REFILLABLE AIR FILTER SYSTEM

Abstract

A refillable air filter system, including: a reusable and collapsible frame; and a disposable filter that is releasably securable within the collapsible frame, wherein the filter is convertible between a storage/collapsed configuration and a functional/expanded configuration.

Claims

1. A refillable air filter system, comprising: a reusable and collapsible frame; and a disposable filter that is releasably securable within the frame, wherein the filter is convertible between a storage/collapsed configuration and a functional/expanded configuration.

2. The refillable air filter system according to claim 1, wherein the air filter system fits in small shipping containers relative to traditional air filters and/or associated air filter systems.

3. The refillable air filter system according to claim 1, wherein the frame comprises a lower horizontal support member, an upper horizontal support member, and a plurality of vertical support members.

4. The refillable air filter system according to claim 3, wherein the frame further comprises one or more intermediate horizontal support members frictionally secured to the plurality of vertical support members.

5. The refillable air filter system according to claim 3, wherein the lower horizontal support member comprises a living hinge.

6. The refillable air filter system according to claim 3, wherein the lower horizontal support member comprises a pair of end cap cavities for retaining ends of the disposable filter.

7. The refillable air filter system according to claim 3, wherein the lower horizontal support member comprises channels for frictionally retaining the plurality of vertical support members.

8. The refillable air filter system according to claim 3, wherein the lower horizontal support member comprises one or more magnets for magnetically enclosing the frame.

9. The refillable air filter system according to claim 3, wherein at least one of the upper and lower horizontal support members comprise one or more angled walls for reducing entrapment of debris therefrom.

10. The refillable air filter system according to claim 3, wherein the lower horizontal support member comprises one or more prongs to engage and secure the filter from displacement.

11. The refillable air filter system according to claim 3, wherein the upper horizontal support member comprises a pair of end cap cavities for retaining ends of the disposable filter.

12. The refillable air filter system according to claim 3, wherein the upper horizontal support member comprises channels for frictionally retaining the plurality of vertical support members.

13. The refillable air filter system according to claim 3, wherein the upper horizontal support member comprises one or more magnets for magnetically enclosing the frame.

14. The refillable air filter system according to claim 3, wherein the upper horizontal support member includes a finger relief region for assisting with opening the frame.

15. The refillable air filter system according to claim 1, wherein the filter comprises an expandable pleated filter.

16. The refillable air filter system according to claim 1, wherein the filter comprises an expandable non-pleated, mesh filter.

17. The refillable air filter system according to claim 1, wherein the filter is compostable within ASTM-D6400 standards.

18. The refillable air filter system according to claim 1, wherein the filter is 100% bio-based.

19. A refillable air filter system, comprising: a reusable and collapsible frame, wherein the frame comprises a lower horizontal support member, an upper horizontal support member, a plurality of vertical support members, and one or more intermediate horizontal support members frictionally secured to the plurality of vertical support members, wherein the lower horizontal support member comprises a living hinge, wherein the lower horizontal support member comprises a pair of end cap cavities for retaining ends of the disposable filter, wherein the lower horizontal support member comprises channels for frictionally retaining the plurality of vertical support members, wherein the lower horizontal support member comprises one or more magnets for magnetically enclosing the frame, wherein the upper and lower horizontal support member comprise one or more angled walls for reducing entrapment of debris therefrom, and wherein the lower horizontal support member comprises one or more prongs to engage and secure the filter from displacement; and a disposable filter that is releasably securable within the frame, wherein the filter is convertible between a storage/collapsed configuration and a functional/expanded configuration.

20. The refillable air filter system according to claim 19, wherein the filter is compostable within ASTM-D6400 standards.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0039] Certain embodiments of the present invention are illustrated by the accompanying figures. It will be understood that the figures are not necessarily to scale and that details not necessary for an understanding of the invention or that render other details difficult to perceive may be omitted.

