Air cleaner airflow shaper

An airflow shaper for use in an air cleaner is provided according to an embodiment of the invention. The airflow shaper includes a body including a substantially central axis and a raised central region formed on the body. The raised central region transitions an impinging axial airflow into a substantially radial airflow or transitions an impinging radial airflow into a substantially axial airflow.

TECHNICAL FIELD

The present invention relates to an air cleaner, and more particularly, to an air cleaner airflow shaper.

BACKGROUND OF THE INVENTION

Air cleaners and purifiers are widely used for removing foreign substances from the air. The foreign substances can include pollen, dander, smoke, pollutants, dust, etc. In addition, an air cleaner can be used to circulate room air. An air cleaner can be used in many settings, including at home, in offices, etc.

One type of air cleaner is an electrostatic precipitator. An electrostatic precipitator operates by creating an electrical field. Dirt and debris in the air becomes ionized when it is brought into the electrical field by an airflow. Charged positive and negative electrodes in the electrostatic precipitator air cleaner, such as positive and negative plates, attract the ionized dirt and debris. The electrodes can release the dirt and debris when not powered, and the electrostatic precipitator can be removed and cleaned. Because the electrostatic precipitator comprises electrodes or plates through which airflow can easily and quickly pass, only a low amount of energy is required to generate the airflow. As a result, foreign objects in the air can be efficiently and effectively removed without the need for a mechanical filter element.

In the prior art, typically air cleaners are manufactured in a square or cylindrical shape. Such a shape is the easiest and most obvious shape for accommodating a rotating fan unit and rectangular filter elements.

The prior art has several drawbacks. A squarish or cylindrical prior art air cleaner has a relatively large floor footprint for the available air volume and cleaning capacity. The prior art air cleaner is unidirectional, and has to be properly positioned to avoid blocking of inlet and outlet airflow. The prior art tower air cleaner does not uniformly clean or circulate the surrounding room air. A prior art tower air cleaner comprises a squarish or cylindrical air cleaner positioned in a tower structure, wherein an airflow travels laterally and strictly horizontally through the prior art tower air cleaner. A prior art tower air cleaner therefore has a limited air volume capacity and a limited air cleaning capacity.

SUMMARY OF THE INVENTION

An airflow shaper adapted for use in an air cleaner is provided according to an embodiment of the invention. The airflow shaper comprises a body including a substantially central axis and a raised central region formed on the body. The raised central region transitions an impinging axial airflow into a substantially radial airflow or transitions an impinging radial airflow into a substantially axial airflow.

An airflow shaper adapted for use in an air cleaner is provided according to an embodiment of the invention. The airflow shaper comprises a body including a substantially central axis and a raised central region formed on the body. The raised central region is substantially cylindrical. The raised central region transitions an impinging axial airflow into a substantially radial airflow or transitions an impinging radial airflow into a substantially axial airflow.

A tower air cleaner is provided according to an embodiment of the invention. The tower air cleaner comprises a base portion, a tower portion extending substantially vertically above the base portion, an air inlet extending at least partially around a first circumference of the tower portion, an air outlet, an air duct connecting the air inlet to the air outlet and including an inlet end and an outlet end, and at least one airflow shaper positioned in the air duct. The airflow shaper transitions airflow in the tower air cleaner between a substantially vertical airflow and an airflow at an angle less than vertical.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1shows a tower air cleaner100according to an embodiment of the invention. The air cleaner100includes a base portion101and a tower portion102. The tower portion102can be generally vertically positioned and elongate in shape. In one embodiment, the tower portion102can be substantially cylindrical in shape. The tower portion102includes a shell103, one or more doors104, and a control panel110. The tower portion102further includes an air inlet105and an air outlet106. Air is drawn in through the air inlet105, is cleaned inside the tower portion102, and the cleaned air is exhausted from the air outlet106.

In one embodiment, the air outlet106is vertically spaced apart from the air inlet105. Although the airflow apertures of the air inlet105and the air outlet106are shown as comprising vertically oriented apertures, it should be understood that the apertures can be horizontally oriented or can be oriented in any direction. Consequently, airflow travels substantially vertically through the tower air cleaner100when traveling from the air inlet105to the air outlet106. In one embodiment, one or more filter elements are positioned between the air inlet105and the air outlet106. As a result, an airflow traveling from the air inlet105to the air outlet106passes through the one or more filter elements (seeFIG. 2).

