Abstract:
Provided is an apparatus for receiving a filter member. The apparatus, in this embodiment, includes a plurality of discrete substantially rigid frame sections. In this embodiment, each respective section of the plurality of sections lies generally in a respective plane substantially oriented about a respective axis and has a respective length greater than a respective width. Furthermore, in this embodiment, the plurality of sections are joined width-to-width generally oriented with respect to a plane in an assembled orientation to circumscribe a quadrilaterally bound zone for effecting said receiving. Further to this embodiment, adjacent portions of respective joined sections in the assembled orientation establish respective joining structures. Even further to this embodiment, each respective joining structure maintains the adjacent portions oriented substantially about a respective axis.

Description:
CROSS REFERENCE RELATED APPLICATION 
       [0001]    This Application is a Divisional of U.S. application Ser. No. 11/954,207 filed on Dec. 11, 2007, to Ammar Kailani, et al., entitled “FRAME FOR RECEIVING A FILTER ELEMENT AND METHOD FOR PROVIDING,” currently allowed; commonly assigned with the present invention and incorporated herein by reference. 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    The present invention is directed to frames for receiving filter elements, and especially to frames for receiving air filter elements for use in heating, ventilating and air conditioning (HVAC) systems. 
         [0003]    HVAC systems may include or employ filter elements for removing particles or other elements from air circulated within the system in order to provide cleaner air for spaces serviced by the system. The air filter elements may be supported in predetermined positions within an air duct or similar locus in the HVAC system. The filter elements may require removal for replacement or cleaning. It is preferred that replacement filters with associated frames for supporting the elements in a duct or other locus in an HVAC system may occupy little storage space and present a compact package for shipping to storing sites or to users. 
         [0004]    There is a need for a frame for supporting a filter element that may be configured to be collapsible yet may provide substantially strong support for a filter element in when in an assembled orientation and employed for receiving a filter element. 
       SUMMARY OF THE INVENTION 
       [0005]    Provided is an apparatus for receiving a filter member. The apparatus, in this embodiment, includes a plurality of discrete substantially rigid frame sections. In this embodiment, each respective section of the plurality of sections lies generally in a respective plane substantially oriented about a respective axis and has a respective length greater than a respective width. Furthermore, in this embodiment, the plurality of sections are joined width-to-width generally oriented with respect to a plane in an assembled orientation to circumscribe a quadrilaterally bound zone for effecting said receiving. Further to this embodiment, adjacent portions of respective joined sections in the assembled orientation establish respective joining structures. Even further to this embodiment, each respective joining structure maintains the adjacent portions oriented substantially about a respective axis. 
         [0006]    Provided, in another embodiment, is a method for providing a frame for receiving a filter element. The method, in this embodiment, includes providing a pair of first members, and providing a pair of second members. Further to this embodiment, the method includes arranging the first members alternately with the second members in an assembled orientation to establish a plurality of joining structures between adjoining first and second members, wherein each respective joining structure maintains the members oriented substantially about a respective axis, and further wherein the first members and the second members cooperate to define a volume for effecting said receiving. 
         [0007]    Further features of the present invention will be apparent from the following specification and claims when considered in connection with the accompanying drawings, in which like elements are labeled using like reference numerals in the various figures, illustrating the preferred embodiments of the invention. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0008]      FIG. 1  is a perspective view of an assembled frame apparatus with a received filter element. 
           [0009]      FIG. 2  is a top plan view of a first member of the frame illustrated in  FIG. 1 . 
           [0010]      FIG. 3  is a bottom plan view of the first member illustrated in  FIG. 2 . 
           [0011]      FIG. 4  illustrates details of the first member, viewed along section line  4 - 4  in FIG. 
           [0012]      FIG. 5  is a perspective view of the first member being assembled with a filter element. 
           [0013]      FIG. 6  is an end view of the first member, viewed along section line  6 - 6  in  FIG. 1 . 