[0040] It will be further understood that the invention is not necessarily limited to the particular embodiments illustrated herein.

[0041] The invention will now be described with reference to the drawings wherein:

[0042] FIG. 1 of the drawings is a perspective view of a refillable air filter system of the present invention;

[0043] FIG. 2 of the drawings is an exploded perspective view of a refillable air filter system of the present invention;

[0044] FIG. 3 of the drawings is a perspective view of a frame of the present invention;

[0045] FIG. 4 of the drawings is a front view of a frame of the present invention;

[0046] FIG. 5 of the drawings is a top plan view of a frame of the present invention;

[0047] FIG. 6 of the drawings is a bottom plan view of a frame of the present invention;

[0048] FIG. 7 of the drawings is a side view of a frame of the present invention;

[0049] FIG. 8 of the drawings is a fragmented perspective view of a lower horizontal support member showing magnets associated therewith;

[0050] FIG. 9 of the drawings is a cross-sectional view of the frame (closed position) taken along line IX of FIG. 4;

[0051] FIG. 10 of the drawings is a cross-sectional view of the frame of FIG. 9 shown in an open position;

[0052] FIG. 11 of the drawings is a cross-sectional view of the frame of FIG. 10 associated with a filter;

[0053] FIG. 12 of the drawings is a cross-sectional view of the frame of FIG. 11 in a closed position;

[0054] FIG. 13 of the drawings is a fragmented perspective view of an upper horizontal support member showing magnets associated therewith;

[0055] FIG. 14 of the drawings is a cross-sectional view of the frame (closed position) taken along line XIV of FIG. 4;

[0056] FIG. 15 of the drawings is an exploded perspective view of an alternative embodiment of a refillable air filter system of the present invention; and

[0057] FIG. 16 of the drawings is a perspective view of an accordion-type, pleated filter of the present invention shown in a closed and open configuration.

DETAILED DESCRIPTION OF THE INVENTION

[0058] While this invention is susceptible of embodiment in many different forms and applications, there are shown in the drawings and described herein in detail several specific embodiments with the understanding that the present disclosure is to be considered as an exemplification of the principles of the invention and is not intended to limit the invention to the embodiments illustrated.

[0059] It will be understood that like or analogous elements and/or components, referred to herein, may be identified throughout the drawings by like reference characters. In addition, it will be understood that the drawings are merely schematic representations of one or more embodiments of the invention, and some of the components may have been distorted from their actual scale for purposes of pictorial clarity.

[0060] In accordance with the present invention, the air filter systems and assemblies of the present invention include a reusable and collapsible frame, and a disposable filter that is releasably securable within the frame. The air filter systems and assemblies of the present invention are configured to fit in small shipping containers compared to traditional air filters and/or associated air filter systems.

[0061] Referring now to the drawings, and to FIGS. 1-7 in particular, a first embodiment of refillable air filter system or assembly 10, is shown as generally comprising reusable and collapsible frame 12, and disposable filter 14. Filter 14 is preferably releasably securable within the frame, and convertible between a storage/collapsed configuration and a functional/expanded configuration (See FIG. 16).

[0062] In a preferred embodiment of the present invention, frame 12 comprises lower horizontal support member 16, upper horizontal support member 18, and one or more (e.g., 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, etcetera) of vertical support members 20.

[0063] Frame 12 may optionally comprise one or more (e.g., 1, 2, 3, 4, 5, 6, 7, 8, 9, 10, etcetera) intermediate horizontal support members 22 that are frictionally secured to vertical support members 20.

[0064] As is best shown in FIGS. 8 and 9, lower horizontal support member 16 comprises living hinge 24.

[0065] Referring now to FIGS. 3 and 8, lower horizontal support member 16 preferably comprises end cap cavities 26 for retaining the ends of the disposable filter.

[0066] As is best shown in FIGS. 2 and 8, lower horizontal support member 16 preferably comprises channels 28 for frictionally retaining vertical support members 20.

