
830A-830D can be brought into contact with framework of the air
filter compartment, promoting a seal between the air filter device
820 and the air filter compartment.
[0082] Features or components of two or more of the expansion units
224, 324, 424, 524, 624, 724, 824 described above can be combined.
For example, any of the expansion units described above can further
include at least the depth standoffs 230C (FIG. 4A).
[0083] Returning to FIG. 1, the air filter devices of the present
disclosure are useful in a wide variety of air handling
applications. In some embodiments, the air filter device can be
configured for use with HVAC systems. With these and other
embodiments, a user is afforded the ability to custom fit the air
filter device 20 (via expansion in one or more of the length,
width, and depth directions L, W, D) to an exact size of the air
filter compartment provided with the user's actual HVAC system. In
related embodiments, the air filter device 20 can be provided as a
universal product, appropriate for use with a number of different
HVAC systems that might otherwise have slightly different air
filter compartment dimensions. By way of example, different HVAC
system manufacturers may each specify to a user that a
16''.times.20''.times.4'' air filter should be used with their HVAC
system, yet the actual air filter compartment is sized and shaped
to provide a best fit with slightly different dimensions (e.g.,
16''.times.19''.times.4''; 16''.times.21''.times.4'';
15''.times.20''.times.4''; 17''.times.20''.times.4'';
16''.times.20''.times.3.5''; 16''.times.20''.times.4.5''; etc.).
With this in mind, the air filter device 20 of the present
disclosure can be configured such that outer length, width and
depth dimensions of the air filter unit 22 correspond with the
smallest expected air filter compartment dimensions utilized by
several different HVAC system manufacturers. Continuing with the
above example, then, the air filter unit 20 can be configured to
have outer dimensions of 15''.times.19''.times.3.5'', and promoted
to potential users as being acceptable for use with any HVAC system
requiring a 16''.times.20''.times.4'' air filter. Upon evaluating
the size of the actual air filter compartment, the user can then,
if necessary, effectively expand the 15''.times.19''.times.3.5''
air filter unit 22 in one or more of the length, width and depth
directions L, W, D as described above, transitioning the air filter
device 20 to an expanded state having dimensions corresponding with
those of the actual air filter compartment. Similar benefits can be
recognized in other, non-HVAC air filter applications, such as with
room air purifier filters, window air filters, etc.
[0084] The air filter devices and related methods of use of the
present disclosure provide a marked improvement over previous
designs. By promoting simple, manual expansion in one or more of
the length, width and depth directions, the air filter devices of
the present disclosure afford a user the ability to achieve a "best
fit" with the air handling device to which the air filter is
installed.
[0085] Although the present disclosure has been described with
reference to preferred embodiments, workers skilled in the art will
recognize that changes can be made in form and detail without
departing from the spirit and scope of the present disclosure.
* * * * *