The air inlet105is shown as being at the lower end of the tower portion102. However, it should be understood that alternatively the relative positions of the air inlet105and the air outlet106could be swapped.

The figure shows the incoming airflow traveling into the air inlet105and the exhausted cleaned airflow traveling out of the air outlet106. As can be seen from the figure, the inlet airflow traveling into the air inlet105is traveling substantially radially and therefore substantially horizontally. Likewise, the outlet airflow traveling out of the air outlet106can travel substantially radially and therefore substantially horizontally. Alternatively, the airflow can travel at an angle to the horizontal, i.e., the airflow can travel at an at least partially upward angle.

In one embodiment, an inlet airflow traveling into the air inlet105is admitted around substantially 360 degrees of the tower portion102. In one embodiment, an outlet airflow traveling out of the air outlet106is exhausted around substantially 360 degrees of the tower portion102. Because of this feature, the tower air cleaner100can be placed in any location in a room and will still function effectively. As a result, the orientation of the tower air cleaner100is immaterial, as the tower air cleaner100will not need to be turned or positioned in a certain orientation in order to properly drawn in and exhaust the airflow. In addition, the 360 degree airflow feature makes the tower air cleaner100non-susceptible to blocking by nearby objects, walls, etc. Further, the 360 degree airflow feature provides a larger inlet and outlet area, reducing the amount of energy needed to maintain the airflow and reducing noise generated by the tower air cleaner100.

FIG. 2shows internal components of the air cleaner100according to an embodiment of the invention. Elements in common with other figures share reference numbers. The figure shows internal detail of the airflow path of the tower air cleaner100. The tower air cleaner includes an air duct201connecting the air inlet105to the air outlet106. The air duct201includes an inlet end210located adjacent to the air inlet105and includes an outlet end211located adjacent to the air outlet106. The air duct201in one embodiment can accommodate components of the tower air cleaner100. For example, the air duct201can accommodate a filter element203, a filter element204, a filter element205, and an air moving device206(such as a fan unit, for example). The various filter elements203,204, and205can comprise any type of device or apparatus that removes impurities from the air or that otherwise clean the air or add desirable properties or attributes to the air. For example, the various filter elements203,204, and205can physically filter dirt and debris from the airflow. In some embodiments, the filter elements203,204, and205can remove odors from the airflow. In some embodiments, the filter elements203,204, and205can remove Volatile Organic Chemicals (VOCs) from the airflow. In some embodiments, the filter elements203,204, and205can remove ozone from the airflow. In some embodiments, the filter elements203,204, and205can add fragrance or scent to the airflow.

It should be understood that various types, numbers, and configurations of filter elements can be employed. For example, the filter element203can comprise a pre-filter element and the filter element205can comprise a post-filter element.

In one embodiment, the filter element204can comprise an electrostatic precipitator204. The electrostatic precipitator204can comprise an electrostatic precipitator element. Alternatively, the electrostatic precipitator204can comprise an electrostatic precipitator element and a pre-ionizer, for example.

As can be seen from this figure, the air inlet105and the air outlet106in the embodiment shown comprise a plurality of airflow apertures212in the shell103of the tower portion102. An airflow aperture212can comprise any desired aperture shape that allows airflow to pass through, such as a slot aperture (shown), circular, rectangular, irregular, etc.

The air duct201in one embodiment includes an airflow shaper207located at the air outlet end211of the air duct201. The airflow shaper207smoothly transitions the substantially cleaned, substantially vertical airflow into an airflow at an angle less than vertical, such as a substantially horizontal exhaust airflow or an angled airflow between vertical and horizontal. The airflow shaper207accomplishes the transition with a minimum of airflow turbulence in order to minimize the energy needed to create and sustain the airflow and in order to minimize noise generated by the tower air cleaner100.