[0067] Referring now to FIGS. 8-10, lower horizontal support member 16 comprises one or more magnets 30 for magnetically enclosing the frame.

[0068] As is best shown in FIG. 3, lower horizontal support member 16 preferably comprises one or more angled surfaces (e.g., 30°, 35°, 40°, 45°, 50°, 55°, 60°, 65°, etcetera) relative to the bottom surface of the lower horizontal support member. This angled surface helps to reduce entrapment of debris. It will be understood that the upper horizontal support member may also comprises one or more angled surfaces.

[0069] Referring now to FIGS. 10-12, lower horizontal support member 16 preferably comprises one or more prongs 32 to engage and secure filter 14 from displacement.

[0070] Referring now to FIGS. 2 and 13, upper horizontal support member 18 comprises end cap cavities 26 for retaining ends of the disposable filter. Upper horizontal support member 18 preferably comprises channels 28 for frictionally retaining vertical support members 20. It will be understood that upper and lower horizontal support members cooperate to retain the vertical support members at each end.

[0071] As is best shown in FIGS. 13-14, upper horizontal support member 18 preferably comprises one or more magnets 30 for magnetically enclosing the frame.

[0072] As is best shown in FIG. 3, upper horizontal support member 18 preferably includes finger relief region or indent 34 for assisting with opening of the frame.

[0073] Frame 12 is preferably fabricated from a unitary or multi-piece of material selected from the group consisting of a metal, a metal alloy, a natural resin, a synthetic resin, a plastic, a composite, fiberglass and/or wood.

[0074] As is best shown in FIG. 16, filter 14 preferably comprises an expandable pleated filter. However, filter 14 may also comprise an expandable non-pleated, mesh filter (See FIG. 15). Preferably the filter is made from a material that is compostable within ASTM-D6400 standards, recyclable, and/or 100% bio-based.

[0075] Air filter system 10 includes either hinged or non-hinged frame designs. These unique frame designs allows the filter to be used in either direction. There is no need for an airflow direction (i.e., the user can put in the HVAC unit on either side).

[0076] In one embodiment of the present invention, the frame ends are supported with a plurality of vertical supports to hold the filter media in place. These supports are designed for a one-time assembly so that the frame itself can ship in an economically and environmentally friendly way.

[0077] In accordance with the present invention, to open or close the filter, the frame may deploy a plurality of closing mechanisms including latches, magnetics, tabs, or others to lock the filter in place in a plurality of areas within the frame. With the symmetrical sides which include vertical supports and end walls, the filter can be assembled to lock-in the filter in multiple orientations.

[0078] Preferably, the filter expands from a small, condensed box that holds the filter media to become two of the sides of the filter solution. This design accomplished several objectives. First, it allows the filter to ship in one of the smallest and economical form factors. Second, it acts as a supporting wall on two of the sides of the frame. Third, it serves as a convenient containment vessel for the dirty filter, as it can accordion back up and be sealed for recycling/disposal without lofting contaminants around.

[0079] In further accordance with the present invention, the top/bottom rail ends come to a termination point where the filter carton encases the filter media and locks it in position. The endpoints of the top/bottom rail may have an accommodation to allow the consumer to interact with the frame or carton end walls to provide a solution for removing the filter at time of replacement.

[0080] Advantageously, to assist in the opening of the frame in the sequence of changing filters, finger relief indentations 34 allow for breaking the magnetic seal or other mechanical sealing method which further assist the user in swapping out filters (See FIG. 3).

[0081] Preferably, the frame rails (top and bottom, on each side) have an accommodation for a filter extraction point if needed—through die-cut 25 in the filter media carton that can be pushed in and used to help extract the filter from the HVAC filter pocket if need be (See FIG. 3).

