Abstract:
Methods and apparatus for providing a software upgrade are disclosed. A replaceable media assembly in accordance with the present invention includes a replaceable media component, and an information storage device fixed to the replaceable media component. An interconnect is coupled to the information storage device for electrically connecting the information storage device to the controller of a system that receives the replaceable media assembly.

Description:
FIELD OF THE INVENTION  
         [0001]    The present invention relates generally to systems that use replaceable media, and more specifically, to replaceable media that include a micro-controller or a storage device.  
         BACKGROUND OF THE INVENTION  
         [0002]    Nearly every consumer living in an industrialized nation makes use of a system that uses replaceable media. For example, many heating, ventilation, and air conditioning (HVAC) systems for homes and buildings use one or more filters that must be periodically replaced. Similarly, most braking system used in vehicles have brake pads and/or brake shoes that must be periodically replaced.  
           [0003]    A difficulty with many such systems is that the user or operator of the system must periodically inspect and/or replace the replaceable media. Because the users of such system often do not take the time to periodically inspect the replaceable media, the manufacturer of such systems often provide maintenance schedules. For many home HVAC systems, for example, the manufacturer often specifies that the filter should be replaced every three months. Likewise, for automobiles, the manufacturer often specifies that the brake pads should be replaced every 30,000 miles, or the oil filter should be replaced every 3,000 miles.  
           [0004]    A limitation of rigid maintenance schedules is that the actual condition of the replaceable media at the end of the maintenance period is dependent on the environment or use of the system, and the quality of the replaceable media itself. For example, the actual condition of the filter used in a home HVAC system at the end of a suggested maintenance period will depend on the condition or use of the house, and on the quality and/or performance characteristics of the particular filter used. Similarly, the actual condition of the brake pads on a vehicle at the end of a suggested maintenance period will depend on the driving habits of the driver, and the quality and/or performance characteristics of the particular brake pads used.  
           [0005]    There are often many manufacturers that provide replaceable media for various systems. The quality and performance characteristics of the replaceable media can vary between manufacturers, and between targeted price points. Accordingly, the quality and performance of the replaceable media is usually difficult to predict in advance. This is particularly problematic when the quality and performance characteristics of the replaceable media effects the operation or performance of the overall system.  
           [0006]    Many systems that use replaceable media also have a controller for controlling at least part of the operation of the system. Most controllers used in such systems are programmable, that is, they have a memory for storing a program that controls the operation of the controller. In some circumstances, it would be desirable to replace or upgrade the program in the memory of the controller. For example, if a manufacturer of a system identifies new ways to improve the performance of the system through a software upgrade, or identifies one or more bugs in the original software, it may be desirable to replace or upgrade the program in the memory of the controller.  
           [0007]    Providing a program upgrade to a system in the field can be difficult and expensive. One method is to have a technician visit the location (e.g., home, factory, etc.) where the system is used, and install a new program in the memory of the system. This, however, requires paying for the time and travel expenses of the technician. Another method is to ship the system back to the factory for upgrading. However, this is usually prohibitively expensive, and may require that the system to be down for an extended period of time.  
         SUMMARY OF THE INVENTION  
         [0008]    The present invention overcomes many of the disadvantages of the prior art by providing a replaceable media assembly for use in a system, wherein the replaceable media assembly includes a controller or storage element that can communicate with the system. Providing a controller or storage element in conjunction with a replaceable media element can provide a number of advantages. For example, when the controller or storage element stores information about the replaceable media, this information can be passed to the system. The system may then identify the replaceable media, identify the performance characteristics of the replaceable media, and/or optimize the performance of the system based on the performance characteristics of the replaceable media. Alternatively, or in addition, the system may receive software upgrades from the controller or storage element of the replaceable media assembly.  
           [0009]    One illustrative embodiment of a replaceable media assembly is adapted for use with a heating, ventilation, and air conditioning (HVAC) system. The HVAC system may include a filter housing disposed in fluid communication with a blower. The filter housing may include a plurality of walls defining a chamber. In a preferred embodiment, the filter housing is adapted to receive a replaceable media assembly. In a preferred embodiment, the replaceable media assembly includes an air filter, and the blower is selectively actuated to force air through the filter housing and through the air filter.  
