FILTER ELEMENT WITH INTEGRATED SENSING COMPONENTS

Abstract

A filtration system comprising: a housing defining an air inlet, an air outlet, a first filter receptacle, and an airflow pathway extending from the inlet to the outlet through the first filter receptacle; a first pair of electrodes in communication with the first filter receptacle configured to define a first conductive pathway across the first filter receptacle; a second pair of electrodes in communication with the first filter receptacle configured to define a second conductive pathway across the first filter receptacle; a controller in communication with the first and second pair of electrodes configured to measure a first electrical property across the first filter receptacle using the first pair of electrodes and a second electrical property across the first filter receptacle using the second pair of electrodes; and an interface in communication with the controller configured to report a filter element status based on the first and second electrical property.

Claims

1. A filtration system comprising: a system housing defining an air inlet, an air outlet, a first filter receptacle configured to receive a first filter element, and an airflow pathway extending from the air inlet to the air outlet through the first filter receptacle; a first pair of electrodes in electrical communication with the first filter receptacle, the first pair of electrodes configured to define a first conductive pathway across the first filter receptacle; a second pair of electrodes in electrical communication with the first filter receptacle, the second pair of electrodes configured to define a second conductive pathway across the first filter receptacle; a controller in communication with the first pair of electrodes and the second pair of electrodes, wherein the controller is configured to measure a first electrical property across the first filter receptacle using the first pair of electrodes and a second electrical property across the first filter receptacle using the second pair of electrodes; an interface in communication with the controller, wherein the interface is configured to report a filter element status based on the first electrical property and the second electrical property; and the first filter element disposed in the first filter receptacle, the first filter element comprising: first filter media having a first media fiber composition, the first filter media defining a flow face and a periphery about the flow face, the periphery comprising a first edge and a second edge opposite the first edge; and a first reactive fibrous strip having a first fiber composition different from the first media fiber composition, and wherein the first reactive fibrous strip of the first filter element is in electrical communication with the first pair of electrodes and the first reactive fibrous strip has a first electrical property that varies based on exposure to a first air constituent.

2. The filtration system of claim 1, wherein the first filter media has a media electrical property and the first electrical property of the first reactive fibrous strip is generally unequal to the media electrical property, wherein the first electrical property and the media electrical property are the same type of electrical property.

3. The filtration system of claim 1, further comprising a second reactive fibrous strip extending from the first edge to the second edge, wherein the second reactive fibrous strip comprises a second fiber composition different from the media fiber composition and the first fiber composition, wherein the second reactive fibrous strip is in electrical communication with the second pair of electrodes and the second reactive fibrous strip has a second electrical property that varies based on exposure to a second air constituent different from the first air constituent.

4. The filtration system of claim 3, wherein the first filter media has a media electrical property and the second electrical property of the second reactive fibrous strip is generally unequal to the media electrical property, wherein the second electrical property and the media electrical property are the same type of electrical property.

5. The filtration system of claim 3, or wherein the first filter media separates the first reactive fibrous strip and the second reactive fibrous strip.

6. The filtration system of claim 1, wherein the system housing further defines a second filter receptacle configured to receive a second filter element.

7. The filtration system of claim 1, wherein the system housing defines a liquid reservoir in vapor communication with the airflow pathway.

8. The filtration system of claim 1, further comprising an ultraviolet (UV) light source operatively coupled to the system housing, wherein the UV light source is positioned to emit light in the airflow pathway.

9. The filtration system of claim 7, further comprising an ultraviolet (UV) light source operatively coupled to the system housing, wherein the UV light source is positioned to emit light in the liquid reservoir.

10. The filtration system of claim 1, further comprising an ultraviolet (UV) light source operatively coupled to the system housing, wherein the UV light source is positioned to emit light onto the first filter element.