[0082] In accordance with the present invention, the filter media preferably uses a type of material called a self-supported pleat which by nature of its construction is different than supported pleats. The difference is that self-supported pleats can be expanded/opened or collapsed/closed and contain rigidity so that they are not deformed in the same manner as non-supported pleated filters when under pressure that is found typically in HVAC systems. The use of this specific type of filter media aids in the solutions ability support economical and environmentally efficient shipment of replacement filters. It also allows the user to dispose of used/contaminated filters when replacing conveniently and safely. In this solution the filter media is opened and contains a plurality of pleats which are expanded across the assembled frame to complete two of the four outside edges of the perimeter of the frame.

[0083] Additional disclosure pertaining to the refillable air filter system of the present invention is provided in Appendix A of U.S. Provisional Application Ser. No. 63/324,305, entitled “REFILLABLE AIR FILTER SYSTEM,” filed Mar. 28, 2022— which is hereby incorporated herein by reference in its entirety, including all appendixes and references cited therein.

[0084] The foregoing description merely explains and illustrates the invention and the invention is not limited thereto except insofar as the appended claims are so limited, as those skilled in the art who have the disclosure before them will be able to make modifications without departing from the scope of the invention.

[0085] While certain embodiments have been illustrated and described, it should be understood that changes and modifications can be made therein in accordance with ordinary skill in the art without departing from the technology in its broader aspects as defined in the following claims.

[0086] The embodiments, illustratively described herein may suitably be practiced in the absence of any element or elements, limitation or limitations, not specifically disclosed herein. Thus, for example, the terms “comprising,” “including,” “containing,” etcetera shall be read expansively and without limitation. Additionally, the terms and expressions employed herein have been used as terms of description and not of limitation, and there is no intention in the use of such terms and expressions of excluding any equivalents of the features shown and described or portions thereof, but it is recognized that various modifications are possible within the scope of the claimed technology. Additionally, the phrase “consisting essentially of” will be understood to include those elements specifically recited and those additional elements that do not materially affect the basic and novel characteristics of the claimed technology. The phrase “consisting of” excludes any element not specified.

[0087] The present disclosure is not to be limited in terms of the particular embodiments described in this application. Many modifications and variations can be made without departing from its spirit and scope, as will be apparent to those skilled in the art. Functionally equivalent methods and compositions within the scope of the disclosure, in addition to those enumerated herein, will be apparent to those skilled in the art from the foregoing descriptions. Such modifications and variations are intended to fall within the scope of the appended claims. The present disclosure is to be limited only by the terms of the appended claims, along with the full scope of equivalents to which such claims are entitled. It is to be understood that this disclosure is not limited to particular methods, reagents, compounds compositions or biological systems, which can of course vary. It is also to be understood that the terminology used herein is for the purpose of describing particular embodiments only, and is not intended to be limiting.

[0088] In addition, where features or aspects of the disclosure are described in terms of Markush groups, those skilled in the art will recognize that the disclosure is also thereby described in terms of any individual member or subgroup of members of the Markush group.

[0089] As will be understood by one skilled in the art, for any and all purposes, particularly in terms of providing a written description, all ranges disclosed herein also encompass any and all possible subranges and combinations of subranges thereof. Any listed range can be easily recognized as sufficiently describing and enabling the same range being broken down into at least equal halves, thirds, quarters, fifths, tenths, etcetera. As a non-limiting example, each range discussed herein can be readily broken down into a lower third, middle third and upper third, etcetera. As will also be understood by one skilled in the art all language such as “up to,” “at least,” “greater than,” “less than,” and the like, include the number recited and refer to ranges which can be subsequently broken down into subranges as discussed above. Finally, as will be understood by one skilled in the art, a range includes each individual member.

[0090] All publications, patent applications, issued patents, and other documents referred to in this specification are herein incorporated by reference as if each individual publication, patent application, issued patent, or other document was specifically and individually indicated to be incorporated by reference in its entirety. Definitions that are contained in text incorporated by reference are excluded to the extent that they contradict definitions in this disclosure.

[0091] Other embodiments are set forth in the following claims.