           [0014]      FIG. 7  is a top plan view of a second member of the frame illustrated in  FIG. 1 . 
           [0015]      FIG. 8  is a side view of the second member, viewed along section line  8 - 8  in FIG. 
           [0016]      FIG. 9  is a bottom plan view of the second member illustrated in  FIG. 7 . 
           [0017]      FIG. 10  is an end view of the second member illustrated in  FIGS. 7-9 , viewed along section line  10 - 10  in  FIG. 9 . 
           [0018]      FIG. 11  is a section view of a latching insertion structure, viewed along section line  11 - 11  in  FIG. 9 . 
           [0019]      FIG. 12  is a section view of an insertion structure, viewed along section line  12 - 12  in  FIG. 9 . 
           [0020]      FIG. 13  is a schematic side view of a ramp structure poised for engagement with a stop portion. 
           [0021]      FIG. 14  is a schematic side view of a ramp structure in the process of engaging with a stop portion. 
           [0022]      FIG. 15  is a schematic side view of a ramp structure engaged with a stop portion. 
           [0023]      FIG. 16  is a flow chart illustrating an embodiment of the method of the invention. 
       
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
       [0024]      FIG. 1  is a perspective view of an assembled frame apparatus with a received filter element. In  FIG. 1 , a frame apparatus  10  includes a pair of first members  12 ,  14  arranged alternately with a pair of second members  16 ,  18  to establish a plurality of joining structures  20 ,  22 ,  24 ,  26 . Joining structure  26  is not clearly visible in  FIG. 1 . Preferably, joining structure  26  is substantially similar to joining structures  20 ,  22 ,  24 . Joining structure maintains adjoining members  12 ,  16  oriented substantially about a linear axis  30 . Joining structure  22  maintains adjoining members  12 ,  18  oriented substantially about a linear axis  32 . Joining structure  24  maintains adjoining members  14 ,  18  oriented substantially about a linear axis  34 . Joining structure  26  maintains adjoining members  14 ,  16  oriented substantially about a linear axis  36 . 
         [0025]    In the assembled orientation illustrated in  FIG. 1 , members  12 ,  14 ,  16 ,  18  cooperated through joining structures  20 ,  22 ,  24 ,  26  to define a volume  40  for receiving a filter element  42 . 
         [0026]      FIG. 2  is a top plan view of a first member of the frame illustrated in  FIG. 1 .  FIG. 3  is a bottom plan view of the first member illustrated in  FIG. 2 . Regarding  FIGS. 2 and 3  together, first frame member  12  includes a substantially planar base portion  50  supporting spaced tab members  52 ,  54 . First frame member  12  has a length L.sub. 1  and a width W.sub. 1 . Length L.sub. 1  is greater than width W.sub. 1 . 
         [0027]    Spaced tab members  52 ,  54  present a space between themselves and base portion  50  (not specifically illustrated) to permit a sliding installation of a planar base member for filter element  42  to removable affix filter element  42  with respect to first member  12  generally against base portion  50 . This installation of filter member  42  with first member  12  is illustrated in greater detail in  FIG. 5 . 
         [0028]    First member  12  also includes receiver structures  56 . Preferably one receiver structure  56  is situated at each corner of first member  12 . Receiver structures  56  are joining elements that may participate in establishing joining structures  20 ,  22 ,  24 ,  26 , as will be described in greater detail below. 
         [0029]    First member  12  also includes stop structures  58 . Preferably one stop structure  58  is situated at each end of first member  12  on the top side of base portion  50  (visible in  FIG. 2 ). Stop structures  58  are joining elements that may also participate in establishing joining structures  20 ,  22 ,  24 ,  26 , as will be described in greater detail below. 
         [0030]    First frame member  14  may be substantially similar to first frame member  12 . In order to avoid prolixity, a repetitive description of first frame member  14  will not be presented. 
