Magnetic filter fastener

A fastener for removably securing sheeting to a support surface, such as an HVAC system or other device. The fastener includes a base, a rare-earth magnet to removably couple the base to the support surface, the rare-earth magnet having an epoxy coating and being capable of securing the base to a pre-selected location on the support surface, and a locking member pivotably coupled to the base and adjustable between a selectable first position and a second position, and wherein the locking member remains in the selected position unless acted upon by a user.

BACKGROUND

The present disclosure relates to filter fasteners, and more specifically to a filter fastener that may be mounted in multiple orientations.

In industrial or commercial setting, air intakes, HVAC units and other forms of industrial equipment are often located in hostile environments which allow airborne particles and debris to enter sensitive equipment and cause loss of efficiency or equipment breakdown. Intake screens or filters are used to filter out that debris or particulate before it can gain entrance to the equipment. Because of the wide variety of equipment types, there are various orientations and configurations which must be considered. Additionally because of the variety of physical locations where equipment is located or used, the screens or filters should be easy to install, remove and replace. It would be helpful for the mounting fasteners to be useable in a wide range or variously configured and oriented intakes. Current fastener designs must generally be mounted by drilling into equipment, risking puncture of cooling coils and release of refrigerant gases into the atmosphere. Other mounting options such as pulleys or sliding loops must also include modification to the equipment surface. Furthermore, due to the hostile environments in which the screens and filters are positioned, delicate rare earth magnets, which are able to provide high magnetic coupling strength, easily corrode limiting their useful life.

SUMMARY

In one aspect, a fastener for removably securing sheeting to a support surface, including a rare-earth magnet to removably couple the base to the support surface, the rare-earth magnet having an epoxy coating and being capable of securing the base to a pre-selected location on the support surface, and a locking member pivotably coupled to the base and adjustable between a selectable first position and a second position, and wherein the locking member remains in the selected position unless acted upon by a user.

In another aspect, a fastener for removably securing sheeting to a support surface, including a base having a mounting shaft extending therefrom, where the mounting shaft defines a slot having a first width, a coupling member to removably couple the base to the support surface, and a locking member pivotably coupled to the base and at least partially positioned within the slot, the locking member being pivotable with respect to the base into different selected orientations with respect thereto, where the first width of the slot is such that the slot creates a frictional force against the locking member sufficient to maintain the locking member in its selected orientation with respect to the base regardless of the force of gravity.

In still another aspect, a fastener for removably securing sheeting to a support surface, including a base having a mounting shaft extending therefrom, the mounting shaft defining a slot having a first width, a rare-earth magnet to removably couple the base to the support surface, the rare-earth magnet having an epoxy coating and being capable of securing the base to a pre-selected location on the support surface, and a locking member pivotably coupled to the base and at least partially positioned within the slot, the locking member being pivotable with respect to the base into different selected orientations with respect thereto, where the first width of the slot is such that the slot creates a frictional force against the locking member sufficient to maintain the locking member in its selected orientation unless acted upon by a user.

DETAILED DESCRIPTION

Before any embodiments of the disclosure are explained in detail, it is to be understood that the disclosure is not limited in its application to the details of the formation and arrangement of components set forth in the following description or illustrated in the accompanying drawings. The disclosure is capable of supporting other implementations and of being practiced or of being carried out in various ways.

FIGS. 1, 2 and 4-7generally illustrate a filter fastener10of the present invention. The filter fastener10is generally utilized, in combination with other filter fasteners10, to secure sheeting14to a support surface18. For the purposes of this application, sheeting14may include, but is not limited to filters, screens, coiled blankets, solid blockers, tarps, shrouds, and other forms of sheeting material. More specifically, the filter fastener10may be used to position the sheeting14over the air intake of an industrial device, such as an HVAC system and the like (FIG. 2). In the illustrated construction, the sheeting14includes filter material22to remove particulates from the air passing therethrough, edging26at least partially supporting the filter material22, and a plurality of mounting apertures32(FIG. 3). In the illustrated construction, the mounting apertures32are circular in shape defining a first inner diameter36. However, in alternative constructions, the mounting apertures32may include different sizes or shapes as necessary. In still other constructions, the sheeting14may include any form that is well known in the art.