11. The filtration system of claim 8, wherein the UV light source comprises a multi-faceted reflector.

12. The filtration system of claim 9, wherein the system housing comprises a transparent wall isolating the liquid reservoir from the airflow pathway, and the light from UV light source is configured to pass through the transparent wall.

13. A method of filtering room air comprising: passing air through a first flow face of a first filter element to obtain first filtered air, wherein the first filter element comprises filer media having a media fiber composition; measuring a first electrical property of a first reactive fibrous strip defined by the first filter element at a first time, wherein the first reactive fibrous strip is an elongate region comprising a first plurality of conductive fibers that extend across the first flow face of the first filter element; and measuring a second electrical property of a second reactive fibrous strip defined by the first filter element at a first time, wherein the second reactive fibrous strip is an elongate region comprising a second plurality of conductive fibers that extend across the first flow face of the first filter element, wherein the first plurality of conductive fibers and the second plurality of conductive fibers have fiber compositions that differ from the media fiber composition.

14. The method of claim 13, further comprising reporting first filter element status correlating to the first electrical property.

Description

[0122] Examples will now be further described with reference to the figures in which:

[0123] FIG. 1 is an example filter element consistent with embodiments.

[0124] FIG. 2 is a cross-sectional view of an example filter system.

[0125] FIG. 3 is another cross-sectional view of an example filter system.

[0126] FIG. 4 is another cross-sectional view of an example filter system.

[0127] FIG. 1 depicts an example of a filter element 2. The filter element 2 is generally configured to filter air. The filter element 2 has filter media 24 configured to filter air passing through the filter element 2. The filter media defines a flow face 10 and a periphery 11 about the flow face. The periphery 11 has a first edge 12 and a second edge 13, where the second edge 13 is opposite the first edge 12. In some embodiments, the filter media has a media fiber composition. The media fiber composition may include cellulosic, polymeric, glass, and other types of fibers and combinations of fibers. In some embodiments the filter media may be constructed of particulate matter. The filter media may be constructed of layers of different filter media. The filter media will generally have various intrinsic characteristics including a media electrical property.

[0128] The filter element has a first reactive fibrous strip 21 having a first fiber composition different from the first media fiber composition. The first reactive fibrous strip 21 extends from the first edge 12 to the second edge 13 of the filter media 24. The first reactive fibrous strip 21 extends across the flow face 10 of the filter media 24. The first reactive fibrous strip 21 may have a first electrical property that varies based on exposure to a first air constituent. The first electrical property of the first reactive fibrous strip may be unequal to the same type of electrical property of the filter media, which has been discussed in detail, above. In this example, the filter element 2 has a second reactive fibrous strip 22. The second reactive fibrous strip 22 extends from the first edge 12 to the second edge 13 of the filter media. The second reactive fibrous strip 22 has a second fiber composition that is different from the media fiber composition. The second reactive fibrous strip 22 has a second fiber composition that is different from the first fiber composition of the first reactive fibrous strip 21. However, the second reactive fibrous strip 22 may be constructed in a manner consistent with the description above regarding the construction of the first reactive fibrous strip. The second reactive fibrous strip 22 has a second electrical property that varies based on exposure to a second air constituent different from the first air constituent. Such a configuration advantageously allows detection of a second air constituent that is different from the first air constituent that is configured to be detected by the first reactive fibrous strip 21.

[0129] The second electrical property of the second reactive fibrous strip 22 is generally unequal to the corresponding electrical property (the same type of electrical property) of the filter media 24. For example, the electrical resistance of the second reactive fibrous strip 22 may be unequal to, such as less than, the electrical resistance of the filter media 24, similar to that described above with reference to the first reactive fibrous strip 21. The first filter media 24 separates the first reactive fibrous strip 21 and the second reactive fibrous strip 22. Such a configuration advantageously may prevent electrical interference between the first reactive fibrous strip 21 and the second reactive fibrous strip 22 when measuring electrical properties of one of reactive fibrous strips.