         [0031]      FIG. 4  illustrates details of the first member, viewed along section line  4 - 4  in  FIG. 1 . In  FIG. 4 , a receiver structure  56  includes an upper wall  60 , a lower wall  62 , a rear wall  66  and a front wall  66  (not visible in  FIG. 4 , see  FIG. 2 ). Walls  60 ,  62 ,  64 ,  66  define a channel  68 . Channel  68  is oriented substantially symmetrically about an axis  69 . 
         [0032]      FIG. 5  is a perspective view of the first member being assembled with a filter element. In  FIG. 5 , filter element  42  is illustrated in the process of sliding engagement with first member  12 . Filter element  42  includes an air-permeable portion  48  coupled with substantially inflexible end portions  44 ,  46 . End portion  44  has a thickness appropriate for sliding between base portion  50  and spaced tab members  52 ,  54  (see  FIG. 2 ) to establish a slidably removable joining between first member  12  and end portion  44 . End portion  46  is similarly proportioned to permit similar sliding removable joining with another end portion  12  (not shown in  FIG. 5 ). Air-permeable portion  48  may be compressible along an axis  47  substantially perpendicular with end portions  44 ,  46  to permit orienting filter element  42  in a smaller volume. Such a smaller volume is amenable to shipping filter element  42  in a reduced volume package. 
         [0033]      FIG. 6  is an end view of the first member, viewed along section line  6 - 6  in  FIG. 1 . In  FIG. 6 , a first member in end view presents two receiver structures  56  on either corner of first member  12 , and a stop structure  58  generally midway between receiver structures  56 . Each receiver structure  56  includes an upper wall  60 , a lower wall  62 , a rear wall  64  and a front wall  66  establishing a channel  68 . Stop structure  58  includes a top wall  70  supported in spaced relation from base portion  50  of first member  12  by side walls  72 ,  74 . A channel  76  is established by base portion  50  in cooperation with side walls  72 ,  74  and top wall  70 . Channel  76  may be trapezoidal, as illustrated in  FIG. 6 . Alternatively, channel  76  may have another quadrilateral shape, a trilateral shape or another polygonal shape appropriate for receiving an inserted member. 
         [0034]      FIG. 7  is a top plan view of a second member of the frame illustrated in  FIG. 1 .  FIG. 8  is a side view of the second member, viewed along section line  8 - 8  in  FIG. 7 .  FIG. 9  is a bottom plan view of the second member illustrated in  FIG. 7 . Regarding  FIGS. 7-9  together, second frame member  16  includes a substantially planar base portion  80 . Second frame member  16  has a length L.sub. 2  and a width W.sub. 2 . Length L.sub. 2  is greater than width W.sub. 2 . 
         [0035]    Second member  16  also includes insertion structures  82 . Preferably, one insertion structure  82  is situated at each corner of second member  16 . Second member further includes latching insertion structures  84 . Preferably, one latching insertion structure  84  is situated at each end of second member  16  between respective insertion structures  82 . 
         [0036]    Insertion structures  82  are joining elements that may participate in establishing joining structures  20 ,  22 ,  24 ,  26  in cooperation with receiver structures  56  ( FIGS. 2 , and  6 ). Each respective insertion structure  82  at a corner of a second member  16 ,  18  may be inserted within a respective receiver structure  56  at a corner of a first member  12 ,  14  to participate in establishing a respective joining structure  20 ,  22 ,  24 ,  26 . 
         [0037]    Latching insertion structures  84  are also joining elements that may participate in establishing joining structures  20 ,  22 ,  24 ,  26  in cooperation with stop structures  58 . Each respective latching insertion structure  84  at an end of a second member  16 ,  18  may be latchingly inserted within a respective channel  76  of a stop structure at an end of a first member  12 ,  14  to participate in establishing a respective joining structure  20 ,  22 ,  24 ,  26 . Latching insertion will be described in greater detail in connection with  FIGS. 13-15 . 