Illustrated inFIGS. 1 and 4-7, the filter fastener10of the present invention includes a base40, a coupling member44coupled to the base40, and a locking member48pivotably coupled to the base40. During use, each filter fastener10is configured to be removably coupled to both a corresponding one of the mounting apertures32of the sheeting14and the support surface18.

Illustrated inFIGS. 1 and 4-7, the base40of the filter fastener10includes a bottom52and a mounting shaft56extending perpendicularly from the bottom52having a distal end60. The bottom52of the base40may be substantially rectangular in shape, having an upper surface64, a bottom surface68opposite the upper surface64, and defining a pair of apertures72therethrough. When the filter fastener10is assembled, each aperture72is sized to receive a respective rivet, screw or other mechanical fastener76therein. In the illustrated construction, each aperture72is countersunk to permit the fastener76to remain flush with the upper surface64of the bottom52.

The mounting shaft56of the base40extends substantially perpendicular from the upper surface64of the bottom52. The mounting shaft56passes through a corresponding mounting aperture32of the sheeting14to be mounted to support surface18. The mounting shaft56may be substantially cylindrical in shape, having an outer annular surface80that defines a second diameter84and longitudinal axis88therethrough. The mounting shaft56also defines a cylindrically-shaped radial periphery92, with the same second diameter84of the mounting shaft but also projecting axially beyond the shaft56. The second diameter84of the shaft56is sized to be received within a corresponding mounting aperture32of the sheeting14. In the illustrated construction, the mounting shaft56is cylindrical, however in alternative constructions, different shapes or cross-sections for both the shaft56and for periphery92may be utilized as necessary to accommodate the fastening requirements of the corresponding sheeting14.

The mounting shaft56also defines a slot96, originating at the distal end60of the shaft56and extending axially downwardly toward the base40. The slot96also generally extends radially through both sides of the outer annular surface80and is open axially through the distal end60to form two substantially planar interior surfaces in contact with the sides124,128of the locking member48. In the illustrated construction, the slot96extends almost the entire axial length of the mounting shaft56. The width100of the slot96is sized to permit at least a portion of the locking member48to be positioned therein. More specifically, the width100of the slot96is sized such that the locking member48is able to move (i.e., rotate) within the slot96, but the slot96provides sufficient frictional force against the sides124,128(described below) of the locking member48such that the locking member48will remain in its manually set rotational position regardless of the orientation of the base40. Stated differently, the planar interior surfaces of the slot96provides sufficient frictional force against the sides124,128of the locking member48so that, regardless of the orientation of the base40with respect to vertical, the locking member48will not rotate with respect to the base40unless acted upon by an exterior force other than gravity (i.e., the user). In alternative constructions, the slot96may include a detent (not shown), surface texture, ridges, or other forms of locking element to secure the locking member48in its rotational position regardless of the orientation of the base40with respect to vertical. In still other constructions, the slot96may include detents, surfaces textures, ridges, or other forms of locking element to secure the locking member48in any one of a plurality of pre-determined rotational positions regardless of the orientation of the base40with respect to vertical.

The mounting shaft56also defines a shaft pivot aperture104extending radially inwardly from the outer annular surface80and sized to receive at least a portion of a dowel pin108therein. In the illustrated construction, the shaft pivot aperture104is a blind hole, being open on only one side (FIG. 7); however in alternative constructions, the shaft pivot aperture104may extend through the entire diameter of the mounting shaft56. In the illustrated construction (FIG. 7), the shaft pivot aperture104is positioned such that it extends perpendicularly through the slot96, being in communication therewith.

The dowel pin108is at least partially positioned within the shaft pivot aperture104and configured to act as an axis of rotation for the locking member48. The dowel pin108is substantially cylindrical in shape, having an outer diameter corresponding to both the size of the shaft pivot aperture104of the mounting shaft56and the size of the locking pivot aperture112in the locking member48(described below). When the filter fastener10is assembled, the dowel pin108is pressed into the shaft pivot aperture104of the mounting shaft56, allowing the locking member48to pivot about the dowel pin's axis116. In alternative constructions, the dowel pin108may include a polygonal cross-section (i.e., an octagonal-prism shape, and the like) where each flat surface acts as an indexing position for the locking member48, allowing the locking member to remain in a particular indexing position regardless of the orientation of the base40with respect to vertical or the force of gravity.