FIG. 3shows an airflow shaper207according to an embodiment of the invention. The airflow shaper207comprises a base301and a raised central region302. The raised central region302in one embodiment is substantially symmetrically formed about a central axis BB. In one embodiment, the base301includes a radius R that corresponds to a cross-sectional shape of the air duct201(seeFIG. 4B). Alternatively, in another embodiment the body301can be oval, rectangular, etc., and can include other features, such as mounting devices, etc.

In one embodiment, the airflow shaper207transitions from a large circular dimension to a smaller circular dimension, as shown (see alsoFIG. 4A). However, it should be understood that other shapes are contemplated for the airflow shaper207and are within the scope of the description and claims (for example, seeFIGS. 4B-4C).

FIG. 4Ashows the airflow shaper207according to an embodiment of the invention. In this embodiment, the raised central region302comprises curved sides ending in a substantially cylindrical shape. The raised central region302can transition an impinging axial airflow A1into a substantially radial airflow A2or impinging radial airflow A3into a substantially axial airflow A4. This shape can reduce or eliminate recirculation of air above the air moving device206. Consequently, the airflow shaper207can be used at the outlet end211of the air duct201.

The raised central region302can substantially match up to the air moving device206(seeFIGS. 6-7). The raised central region302therefore substantially matches an exterior profile of the air moving device206. In addition, the transition of the outer surface of the airflow shaper207to a corresponding outer surface of a motor or motor mount ring220is substantially smooth and uninterrupted. As a result, the transition between components generates a minimum of disruption in the airflow.

The airflow shaper207can include a flange303that interacts with and fits to a frame portion. As a result, in some embodiments the flange303operates to hold the airflow shaper207in place.

The airflow shaper207can include an ionizer cut-out310. The ionizer cut-out310receives an ionizer element (not shown). The ionizer cut-out310is further shown and discussed inFIG. 7.

The airflow shaper207can include a plurality of vent apertures312. The vent apertures312can permit a cooling airflow to pass through the airflow shaper207, such as for the motor of the air moving device206.

The airflow shaper207can include outer projections315. The outer projections315can comprise ribs or other projections that extend axially along an outer surface of the raised central region302. The outer projections315can provide a stiffening effect to the raised central region302. The outer projections315can provide a stop against which a motor mount ring220can rest (seeFIGS. 6-7). Consequently, the outer projections315can include mount ring gaps316that allow the motor mount ring220to slip over the corresponding bottom portion of the raised central region302. Further, the outer projections315can act like vanes and can provide at least a small straightening effect to airflow from the air moving unit206.

The airflow shaper207can include inner projections318. The inner projections318can comprise ribs or other projections that extend axially along an inner surface of the raised central region302. The inner projections318can provide a stiffening effect to the airflow shaper207.

The airflow shaper207can include fastener apertures319. The fastener apertures319can receive any manner of fasteners. The fastener apertures319enable the motor or the motor mount ring220to be attached to the airflow shaper207.

The airflow shaper207can include cut-outs323. The cut-outs323are formed in a bottom edge of the raised central region302. The cut-outs323can mate with corresponding features of the motor or the motor mount ring220, for example. Alternatively, the cut-outs323can receive any manner of motor mount feature/fastener system240that affixes the motor mount ring220to the motor (seeFIG. 6).

The airflow shaper207can include a wiring channel326. The wiring channel326can fit to an interior surface of the shell103of the air cleaner100. Any manner of wires or wiring harnesses can extend through the wiring channel326.

FIG. 4Bshows an alternative airflow shaper207according to an embodiment of the invention. In the embodiment ofFIG. 4B, the raised central region302comprises a rounded, blended, or rounded and blended conical shape that is formed on the base301. The raised central region302can comprise a substantially bell curve shape in cross-section.

FIG. 4Cshows another alternative airflow shaper207according to an embodiment of the invention. In the embodiment ofFIG. 4C, the raised central region302comprises a substantially curved conical shape formed on the base301, including a sharp transition region304and an apex305. This shape can keep all airflow velocities substantially equal as they are transitioned by the airflow shaper207. Alternatively, the raised central region302can comprise any manner of curves and straight lines, including a rounded transition region304, a rounded apex305, etc.

FIG. 5is another view of the airflow shaper ofFIG. 4A. The airflow shaper207additionally includes two or more fastener stand-offs334and two or more attachment features331. The top region of the airflow shaper207can receive a cap340(seeFIG. 7). The cap340can be attached to the airflow shaper207by two or more fasteners that engage the two or more fastener stand-offs334.

