Filter housing having vanes for filter optimization

The present teachings provide for a housing for a panel filter, the housing including a main body, a plurality of first vanes, and a plurality of second vanes. The main body can define a chamber and a central aperture. The central aperture can extend through the main body and can be in fluid communication with the chamber. The plurality of first vanes can be disposed within the chamber and circumferentially spaced about the central aperture. Each first vane can extend radially outward from the central aperture a first distance. The plurality of second vanes can be disposed within the chamber and can be circumferentially spaced about the central aperture. Each second vane can extend radially outward from the central aperture a second distance that is less than the first distance.

FIELD

The present disclosure relates to a filter housing having vanes for filter optimization.

BACKGROUND

Devices that use air for operations typically include an air filtration system to filter intake air before the intake air enters the device. For example, engines typically include an air filtration system to filter dust and debris out of intake air before the intake air reaches the combustion chamber of the engine. Similarly, heating, cooling, and air conditioning (“HVAC”) systems typically include an air filtration system to filter dust and debris out of intake air before the intake air reaches other elements of the HVAC system (e.g. a blower, evaporator, or heater).

Air filtration systems typically include a housing and a filter disposed within the housing. The filter can be a panel type filter that includes a filter element, which is typically constructed of a corrugated or accordion-shaped, porous material (e.g. paper, fiber, foam), and typically has an overall rectangular or square shape. Filter housings that are designed for square or rectangular panel filters typically draw intake air through the filter element and through an aperture or conduit that is downstream of the filter element and has a smaller flow area than the panel filter. The panel filter is supported within the housing such that intake air must pass through the filter element before entering the aperture. The aperture is typically aligned with the center of the filter element and is configured to direct air to the other components of the air filtration system.

Under typical initial operating conditions, more intake air travels through the portion of the filter element aligned with the aperture (e.g. the center of the filter element). Over time, dust and debris can build up on the central portion of the filter element, while significantly less dust and debris builds up around perimeter areas of the filter element. This uneven distribution of dust and debris can lead to less efficient use of the panel filter and can result in replacement of the filter before the entire filter element is used.

SUMMARY

The present teachings provide for a housing for a panel filter, the housing including a main body, a plurality of first vanes, and a plurality of second vanes. The main body can define a chamber and a central aperture. The central aperture can extend through the main body and can be in fluid communication with the chamber. The plurality of first vanes can be disposed within the chamber and circumferentially spaced about the central aperture. Each first vane can extend radially outward from the central aperture a first distance. The plurality of second vanes can be disposed within the chamber and can be circumferentially spaced about the central aperture. Each second vane can extend radially outward from the central aperture a second distance that is less than the first distance.

The present teachings further provide for a housing for a panel filter, the housing including a main body, a plurality of first vanes, and a plurality of second vanes. The main body can include a plurality of side walls and a bottom wall. The side and bottom walls can define a chamber. The bottom wall can define a central aperture that extends through the main body and is in fluid communication with the chamber. The plurality of first vanes can be disposed within the chamber and can be circumferentially spaced about the central aperture. Each first vane can extend radially inward from the side walls to the central aperture. The plurality of second vanes can be disposed circumferentially between a pair of the first vanes. The second vanes can extend radially outward from the central aperture and can terminate radially inward of the side walls.

The present teachings further provide for an HVAC assembly including a housing, a filter, and a blower unit. The housing can define a first chamber, a second chamber, and a central aperture that can fluidly couple the first and second chambers. The housing can include a plurality of first vanes that can be disposed within the first chamber and circumferentially spaced about the central aperture. Each first vane can extend radially outward from the central aperture a first distance. The plurality of second vanes can be disposed within the first chamber and circumferentially spaced about the central aperture. Each second vane can extend radially outward from the central aperture a second distance that is less than the first distance. The filter can be disposed within the housing and upstream of the first chamber. The blower unit can include a fan and an electric motor. The fan can be disposed within the housing and downstream of the central aperture. The electric motor can be drivingly coupled to the fan. The blower unit can be configured to draw air through the filter and into the second chamber.

DETAILED DESCRIPTION

The present teachings are directed to an air intake device having a rectangular panel filter and a housing. The housing includes a plurality of vanes that support the filter above an aperture within the housing. The aperture has a flow area that is less than the flow area of the panel filter. The vanes promote more even flow across the entire area of the panel filter.

With specific reference toFIG. 1, an air intake device10of a representative vehicle14is illustrated. It is understood that the air intake device10can be used in other applications where intake air is drawn through a panel filter besides vehicles. The air intake device10can be any suitable type of air intake device and can include a housing18, a panel filter22, an inlet26and an outlet30. For example, the air intake device10can be a heating, cooling, and air conditioning (“HVAC”) system of the vehicle14. In such an example, the air intake device10can draw intake air, through the inlet26, from inside (e.g. air34) and/or outside (e.g. air38) of the vehicle14. The air can flow through the panel filter22to trap debris (e.g. dust, dirt, allergens, particulate matter). The air intake device10can then heat, cool, and/or otherwise condition the filtered air. The air can then flow from the outlet270to a passenger compartment42of the vehicle14.

In another example, the air intake device10can be a power plant (e.g. internal combustion engine) of the vehicle14. In such an example, the air intake device10can draw intake air, through the inlet26, from outside (e.g. air38) the vehicle14. The air can flow through the panel filter22to trap debris (e.g. dust, dirt, allergens, particulate matter). The intake device10can then use the filtered air to generate propulsive power (e.g. through internal combustion). In such an example, the outlet270(i.e. exhaust) does not expel the used air into the passenger compartment42, but instead can expel the combustion products back outside (e.g. air46) the vehicle14.

With reference toFIGS. 2-5, an example of one type of the air intake device10ofFIG. 1is illustrated in greater detail and indicated by reference numeral210. In the example provided, the air intake device210is an HVAC system and can operate as generally described above with reference to the air intake device10ofFIG. 1. More specifically, the air intake device210can include a panel filter214, a housing218, and a blower unit222.

The panel filter214can be any suitable shaped panel filter. In the example provided, the panel filter214has an outer perimeter234that is a generally rectangular shape, though the panel filter214can be square or another suitable shape (e.g. elliptical, polygonal). The panel filter214can include a filter element238formed of any suitable material (e.g. paper, fibers, foam) such that air can pass through the filter element238and the filter element238can trap debris to prevent debris from passing through the panel filter214. In the example provided, the filter element238has a generally accordion shaped or corrugated construction, though other configurations can be used. The filter element238can have an upstream side242and a downstream side246and the distance between the upstream and downstream sides242,246can be less than the distance between opposite sides of the outer perimeter234. In other words, the thickness of the filter element238can be less than the length and height of the filter element238such that the filter element238generally has a panel shape.

The housing218can include a first shell250, a second shell254, and a cover258. The first and second shells250,254can mate together to define a blower chamber262and a flue266. The flue266can fluidly couple the blower chamber262with an outlet270of the housing218which can be fluidly coupled to the passenger compartment of a vehicle (e.g. passenger compartment42of vehicle14shown inFIG. 1).

The outlet270can fluidly couple the flue266to a heater (not shown). The heater (not shown) can be configured such that the air flowing through the heater from the flue266can absorb heat from the heater (e.g. from a heating fluid or electric heating element in a conventional manner) to raise the temperature of the air before it is expelled to the passenger compartment (e.g. passenger compartment42of vehicle14shown inFIG. 1). The outlet270can also fluidly couple the flue266to an evaporator (not shown). The evaporator can be configured such that the air flowing through from the evaporator can expel heat to the evaporator e.g. to a cooling fluid in a conventional manner). A series of flues (not shown) and flue doors (not shown) can control the amount of air that flows from the outlet270, to the evaporator and/or the heater before exiting to the passenger compartment (e.g. passenger compartment42of vehicle14shown inFIG. 1).

With specific reference toFIG. 4, the first shell250can include a perimeter wall310and a back wall314that define an air chamber318. The first shell250can further include a plurality of vanes322disposed within the air chamber318. The vanes322can be integrally formed with the first shell250. The vanes322will be described in greater detail below. The perimeter wall310can define the perimeter of the air chamber318which can be generally rectangular having a longitudinal side326and a lateral side330that is shorter than the longitudinal side326, though other configurations can be used (e.g. square, polygonal, circular, elliptical). The perimeter wall310can define an outer face334and can define one or more support lips338disposed about the perimeter of the air chamber318and recessed from the outer face334. The shape of the outer perimeter234of the panel filter214can generally correspond to the shape of the perimeter wall310such that the panel filter214can be received within a portion of the perimeter wall310, and such that the outer perimeter234of the panel filter214can be supported above the air chamber318by the support lips338. The panel filter214can form a seal with the perimeter wall310and/or with the support lip338.