[0130] Here the filter element has a third reactive fibrous strip 23. The third reactive fibrous strip 23 has a third electrical property that varies based on exposure to a third air constituent different from the first air constituent and the second air constituent. Such a configuration may advantageously allow detection of a third air constituent that is different from the first air constituent that is configured to be detected by the first reactive fibrous strip 21. Such a configuration may advantageously allow detection of a third air constituent that is different from the second air constituent that is configured to be detected by the second reactive fibrous strip 22.

[0131] The third electrical property of the third reactive fibrous strip 23 is generally unequal to the corresponding electrical property (the same type of electrical property) of the filter media 24. For example, the electrical resistance of the third reactive fibrous strip 23 may be unequal to, such as less than, the electrical resistance of the filter media 24, similar to that described above with reference to the first reactive fibrous strip 21. The filter media 24 separates the second reactive fibrous strip 22 and the third reactive fibrous strip 23. As discussed above, filter elements consistent with the present technology may have additional reactive fibrous strips. In some embodiments the third reactive fibrous strip 23 may be omitted. Each of the reactive fibrous strips may be configured to react to different air constituents. Each of the reactive fibrous strips 21, 22, 23, may be configured to have a different resistance than the filter media. In some embodiments, each of the reactive fibrous strips may have a lower electrical resistivity than the filter media.

[0132] In an example, the flow face 10 of the filter media 24 may have a width of about 475.0 mm, a height of about 490.1 mm and an area of about 232, 787 mm.sup.2. The first reactive fibrous strip 21 may have a surface area of about 4% of the flow face 10. The second reactive fibrous strip 22 may have a surface area of about 4% of the flow face 10. The third reactive fibrous strip 23 may have a surface area of about 6% of the flow face 10. The combination of the first reactive fibrous strip 21, second reactive fibrous strip 22, and third reactive fibrous strip 23 may have a surface area of about 14% of the surface area of the flow face 10.

[0133] FIG. 2 depicts a cross-sectional view of an example system 1 consistent with embodiments. The system 1 is a filtration system that is generally configured to filter air. The system 1 is configured to receive a first filter element, such as the example filter element of FIG. 1. The filtration system 1 has a system housing 70. The system housing 70 is configured to direct air through a filter element to filter the air.

[0134] The system housing 70 defines a first filter receptacle 17 that is configured to receive a first filter element. The first filter receptacle defined a portion of the airflow pathway, which will be discussed below with reference to FIG. 3. The first filter receptacle 17 may have a sealing structure that is configured to receive a seal about a periphery of the filter element to obstruct airflow around the filter element. Such a seal may be disposed between the filter element and the housing 70. In some embodiments a filter element, such as those discussed above, is disposed in the first filter receptacle 17.

[0135] The system has a first pair of electrodes 71 in electrical communication with the first filter receptacle 17. The first pair of electrodes 71 are generally configured to define a first conductive pathway across the first filter receptacle 17. As such, the first pair of electrodes 71 are configured to define a first conductive pathway across the airflow pathway. When a filter element is disposed in the first filter receptacle 17, such as the filter element of FIG. 1, the first pair of electrodes define a first conductive pathway across the first filter element 2. The first reactive fibrous strip 21 of the first filter element 2 are configured to be in electrical communication with the first pair of electrodes 71 when the first filter element 2 is disposed in the first filter receptacle 17.

[0136] The system has a second pair of electrodes 72 in electrical communication with the first filter receptacle 17. The second pair of electrodes 72 are generally configured to define a second conductive pathway across the first filter receptacle 17. The second pair of electrodes 72 are generally configured to define a second conductive pathway across the airflow pathway. When a filter element 2 (such as that described with reference to FIG. 1) is disposed in the first filter receptacle 17, the second pair of electrodes 72 define a second conductive pathway across the first filter element 2. The second reactive fibrous strip 22 may be in electrical communication with the second pair of electrodes 72 when the first filter element 2 is disposed in the first filter receptacle 17.

[0137] The system has a third pair of electrodes 73 in electrical communication with the first filter receptacle 17. The third pair of electrodes 73 are generally configured to define a third conductive pathway across the first filter receptacle 17. The third pair of electrodes 73 are generally configured to define a third conductive pathway across the airflow pathway. When a filter element 2 (such as that described with reference to FIG. 1) is disposed in the first filter receptacle 17, the third pair of electrodes 73 define a third conductive pathway across the first filter element 2. The third reactive fibrous strip 23 is configured to be in electrical communication with the third pair of electrodes 73 when the first filter element 2 is disposed in the first filter receptacle 17.

[0138] In the current example the system 1 has a liquid reservoir 26. The liquid reservoir 26 is configured to receive a liquid such as water or a water solution. The liquid reservoir 26 is generally isolated from the airflow pathway, which will be discussed in more detail below with reference to FIG. 3.

[0139] FIG. 3. Is another cross-sectional view of a filtration system. The system may be consistent with the system discussed above with reference to FIG. 2. In particular, the cross-section depicted in FIG. 3 may be perpendicular to the cross-section visible in FIG. 2.

[0140] The filtration system 1 has a system housing 70. The system housing 70 is configured to direct air through a filter element to filter the air. The system housing 70 defines an air inlet 40, an air outlet 41, and an airflow pathway 43 extending from the air inlet 40 to the air outlet 41. The system housing 70 defines a first filter receptacle 17 that is configured to receive a first filter element. The airflow pathway 43 extends through the first filter receptacle 17 such that, when a filter element is disposed in the filter receptacle, the airflow pathway 43 extends through the filter element. The airflow pathway 43 extends from the air inlet 40 to the air outlet 41 through the first filter receptacle 17. In the current example, the air inlet 40 and the air outlet 41, or both the air inlet 40 and the air outlet 41 can be defined by a screen structure. A fan 14 is coupled to the housing that is configured to generate fluid flow in the airflow pathway 43.

[0141] The first filter receptacle 17 is generally configured to receive a first filter element, such as a filter element 2 described above with reference to FIG. 1, such that air flowing along the airflow pathway 43 is restricted from bypassing the filter element. The first filter receptacle 17 may extend across the airflow pathway 43. In some embodiments a filter element 2 is disposed in the first filter receptacle 17. The system 1 may have pairs of electrodes, which are not currently visible but are visible and described above with reference to FIG. 2.

[0142] In this example, the system 1 is configured to receive two filter elements for filtration. As such, the system housing 70 defines a second filter receptacle 18 that is configured to receive a second filter element. The second filter receptacle 18 may be defined downstream of the first filter receptacle 17 along the airflow pathway 43. The second filter receptacle 18 may be configured consistently with the description of the first filter receptacle 17, above. One or more pairs of electrodes may be configured to define a conductive pathway across the second filter receptacle 18, similar to the first pair of the electrodes and the second pair of electrodes, discussed above with reference to FIG. 2. In some embodiments including a second filter receptacle 18, a second filter element may be disposed in the second filter receptacle 18. The second filter element may have a construction, materials, and properties that are consistent with the construction, materials, and properties the filter element discussed above with reference to FIG. 1.

[0143] The system housing 70 defines a liquid reservoir 26. The liquid reservoir 26 is configured to be in vapor communication with the airflow pathway 43. The liquid reservoir 26 is configured to allow liquid from the liquid reservoir 26 to evaporate into the airflow pathway 43. Advantageously, the liquid reservoir 26 may improve air quality of the air through the introduction of moisture into the filtered air. The liquid reservoir 26 may be configured to receive water or a water solution. In some embodiments the liquid reservoir 26 is configured to receive a water solution including aromas. The liquid reservoir 26 may be substantially isolated from the airflow pathway 43.