           [0010]    Information is preferably stored in an information storage device, which is fixed to the replaceable media assembly. The information stored in the information storage device may be used by the controller of the system to adjust the operation of the system. For example, the information stored in the information storage device may relate to the performance characteristics of the replaceable media component of the replaceable media assembly. In the present example, the information stored in the information storage device may include a pressure drop value. The pressure drop value may be, for example, the expected pressure drop through the air filter when the air filter is clean. The controller of the system may read the expected pressure drop value and adjust the operation of the blower of the system to accommodate the pressure drop.  
           [0011]    The information stored in the information storage device may also include an expected pressure drop value that relates to the expected pressure drop through the air filter when the air filter is dirty. The controller of the system may read the expected pressure drop value from the information storage device and compare that pressure drop to a current pressure drop measured using a differential pressure sensor coupled to the controller. When the measured pressure drop exceeds the pressure drop expected from a dirty filter, the controller of the system may provide a notification to exchange the replaceable media assembly with a new replaceable media assembly.  
           [0012]    The information stored in the information storage device may also include a time value that relates to the recommended replacement interval of the replaceable media assembly. When the system receives a replaceable media assembly, the controller may read a serial number stored in the information storage device of the replaceable media assembly. The controller may begin tracking the length of time that the replaceable media assembly is in use. When the replacement interval is reached, the controller of system may provide a notification to exchange replaceable media assembly with a new replaceable media assembly.  
           [0013]    The controller or information storage device, which is fixed to the replaceable media assembly, may also contain information about the characteristic pressure drop curve for the particular media material. This information can be used by the controller to determine the proper pressure drop set points for media replacement, controlling the rate of flow in a filter system, controlling the rate of application in an automatic braking system, and determining at what flow rate an active filter system should be turned on.  
           [0014]    The controller or information storage device, which is fixed to the replaceable media assembly, may also contain information about the characteristic pressure drop curve that could be customized for the particular batch of media or for more unstable media. The pressure drop curve could be determined for each device by testing at the time of manufacture and storing that information in the controller or storage device prior to shipment. These methods might be particularly useful on high cost replaceable media such as clean room HEPPA filters. In some embodiments, the controller or information storing device may be the only controller in the system.  
           [0015]    The information stored in the information storage device may also include a model number of the replaceable media assembly. The controller of the system may read the model number from the information storage device and determine the compatibility of the replaceable media assembly with the system. The controller of the system may provide a notification if the replaceable media assembly is not compatible with the system. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0016]    [0016]FIG. 1 is a block diagram of a system in accordance with an exemplary embodiment the present invention;  
         [0017]    [0017]FIG. 2 is a block diagram of an additional exemplary embodiment of a system in accordance with the present invention;  
         [0018]    [0018]FIG. 3 is a perspective view of a replaceable media assembly in accordance with the present invention;  
         [0019]    [0019]FIG. 4 is a partial cross sectional view of a filter housing of a system in accordance with an exemplary embodiment of the present invention; and  
         [0020]    [0020]FIG. 5 is a diagrammatic depiction of a vehicle having a plurality of the wheels and a braking system for slowing and/or stopping the rotation of the wheels. 
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0021]    The following detailed description should be read with reference to the drawings, in which like elements in different drawings are numbered in like fashion. The drawings, which are not necessarily to scale, depict selected embodiments and are not intended to limit the scope of the invention. In some cases, the drawings may be highly diagrammatic in nature. Examples of constructions, materials, dimensions, and manufacturing processes are provided for various elements. Those skilled in the art will recognize that many of the examples provided have suitable alternatives which may be utilized.  
         [0022]    [0022]FIG. 1 is a block diagram of a system  100  in accordance with an illustrative embodiment the present invention. The system  100  is preferably adapted to receive a replaceable media assembly  102 . The system  100  includes a controller  104  and a controller interconnect  106  which is coupled to the controller  104 . The replaceable media assembly  102  includes a replaceable media component  120 , an information storage device  122 , and a storage device interconnect  124  which is coupled to the information storage device  122 . In the embodiment of FIG. 1, the information storage device  122  includes a memory  126 . The storage device interconnect  124  is preferably adapted to releasably mate with the controller interconnect  106  of the system  100  to form a connection  128 . The storage device interconnect  124  and the controller interconnect  106  may each include a plurality of contacts.  
         [0023]    Alternatively, it is contemplated that the storage device interconnect  124  and the controller interconnect  106  may include a wireless connection, such as an RF connection. This may eliminate the need for mechanical connectors. In one embodiment, the storage device interconnect  124  may be a transponder, which receives power from a query signal provided by the controller interconnect  106 , and sends the information back to the controller interconnect  106 .  
         [0024]    [0024]FIG. 2 is a block diagram of an additional exemplary embodiment of a system  200  in accordance with the present invention. The system  200  of FIG. 2 may be generally referred to as a heating, ventilation, and air conditioning (HVAC) system. The system  200  is preferably adapted to control the temperature of the air within an inside space  230 .  
         [0025]    In the illustrative embodiment of FIG. 2, the system  200  includes a motor  238  that is coupled to a blower  232 . The blower  232  is in fluid communication with a first duct  234  and a second duct  236 . The blower  232  may be used to draw air from the inside space  230  through the first duct  234  and return air to the inside space  230  via second duct  236 . The motor  238  may be selectively activated by a controller  204  which is coupled to the motor  238 .  
         [0026]    A filter housing  240  is disposed in fluid communication with the blower  232  and the inside space  230 . The filter housing  240  includes a plurality of the walls  242  defining a chamber  244 . The filter housing  240  also includes an inlet  246  and an outlet  248  in fluid communication with the chamber  244 . In a preferred embodiment, the filter housing  240  of the system  200  is adapted to receive a replaceable media assembly  202 . In the embodiment of FIG. 2, the replaceable media assembly  202  is disposed within the chamber  244  between inlet  246  and outlet  248 .  
         [0027]    The replaceable media assembly  202  includes a replaceable media component  220 , which in the embodiment shown, is an air filter  250 . The replaceable media assembly  202  also includes an information storage device  222 , and a storage device interconnect  224  which is coupled to the information storage device  222 . The storage device interconnect  224  is preferably adapted to releasably mate with a controller interconnect  206  of the system  200  to form a connection  228 . The storage device interconnect  224  and the controller interconnect  206  may each include a plurality of contacts.  
         [0028]    The system  200  also includes a furnace  252  having a heat exchanger  254  that is in fluid communication with the blower  232  and the inside space  230 . The furnace  252  may be used to heat an air stream passing through the heat exchanger  254  and into the inside space  230 . The system  200  of FIG. 2 also includes an air conditioner  256  having a compressor  258 , a condenser  262  and an evaporator  260 . The evaporator  260  may be used to cool an air stream passing through the evaporator  260  and into the inside space  230 . In the embodiment of FIG. 2, the furnace  252  and the air conditioner  256  are both coupled to the controller  204 . The controller  204  may be used to control the temperature of the air in the inside space by selectively activating the furnace  252  and the air conditioner  256 .  
         [0029]    Information is preferably stored in the information storage device  222  of the replaceable media assembly  202 . The information stored in the information storage device  222  may be used by the controller  204  to adjust the operation of the system  200 . For example, the information stored in the information storage device  222  may relate to the performance characteristics of the replaceable media component  220  of the replaceable media assembly  202 . In this example, the information stored in the information storage device  222  may include a pressure drop value. The pressure drop value may be, for example, the expected pressure drop through the air filter  250  when the filter is clean. The controller  204  of the system  200  may read the expected pressure drop value and adjust the operation of the blower  232  of the system  200  to accommodate the pressure drop.  