The two or more attachment features331can receive structural members that attach other air cleaner components to the airflow shaper207. Therefore, the two or more attachment features331can receive any manner of fastener or fastener system. Alternatively, structural members can directly engage the two or more attachment features331.

FIG. 6shows the air moving unit206mated to the airflow shaper207according to an embodiment of the invention. The air moving unit206includes a motor (not visible), an impeller222, and a motor mount ring220. It can be seen from this figure that the airflow shaper207fits substantially smoothly and continuously to the air moving unit206. As previously discussed, the motor mount ring220fits over a portion of the raised central region302of the airflow shaper207. The motor mount ring220can include projections225that substantially match up with the outer projections315of the airflow shaper207. In addition, the impeller222fits substantially smoothly and continuously to the motor mounting ring220.

In the figure, one motor mounting feature240can be seen. The motor can include a plurality of motor mounting features240. The motor mounting feature240extends from the motor and passes through the cut-out323of the airflow shaper207. In one embodiment, the motor mounting feature240receives a fastener that affixes the motor to the airflow shaper207.

FIG. 7shows the combined airflow shaper207and air moving unit206from above. The airflow shaper207in one embodiment includes a cap340. The cap340includes fastener features341that receive fasteners (not shown) which engage the fastener stand-offs334in the airflow shaper207(seeFIG. 5). The cap340further includes attachment feature apertures343that receive the attachment features331. The cap340further includes a motor wire slot349that enables motor wires to pass up through the airflow shaper207, through the cap340, and upwards to the control panel110(seeFIG. 1).

The cap340further includes an ionizer receptacle348that receives and holds an ionizer element (not shown). The ionizer receptacle348in the embodiment shown includes a receptacle dimple347. As a result, the ionizer element extends downward through the ionizer cut-out310of the airflow shaper207and into the airflow.

The cap340further includes an ionizer module receptacle345that receives an ionizer module (not shown). The ionizer module can comprise circuitry for powering the ionizer element, for example. The ionizer module can fit into the ionizer module receptacle345and is retained therein. Consequently, the ionizer module receptacle345can receive the ionizer module with a friction fit, can hold the ionizer module under a tab or other spring member, etc.

FIGS. 8A-8Bshow cross-sectional shapes of an airflow aperture bar801included in the airflow inlet105and the airflow outlet106. The airflow inlet105and the airflow outlet106can each include a plurality of airflow apertures, such as slots, that are separated by a plurality of airflow aperture bars801. The airflow aperture bar801is a sectional shape taken from the section view CC ofFIG. 1.

InFIG. 8A, a conventional square or rectangular airflow aperture bar801ais shown. This is typically an easy shape to manufacture, and is therefore a default shape in the prior art.

InFIG. 8B, an airfoil-shaped airflow aperture bar801bis shown. The airfoil-shaped airflow aperture bar801bpresents less aerodynamic drag to both the inlet airflow and the outlet airflow. The airfoil-shaped airflow aperture bar801btherefore creates less drag and increases the airflow velocity. In addition, the airfoil-shaped airflow aperture bar801bcan create less turbulence (and noise) in the airflow.

The tower air cleaner according the invention can be implemented according to any of the embodiments in order to obtain several advantages, if desired. The invention can provide an effective and efficient tower type air cleaner device. Advantageously, the footprint of the tower air cleaner is relatively small in relation to the air volume cleaning capacity, allowing for placement of a highly efficient air cleaner in a small space. In addition, the tower air cleaner admits and exhausts air substantially around a circumference of the tower portion. Because of this feature, the tower air cleaner can be placed in any location in a room and will function effectively. In addition, the orientation of the tower air cleaner is immaterial, as the tower air cleaner will not need to be turned or positioned in a certain orientation in order to properly drawn in and exhaust the airflow. The 360 degree airflow feature makes the tower air cleaner non-susceptible to blocking by nearby objects, walls, etc. In addition, the 360 degree airflow feature provides a larger inlet and outlet area, reducing the amount of energy needed to maintain the airflow and reducing noise generated by the tower air cleaner.