The back wall314can generally separate the air chamber318from the blower chamber262and can define an aperture342that fluidly couples the air chamber318to the blower chamber262. The aperture342can be smaller than (i.e. have a smaller area than) the air chamber318. The aperture342can be a round aperture and can be located generally in the center of the back wall314and at the center of the air chamber318and blower chamber262. In the example provided, the aperture342is centered about a flow axis346that extends through the center of the panel filter214. It is appreciated that the aperture342can be other shapes besides round (e.g. square, rectangular, elliptical, polygonal) and can be located offset from the center of the back wall314or the center of the air or blower chambers318,262.

The cover258can include a cap350and a cover body354that defines a cover chamber358and one or more apertures362(which can be fluidly coupled to an inlet similar to inlet26ofFIG. 1). The apertures362can fluidly couple the cover chamber358to the exterior of a vehicle (e.g. air38exterior of vehicle14, shown inFIG. 1) and/or to the passenger compartment of the vehicle (e.g. air34within the passenger compartment42, shown inFIG. 1). The cover body354can be configured to be mounted to the first shell250to oppose the outer face334. The cover body354can be mounted to the first shell250with the panel filter214generally axially between the air chamber318and the cover chamber358such that the upstream side242of the filter element238faces the cover chamber358and the downstream side246faces the air chamber318.

The cover body354can define a filter slot366that can be transverse to the flow axis346of the panel filter214. The panel filter214can be received through the filter slot366to be positioned axially between the cover chamber358and the air chamber318. In the example provided, the cover body354includes a set of shoulders370configured to prevent the panel filter214from moving axially away from the first shell250. The cap350can be removably coupled to the cover body354and configured to close the filter slot366to prevent the panel filter214from being removed through the filter slot366when the cap350is attached to the cover body354.

The blower unit222can be constructed in a conventional manner and can generally include a fan374and an electric motor378. The fan374can be disposed within the blower chamber262. The electric motor378can be drivingly coupled to the fan374to rotate the fan374within the blower chamber262. The fan374can be configured to draw air through the cover chamber358, filter element238, air chamber318, and aperture342and into the blower chamber262when rotated by the electric motor378(i.e. to flow in the direction indicated by arrow382). The fan374can be configured to blow the air from the blower chamber262through the flues266, and out the outlet270to the passenger compartment (e.g. passenger compartment42shown inFIG. 1).

With specific reference toFIG. 5, the plurality of vanes322can include a set of first vanes410and a set of second vanes412. The plurality of vanes322can also include additional sets of vanes, such as sets of third through ninth vanes414,416,418,420,422,424,426, though more or fewer sets of vanes can be used. The first through ninth sets of vanes414,416,418,420,422,424,426can be circumferentially spaced about the aperture342and each of the vanes322can extend radially outward from the aperture342.

The vanes322can be configured such that the distance between adjacent ones of the vanes322increases with increased radial distance from the aperture342. In the example provided, the vanes322are planar or straight and aligned with the center of the aperture342such that each vane322extends longitudinally along a line that intersects the flow axis346. The vanes322can contact with and extend axially outward from the back wall314into the air chamber318. The vanes322can terminate axially such that an edge430(FIG. 4) of each vane322can be generally level with the support lip338such that the vanes322can support the panel filter214axially relative to the air chamber318and spaced apart from the aperture342.

The vanes322can be symmetrically disposed about the flow axis346(i.e. the center of aperture342). The vanes322can be equally spaced apart in the circumferential direction. In the example provided, each quadrant of the air chamber318is symmetrical with respect to the relative locations of the first through ninth vanes414,416,418,420,422,424,426. For example, the air chamber318can be divided into quadrants along the first vanes410and the ninth vanes426. When viewed as shown inFIG. 5, the vanes322can be arranged in each quadrant in the following clockwise order (though other configurations can be used): one of the first vanes410, one of the second vanes412, one of the third vanes414, one of the fourth vanes416, one of the fifth vanes418, one of the sixth vanes420, one of the seventh vanes422, one of the eighth vanes424, and one of the ninth vanes426.

Each of the first through ninth sets of vanes414,416,418,420,422,424,426can extend a respective radial length from the aperture342(i.e. the length of the vane322from the aperture to the radially outermost point of the vane322). The respective radial lengths of the sets of vanes414,416,418,420,422,424,426can be different, though some of the sets of vanes414,416,418,420,422,424,426can have similar radial lengths.

In the example provided, the radial lengths of the second vanes412are similar to that of the eighth vanes424, while the ninth vanes426have radial lengths greater than the second vanes412. In the example provided, the sixth vanes420have greater radial lengths than the ninth vanes426, the fourth vanes416have greater radial lengths than the sixth vanes420, the seventh vanes422have greater radial lengths than the fourth vanes416, the first vanes410have greater radial lengths than the seventh vanes422, the third vanes414have greater radial lengths than the first vanes410, and the fifth vanes418have greater radial lengths than the third vanes414, though other configurations can be used.

In the example provided, the first vanes410, third vanes414, fifth vanes418, seventh vanes422, and ninth vanes426extend fully between the aperture342and the perimeter wall310to contact the perimeter wall310, though other configurations can be used. In the example provided, the first vanes410and third vanes414contact the lateral sides330, the seventh vanes422and ninth vanes426contact the longitudinal sides326, and the fifth vanes418contact the corners of the perimeter wall310where the lateral sides330and the longitudinal sides326meet, though other configurations can be used.

When the blower unit222operates with a relatively clean filter element238, a greater amount of air can be drawn through a center zone510of the air chamber318that corresponds to the location of the aperture342and a similar region (not specifically shown) on the filter element238, since this is the airflow path of least resistance. Accordingly, debris can build up on the filter element238at this center zone510. As debris builds up at the center zone510, the debris can inhibit the flow of air through the center zone510and the pressure at the center zone510can increase.

In conventional filter systems (not shown) the buildup of debris in the center zone510would diminish the airflow through the center zone510and the general area where airflow would be most significant through the filter element238would expand to a first intermediate region that is immediately radially outward of the center zone510. As the first intermediate region then becomes more blocked by debris, the general area where airflow would be most significant through the filter would expand to a second intermediate region that is immediately radially outward of the first intermediate region. In this way, the debris would slowly build up in concentrically expanding regions about the center zone510. Typically, this pattern of buildup can lead to lower performance even while the areas of the filter element238that are nearest to the outer perimeter234remain relatively unused.

Returning toFIG. 5, the vanes322can be arranged to define a first intermediate zone514, a second intermediate zone518and an outer zone522. The first intermediate zone514can be an annular area disposed immediately concentrically about the center zone510. The first intermediate zone514can have an outer diameter that corresponds with the radially outermost edge of one or more of the sets of vanes414,416,418,420,422,424,426. In the example provided, the outer diameter of the first intermediate zone514generally corresponds to the radially outermost edges of the second vanes412and the eighth vanes424. In the example provided, the outer diameter of the first intermediate zone514generally corresponds to halfway between the center zone510and the perimeter wall310.

The second intermediate zone518can be an annular area disposed immediately concentrically about the first intermediate zone514. The second intermediate zone518can have an outer diameter that corresponds with the radially outermost edge of one or more of the sets of vanes414,416,418,420,422,424,426. In the example provided, the diameter of the second intermediate zone518generally corresponds to the radially outermost edges of the fourth vanes416and the sixth vanes420. In the example provided, the second intermediate zone518can generally correspond to halfway between the center zone510and the corners of the air chamber318(i.e. where the lateral sides330meet the longitudinal sides326). The outer zone522can generally be the area of the air chamber318that is radially outward of the second intermediate zone518. The distance between adjacent vanes322in the outer zone522can be greater than the distance between adjacent vanes322in the second intermediate zone518. The distance between adjacent vanes322in the second intermediate zone518can be greater than the distance between adjacent vanes322in the first intermediate zone514, but lesser than the distance between adjacent vanes322in the outer zone522. Thus, the vanes322can define discrete funnels or channels526that widen proximate to the outer perimeter234and narrow proximate to the aperture342.

In operation, as the center zone510builds up debris, air flowing through the filter element238into the air chamber318can encounter slightly greater resistance to flow through the filter element238due to the relative distances between the adjacent vanes322in the respective zones514,518,522. The closer the proximity of adjacent vanes322, the higher the resistance and pressure opposing air flow through the filter element238at the respective zone514,518,522. Thus, the resistance or pressure opposing flow through the filter element238at the second intermediate zone518can be lower than at the first intermediate zone514and higher than at the outer zone522. In other words, the pressure opposing flow through the filter element238can decrease with increased radial distance from the center zone510due to the relative proximity of the adjacent vanes322. Additionally, due to the funnel shape of the vanes322, the velocity of the air flowing radially inward between the vanes322increases with decreased radial distance from the aperture342.

Thus, as the center zone510becomes blocked with debris, a greater amount of air can be drawn through the relatively low pressure areas of the outer zone522and second intermediate zone518than would normally occur in conventional systems. The decreasing pressure gradient from the first intermediate zone514to the outer zone522causes air to be drawn more evenly across the entire surface area of the filter element238than would occur in conventional systems. Thus the vanes322inhibit the pattern of concentrically expanding debris buildup caused by conventional systems. Instead, debris can build up more evenly across the filter element238.