Illustrated inFIGS. 5-7, the coupling member44of the filter fastener10is coupled to the bottom surface68of the base40by a pair of fasteners76and includes a contact surface120configured to contact the support surface18, which is for example an air intake surface. Preferably, the coupling member44has sufficient contact surface area, weight, or holding power to maintain its location with respect to the support surface18, taking into account the weight and forces being applied to the sheeting14during use. While not shown, the coupling member44may also include a rubber or other coating placed on the contact surface120to increase the friction formed with the support surface18and minimize any slippage that may occur. In still other constructions, the contact surface120of the coupling member44may include a texture formed therein. In instances where the coupling member44is intended to be attached to curved surfaces, the contact surface120may be contoured to match the same. In alternative constructions, the coupling member44may include Velcro, suction cups, adhesive strips and the like.

In the illustrated construction, the coupling member44includes a rare-earth magnet (e.g., a neodymium magnet or samarium-cobalt magnet) riveted to the bottom surface68of the base40. To protect the magnet in outdoor conditions, the magnet is also coated by epoxy, which helps shield the magnet from the elements and corrosion, providing a longer lifetime than that of an untreated magnet, while also minimizing any interference with the magnetic field. In alternative constructions, the magnet may be coated by different materials such as rubber, plastic, gold, zinc, and the like.

Illustrated inFIGS. 1 and 4-7, the locking member48of the filter fastener10is an elongated plate having a first surface or side124, a second surface or side128spaced a distance from the first surface124, a first end132, and a second end138opposite the first end132. The locking member48also defines an elongated axis140extending therethrough (FIGS. 5-6). The distance between the first and second surfaces124,128generally defines the thickness144of the locking member48. The thickness144of the locking member48must be sufficiently large so as to provide the necessary structural strength to secure the sheeting14in place while also being properly sized so as to fit within and frictionally engage the slot96of the mounting shaft56. Specifically, the level of frictional force exerted between the locking member48and the slot96at least partially dictates the level of force that must be applied to the locking member48to rotate it with respect to the slot96. Generally speaking, the greater the frictional force between the locking member48and the slot96, the greater the required force to rotate the locking member48. In the illustrated construction, both the first and second surfaces124,128are substantially planar; however in alternative constructions, the surfaces124,128may include grooves, knurling, detents, or other textures to increase the frictional forces between the locking member48and the base40. Furthermore, the width148of the locking member48is substantially equal to the second diameter84of the mounting shaft56.

The first end132of the locking member48is substantially rounded, having a constant radius to provide a substantially semi-circular edge. The first end132of the locking member48is configured to act as a leading edge, being shaped such that the locking member48can be easily aligned with and pass through the corresponding mounting aperture32of the sheeting14. In alternative constructions, the first end132may be blunt, or may include a more pointed contour to allow the first end132to physically pierce through items (not shown).

The second end138of the locking member48is asymmetrical having a large radius152extending along one side. The radius152is positioned such that, when the locking member48is installed in the slot96of the mounting shaft56in a first position (FIG. 6, described below), the locking member48can rotate in a first direction156but not in a second direction160. More specifically, the radius152of the second end138is shaped such that the radius152will clear the bottom end164of the slot96when the locking member48is rotated about dowel pin108in the first direction156. However, the second end138will contact the bottom end164of the slot96, restricting the rotation of the locking member48, if the locking member is rotated in the second direction160. In alternative constructions, the second end138may include a pair of radii (not shown) to permit the locking member48to rotate in either direction when installed in the mounting shaft56in the first position. In the illustrated construction, the locking pivoting aperture112for dowel pin108is off-center, being positioned closer to the second end138of the locking member48than the first end132. In alternative constructions, the locking pivot aperture112may be positioned in a more central location (not shown)

During use, the locking member48of the filter fastener10is at least partially positioned within the slot96of the mounting shaft56and rotatable about the axis116of the dowel pin108between a first position (FIG. 6), and a second position (FIG. 5), and one or more intermediate positions therebetween. The locking member48is installed in the slot96such that it will remain in its selected position unless acted upon by a user and regardless of the orientation of the base with respect to vertical. Furthermore, the locking member48will remain in its selected position regardless the force of gravity. In the present application, regardless the force of gravity generally signifies that the locking member48will not move or pivot with respect to the base40under the force of gravity, regardless of the orientation at which the gravitational force is applied to the locking member48.