         [0030]    The information stored in the information storage device  222  may also include an expected pressure drop value that relates to the expected pressure drop through the air filter  250  when the filter is dirty. The controller  204  of the system  200  may read the expected pressure drop value from the information storage device  222  and compare that pressure drop to a current pressure drop measured using a differential pressure sensor  264  coupled to the controller  204 . When the measured pressure drop exceeds the pressure drop expected from a dirty filter, the controller  204  of the system  200  may provide a notification to exchange the replaceable media assembly  202  with a new replaceable media assembly. The notification may be, for example, an audible signal and/or a visual signal.  
         [0031]    The information stored in the information storage device  222  may also include a time value that relates to a recommended replacement interval that is associated with the replaceable media component  220  of the replaceable media assembly  202 . When the system  200  receives a replaceable media assembly  202 , the controller  204  may read a serial number stored in the information storage device  222  of the replaceable media assembly  202 . The controller  204  may begin tracking the length of time that the replaceable media assembly  202  is in use. When the replacement interval is reached, the controller  204  of the system  200  may provide a notification to exchange the replaceable media assembly  202  with a new replaceable media assembly. The notification may be, for example, an audible signal and/or a visual signal.  
         [0032]    In yet another example, the information storage device  222  may include a programmed micro-controller and the information stored in the information storage device  222  may include a program. The program may cause the micro-controller to communicate with the controller  204  of the system  200 . The program may also cause the micro-controller to pass a number of performance parameters related to the replaceable media to the controller of the system. In some embodiments, the program may also cause the micro-controller to provide a software upgrade to the controller  204  of the system  200 .  
         [0033]    It is contemplated that the information stored in the information storage device  222  may include a model number of the replaceable media assembly  202 . The controller  204  of the system  200  may read the model number from the information storage device  222  and determine the compatibility of the replaceable media assembly  202  with the system  200 . The controller  204  of the system  200  may provide a notification if the replaceable media assembly  202  is not compatible with the system  200 . The notification may be, for example, an audible signal and/or a visual signal.  
         [0034]    The information stored in the information storage device  222  may also include additional information without deviating from the spirit and scope of the present invention. Examples of additional information include sound files, graphics files, advertisement files, and user instruction sets.  
         [0035]    [0035]FIG. 3 is a perspective view of a replaceable media assembly  302  in accordance with the present invention. The replaceable media assembly  302  includes a replaceable media component  320  and a carrier  366  for carrying the replaceable media component  320 . In the embodiment of FIG. 3, the replaceable media component  320  is a filter that has a plurality of the fibrils  370  arranged in a substantially randomly intertangled pattern. The fibrils  370  define a plurality of the air flow pathways  372  which are substantially tortuous. It is to be understood that other embodiments of the replaceable media component  320  are possible without deviating from the spirit and scope of the present invention.  
         [0036]    In the embodiment of FIG. 3, the carrier  366  includes a frame  374  that surrounds the outer edges of the replaceable media component  320 . An information storage device  322  is fixed to the carrier  366 . The information storage device  322  is coupled to a storage device interconnect  324  which is preferably adapted to form a connection with the controller of a system. In FIG. 3, it may be appreciated that the storage device interconnect  324  includes a plurality of contacts  376 .  
         [0037]    [0037]FIG. 4 is a partial cross sectional view of a filter housing  440  of a system  400  in accordance with an illustrative embodiment of the present invention. The filter housing  440  includes a plurality of the walls  442  defining a chamber  444 . In a preferred embodiment, the filter housing  440  of the system  400  is adapted to receive a replaceable media assembly  402 . The replaceable media assembly  402  is disposed within the chamber  444  between walls  442 . The position of the replaceable media assembly  402  within the chamber  444  is maintained by a plurality of positioning flanges  478 . The replaceable media assembly  402  includes an information storage device  422 , and a storage device interconnect  424  that is coupled to the information storage device  422 .  
         [0038]    The filter housing  440  also includes a door  480  that is coupled to a wall  442  of the filter housing  440  by a hinge or latching system  482 . In the embodiment of FIG. 4, the door  480  is in a closed position, but the door  480  may be selectively placed in an open position. In the embodiment of FIG. 4, the door  480  is held in the closed position by a latch  484 .  
         [0039]    When the door  480  is in the closed position, the storage device interconnect  424  preferably releasably mates with a controller interconnect  406  to form a connection  428 . The controller interconnect  406  is coupled to a controller  404  of the system  400 . As shown in FIG. 4, a plurality of contacts  476  of the storage device interconnect  424  are coupled to a plurality of contacts  475  of the controller interconnect  406 .  
         [0040]    [0040]FIG. 5 is a diagrammatic depiction of a vehicle  586  having a plurality of the wheels  588  and a braking system  500  for slowing and/or stopping the rotation of the wheels  588 . The braking system  500  includes a brake rotor  590  coupled to each wheel  588 . A brake caliper  592  is disposed proximate each brake rotor  590 . Each brake caliper  592  of the braking system  500  is preferably adapted to receive a replaceable media assembly  502 . Each replaceable media assembly  502  includes a replaceable media component  520  and an information storage device  522 . In the embodiment of FIG. 5, each replaceable media component  520  includes a brake pad  596 .  
         [0041]    The braking system  500  of FIG. 5 also includes a controller  504  that is coupled to the information storage device  522  of each replaceable media assembly  502 . The controller  504  is also coupled to a plurality of the brake actuators  594 . Each brake actuator  594  is coupled to a brake caliper  592  by a hydraulic conduit  598 . In a preferred embodiment, the controller  504  may selectively activate each brake actuator  594 . When a brake actuator  594  is activated, it applies pressure to a cylinder of a brake caliper  592  via hydraulic fluid disposed within the hydraulic conduit  598 . When pressure is applied to the brake caliper  592 , the brake rotor  590  disposed proximate the brake caliper  592  will be squeezed between two brake pads  596 . Each brake actuator  594  may be supplied with pressurized hydraulic fluid by a master cylinder (not shown).  
         [0042]    Information is preferably stored in the information storage device  522  of each replaceable media assembly  502 . The information stored in the information storage device  522  may be used by the controller  504  of the braking system  500  to adjust the operation of the braking system  500 . For example, the information stored in the information storage device  522  may relate to the performance characteristics of the brake pad  596  of each replaceable media assembly  502 .  
         [0043]    The information stored in the information storage device  522  may also include a time value that relates to the recommended replacement interval of the replaceable media assembly  502 . When the system  500  receives a replaceable media assembly  502 , the controller  504  may read a serial number stored in the information storage device  522  of the replaceable media assembly  502 . The controller  504  may begin tracking the length of time that the replaceable media assembly  502  is in use. When the replacement interval is reached, the controller  504  of the system  500  may provide a notification to exchange the replaceable media assembly  502  with a new replaceable media assembly. The notification may be, for example, an audible signal and/or a visual signal.  
         [0044]    The manufacturer of the vehicle  586  may also recommend that the brake pads  596  be replaced at a certain mileage interval. When this is the case, the information stored in the information storage device  522  may include a distance value that relates to a recommended replacement interval for the brake pads  596  of the replaceable media assembly  502 . The controller  504  of the system  500  may read the distance value traveled by the vehicle  586  via a wheel rotation sensor  599 . The controller may track the distance that the vehicle  586  travels after the installation of a replaceable media assembly  502  having a particular serial number stored in the information storage device  522  thereof. When the distance traveled exceeds the distance value stored in the information storage device  522 , the braking system  500  may signal a user of the vehicle  586  that each replaceable media assembly  502  including the brake pad  596  should be replaced.  
         [0045]    Having thus described the preferred embodiments of the present invention, those of skill in the art will readily appreciate that yet other embodiments may be made and used within the scope of the claims hereto attached. Numerous advantages of the invention covered by this document have been set forth in the foregoing description. It will be understood, however, that this disclosure is, in many respects, only illustrative. Changes may be made in details, particularly in matters of shape, size, and arrangement of parts without exceeding the scope of the invention. The invention&#39;s scope is, of course, defined in the language in which the appended claims are expressed.