         [0038]    Second frame member  18  may be substantially similar to second frame member  16 . In order to avoid prolixity, a repetitive description of second frame member  18  will not be presented. 
         [0039]    One skilled in the art of collapsible filter frame manufacture may recognize that receiver structures  56 , stop structures  58 , insertion structures  82  and latching insertion structures  84  may be placed on any of first members  12 ,  14  and second members  16 ,  18  so long as each respective joining structure  20 ,  22 ,  24 , 26  has at least one insertion joining arrangement and a latching joining arrangement. Each insertion joining arrangement includes a mating pair of a receiver structure  56  with an insertion structure  82 . Each latching joining arrangement includes a mating pair of a stop structure  58  with a latching insertion member  84 . It is preferred that each joining structure include two insertion joining arrangements and a latching joining arrangement. 
         [0040]      FIG. 10  is an end view of the second member illustrated in  FIGS. 7-9 , viewed along section line  10 - 10  in  FIG. 9 . In  FIG. 10 , a second member  16  presents insertion structures  82  extending from base portion  80  at corners of second member  16 , and presents a latching insertion structure  84  from base portion  80  between insertion structures  82 . Each insertion structure  82  presents crossed beams  90 ,  92  arranged generally perpendicular to each other to result in a “+” cross-section (viewed from the left side of  FIG. 10 ) for insertion within a receiver structure  56  ( FIGS. 2 ,  4  and  6 ) to participate in establishing an insertion joining arrangement for inclusion in a joining structure  20 ,  22 ,  24 ,  26  ( FIG. 1 ). Insertion structure  82  may present any cross-section, such as the “+” cross-section illustrated In  FIG. 10 , for insertion within receiver structure  56  so long as the fit between insertion structure  82  and receiver structure  56  is snug enough to provide a sturdy and solid insertion joining arrangement for inclusion in a joining structure  20 ,  22 ,  24 ,  26 . It is desirable that the fit between insertion structure  82  and receiver structure  56  be amenable to separation by a user tugging insertion structure  82  and receiver structure  56  apart. Other cross-sections may be usable for insertion structure  82  such as, by way of example and not by way of limitation, a quadrilateral cross section, a triangular cross section, a hexagonal cross-section or another cross-section. 
         [0041]      FIG. 11  is a section view of a latching insertion structure, viewed along section line  11 - 11  in  FIG. 9 . In  FIG. 1 , a latching insertion structure  84  depends from base portion  80 . Latching insertion structure  84  includes a lever portion  100  attached with base portion  80  and a latching portion  102  attached with lever portion  100  distal from base portion  80 . Latching portion  102  includes a flat section  104  generally configured in register with a contiguous portion of lever portion  100 , a ramp section  106  departs from flat section  104  at an acute angle toward the general direction of base portion  80 . A blocking section  108  extends substantially perpendicularly from lever portion  100  to ramp section  106  at a locus displaced from the intersection of flat section  104  and ramp section  106 . When at rest, lever portion  100  and latching portion  102  are oriented generally symmetrically about an initial axis  103 . 
         [0042]      FIG. 12  is a section view of an insertion structure, viewed along section line  12 - 12  in  FIG. 12 , an insertion structure  82  depends from base portion  80 . Insertion structure  82  includes crossed beams  90 ,  92  arranged generally perpendicular to each other to result in a “+” cross-section (as viewed from the bottom of  FIG. 12 ) for insertion within a receiver structure  56  ( FIGS. 2 ,  4  and  6 ) to participate in establishing an insertion joining arrangement for inclusion in a joining structure  20 ,  22 ,  24 ,  26  ( FIG. 1 ). Insertion structure  82  may present any structure for insertion within receiver structure  56  so long as the fit between insertion structure  82  and receiver structure  56  is snug enough to provide a sturdy and solid joining structure  20 ,  22 ,  24 , 26 . It is desirable that the fit between insertion structure  82  and receiver structure  56  be amenable to separation by a user tugging insertion structure  82  and receiver structure  56  apart. Other cross-sections may be usable for insertion structure  82  such as, by way of example and not by way of limitation, a quadrilateral cross section, a triangular cross section, a hexagonal cross-section or another cross-section. 