When the locking member48is in the first position, the elongate axis140of the locking member48is substantially aligned with the axis88of the mounting shaft56. In such an orientation, the first end132of the locking member48extends beyond the distal end60of the mounting shaft56to form the tip of the fastener10(FIG. 6). Furthermore, when the locking member48is in the first position, no portion of the locking member48extends outside the radial periphery92of the shaft56.

Contrarily, when the locking member48is in the second position, the elongate axis140of the locking member48does not align with the axis88of the mounting shaft56and at least a portion of the locking member48extends outside the radial periphery92of the shaft56. In the illustrated construction, both the first end132and the second end138of the locking member48extend outside the radial periphery92of the shaft56when the locking member48is in the second position. More specifically, the first end132and the second end138extend beyond the periphery92of the shaft56to create a locking distance (i.e., the distance between the first end132and the second end138measured perpendicularly to the axis88) that is greater than the first inner diameter36of the mounting apertures32of the sheeting14.

FIG. 8illustrates an adapter plate168for use with the filter fastener10. The adapter plate168is configured to be positioned between and coupled to both the support surface18and the filter fastener10in instances where the coupling member44may not be couplable to the support surface18directly (e.g., a magnetic coupling member44and a non-ferrous support surface18). More specifically, the adapter plate168includes a first interface172configured to be couplable to the support surface18, and a second interface176opposite the first interface172configured to be couplable with the coupling member44of the filter fastener10. In the illustrated construction, the adapter plate168is a metallic plate with an adhesive applied to a surface182. As such, the adhesive provides the first interface172that is couplable to non-ferrous support surfaces while the metallic plate provides a second interface176compatible with a magnetic coupling member44(i.e., a rare earth magnet). In still other embodiments, the adapter plate168may include any combination of coupling types (e.g., different types of adhesives, Velcro, magnets, hooks, clips, apertures, protrusions, and the like) applied to the first and second interfaces172,176to accommodate the mounting type of the support surface18and the type of coupling member44coupled to the filter fastener10.

To secure a sheeting14on a support surface18, the user first obtains the desired number of filter fasteners, typically one filter fastener10for each mounting aperture32in the sheeting14. The user then aligns a filter fastener10with a corresponding mounting aperture32in the sheeting14(FIG. 2). To do so, the user first rotates each locking member48into the first position (FIG. 6). With the locking member48in position, the user then axially aligns and inserts the mounting shaft56into the corresponding mounting aperture32allowing the curvature of the first end132to help aid alignment and insertion. Once the mounting shaft56is completely inserted, the user may then rotate the locking member48with respect to the mounting shaft56from the first position to the second position (FIG. 5). By rotating the locking member48, both the first end132and the second end138of the locking member48extend beyond the radial periphery92of the shaft56and create a locking distance that is greater than the first inner diameter36of the mounting aperture32. As such, the mounting aperture32cannot be axially removed inadvertently from the shaft56. The user then repeats the preceding steps for each remaining filter fastener10and mounting aperture32.

With all the filter fasteners10in place, the user may then anchor the sheeting14to the support surface18by placing the contact surface120of each coupling member44of the filter fasteners10in contact with the support surface18. The collective holding power of the coupling members44then maintain the position of the sheeting14on the support surface18.

Typically, once the filter fasteners are anchored to the support surface, the filter fasteners do not need to be moved, although that is easily accomplished when the coupling members44are magnetic. To remove or replace the sheeting14, the user first rotates the locking member48from the second position (FIG. 5) to the first position (FIG. 6), thereby causing the locking member48to be positioned inside the radial periphery92of the shaft56and also within the inner diameter36of the mounting aperture32. As a result, the locking distance becomes effectively zero and the shaft56may then be axially removed from the mounting aperture32.