[0144] In this example, the liquid reservoir 26 is in vapor communication with the airflow pathway 43 through a wicking material 20 that extends from the liquid reservoir 26 into the airflow pathway 43. Airflow through the airflow pathway 43 may contribute to the evaporation of the liquid on the wicking material 20, which may result in moisturizing the air in the airflow pathway 43. In this example, the wicking material 20 is downstream of the air inlet 40, the first filter receptacle 17, and the second filter receptacle 18, although other configurations are contemplated. The wicking material 20 is adjacent the air outlet 41 of the system housing 70.

[0145] Various systems may have a controller 19 in communication with the pairs of electrodes, which were discussed above with reference to FIG. 2. The controller 19 may be configured to apply a voltage across the relevant pair of electrodes and measure corresponding electrical properties across a filter receptacle. The electrical properties may allow the controller to determine a filter element status, as has been discussed in detail, above. Although not currently visible, the system 1 may have an interface 28 in communication with the controller 19. The interface 28 may be configured to report a filter element status based on the first electrical property and the second electrical property, which has been discussed in detail above.

[0146] Here the system 1 has an ultra-violet light source 15 is incorporated in the system. The UV light source 15 is operatively coupled to the system housing 70. In this example, the UV light source 15 has two UV light bulbs. The UV light source 15 is positioned to emit light in the airflow pathway 43. Such a configuration may advantageously neutralize or limit the growth of microbes within the airflow pathway 43. Here, the UV light source 15 is positioned to emit light in the liquid reservoir 26. Such a configuration may advantageously neutralize or limit the growth of microbes within the liquid reservoir 26. In the current example, The UV light source is coupled to the housing 70 between the airflow pathway 43 and the liquid reservoir 26. The system housing 70 has a transparent wall 27 isolating the liquid reservoir 26 from the UV light source 15. The light from UV light source 15 is configured to pass through the transparent wall 27. In this example, the UV light source 15 is also positioned to emit light into the first filter receptacle 17 and, therefore, a first filter element disposed in the first filter receptacle 17. In this example, the UV light source 15 is also positioned to emit light into the second filter receptacle 18 and, therefore, a second filter element disposed in the second filter receptacle 18. Such a configuration may advantageously neutralize or limit the growth of microbes on the relevant filter elements.

[0147] As mentioned, here the UV light source 15 includes two UV light bulbs that are configured to be energized by the system. In embodiments the UV light source 15 includes a reflector that reflects UV light from a UV light bulb, which will be discussed below with reference to FIG. 4.

[0148] FIG. 4 depicts a cross-sectional view of another system 50 consistent with embodiments. The system 50 is similar to the systems described above with reference to FIGS. 2 and 3 except that here the liquid reservoir 26 is positioned between the airflow pathway and the UV light source 4. A transparent wall 5 is positioned between the liquid reservoir 26 and the airflow pathway 43 such that UV light extends from the UV light source 4, through the liquid reservoir 26, through the transparent wall 5 and into the airflow pathway 43. Also, in the current example, here the UV light source includes a reflector 6 defined by one or more surfaces within the system housing 70 that are configured to reflect UV light. The reflector 6 is configured to reflect UV light in additional directions. Such a configuration may advantageously allow a single bulb to be used to direct UV light in multiple directions.

[0149] For the purpose of the present description and of the appended claims, except where otherwise indicated, all numbers expressing amounts, quantities, percentages, and so forth, are to be understood as being modified by the term “precisely” or “about”. In the context of “about”, a number A is generally understood as A±5% or less of A. For example, a number A may be A±3% or less of A, such as A±2% or less of A. Within this context, a number A may be considered to include numerical values that are within general standard error for the measurement of the property that the number A modifies. The number A, in some instances as used in the appended claims, may deviate by the percentages enumerated above provided that the amount by which A deviates does not materially affect the basic and novel characteristic(s) of the claimed invention. Also, all ranges include the maximum and minimum points disclosed and include any intermediate ranges therein, which may or may not be specifically enumerated herein.