         [0043]      FIG. 13  is a schematic side view of a ramp structure poised for engagement with a stop portion.  FIG. 14  is a schematic side view of a ramp structure in the process of engaging with a stop portion.  FIG. 15  is a schematic side view of a ramp structure engaged with a stop portion. Regarding  FIGS. 13-15  together, before a latching engagement operation is begun lever portion  100  and integrally formed latching portion  102  are at rest substantially symmetrically oriented about an initial axis  103 . A latching engagement operation is initiated by moving one or both of latching portion  102  and stop structure  58  to displace latching portion  102  relative to stop structure  58  along an installation path, indicated by an arrow  105 . 
         [0044]    As latching portion  102  and stop structure  58  are urged together, ramp section  106  passes within channel  76  between side walls  72 ,  74  (only side wall  72  is shown in  FIGS. 13-15 ) and ramp section  106  bears against top wall  70 . As latching portion  102  and stop structure  58  are urged further together ramp section  106  is deflected from initial axis  103  and passes through channel  76 . Deflection of ramp section  106  establishes a deflection force in lever portion  100  urging lever portion  100  in the direction indicated by arrow  107  ( FIG. 14 ). 
         [0045]    When the intersection between blocking section  108  and ramp section  106  passes clear of top wall  70 , ramp section  106  responds to the deflection force established in lever portion  100  to return toward symmetry with axis  103  to a position in which blocking section  108  is in a substantially abutting relation with top wall  70 . Blocking section  108  resists removal of latching portion  102  back along the installation path (indicated by arrow  105 ) without first deflecting latching portion  102  from axis  103 . 
         [0046]    Joining structures  20 ,  22 ,  24 ,  26  ( FIG. 1 ) may thus be established, preferably in combination, by insertion of insertion structures  82  within receiver structures  56  and by insertion of latching insertion structures  84  within stop structures  58 . It is preferred that receiver structures  56 , stop structures  58 , insertion structures  82  and latching insertion structures  84  each be integrally formed with a respective first member  12 ,  14  or a respective second member  16 ,  18  as appropriate to establish joint structures  20 ,  22 ,  24 ,  26  substantially rigidly about respective axes  30 ,  32 ,  34 ,  36  ( FIG. 1 ). While any polygonal structure may be established circumscribing volume  40  ( FIG. 1 ) using the teachings of the present invention, a preferred polygonal shape is a quadrilateral shape, and especially a rectangular shape. Maintaining a predetermined polygonal shape for a filter element contributes to reduced air leakage around the filter element when it installed in an air duct or other installation site. 
         [0047]      FIG. 16  is a flow chart illustrating an embodiment of the method of the invention. In  FIG. 16 , a method  200  for providing a frame for receiving a filter element begins at a START locus  202 . Method  200  continues by in no particular order: (1) providing a pair of first members, as indicated by a block  204 ; and (2) providing a pair of second members, as indicated by a block  206 . 
         [0048]    Method  200  continues with the step of arranging the first members alternately with the second members in an assembled orientation to establish a plurality of joining structures between adjoining the members, as indicated by a block  208 . Each respective joining structure of the plurality of joining structures maintains the adjoining members oriented substantially about a respective axis. The first members and the second members cooperate to define a volume for effecting the receiving of the filter element. 
         [0049]    It is to be understood that, while the detailed drawings and specific examples given describe preferred embodiments of the invention, they are for the purpose of illustration only, that the apparatus and method of the invention are not limited to the precise details and conditions disclosed and that various changes may be made therein without departing from the spirit of the invention which is defined by the following claims: