Track and fastener assembly, kit and method for securing a filter screen or covering to an air intake face

A kit and assembly for securing any filter, screen or covering to a perimeter intake face surrounding an opening. The kit and assembly includes a series of tracks adapted to mount against the intake face in surrounding fashion around the opening. A plurality of fasteners are slidably installed upon each of the tracks prior to inter-assembly. The tracks further include opposite exterior rail locations which oppose tabs configured into interior facing locations of the fasteners so that the fasteners are adjustable along the tracks. The filter, screen or covering further includes a plurality of perimeter spaced apertures for securing to engaging portions of the fasteners and in order to mount the filter, screen or covering to the intake face.

FIELD OF THE INVENTION

The present invention relates generally to filtration assembly kits for covering an air intake face. More specifically, the present invention discloses a kit and assembly for securing any filter, screen or covering to a perimeter intake face surrounding an opening. The kit includes a series of mounting tracks with corner or T connectors for mounting flush against the intake face surrounding an opening. A plurality of fasteners install upon each of the tracks along opposite exterior side rail locations and are adjustable along the lengths of the tracks. The filter, screen or covering includes a plurality of perimeter spaced apertures, such as which can incorporate a reinforced edging containing any type of grommets for securing the screen or covering to each of the pre-positioned fasteners and in order to mount the covering to the intake face.

DESCRIPTION OF THE BACKGROUND ART

The prior art is documented with various examples of assemblies, kits and methods for assembling a filter, cover or the like over an air intake opening. As is further known, filter installations tend to exert increasing load (also identified as resistance to passage of airflow through the filter) resulting from the progressive aggregation of contaminates entrapped by the filter positioned over the air intake opening. In particular instances in which the filter edges are not secured flush to the intake face, this results in progressive intake/admittance of bypass air and contaminates around the edges of the filter.

Examples of existing filter screen assemblies are disclosed in each of Simmons U.S. Pat. Nos. 9,561,456, 9,827,521, 9,827,522, 10,040,149. In each of the above instances, the kit and assembly of Simmons disclose a fastening system for applying, over an opening and surrounding fascia of a structure, a covering material including either of a flexible or rigid outer reinforced extending perimeter, within which is configured a plurality of receiving apertures. A plurality of elongated rails are adapted to being secured to the fascia in extending fashion proximate the opening, with each of the rails exhibiting a three dimensional cross sectional shape with a forwardly projecting support surface within which is configured an outwardly facing narrowed slot.

A plurality of fasteners each include a planar shaped base installable through an accessible end location of each of the rails so as to be traversable along an interior channel defined in the rail. A further rotatable portion of each fastener projects from the insertable base through the outwardly facing slot and in order to be rotated from a first position aligning with and seating over perimeter defined receiving apertures of the covering material to a second position in order to affix the material.

Also disclosed is the Deltrian Pro Safe Screen which depicts a four-sided track, upon which are arranged a plurality of exterior adjustable fasteners or cars having rotatable twist lock portions for retaining edge locations of the screen. Of note, the adjustable fasteners slidably engage along underside locations of each of the interconnected tracks which are spaced upwardly from the intake surface, such that only the individual corner locations of each track section is directly mounted to the intake surface.

SUMMARY OF THE PRESENT INVENTION

The present invention seeks to provide an improved kit and assembly for securing any filter, screen or covering to a perimeter intake face surrounding an opening, and in which an arrangement of end-to-end interconnected tracks are adapted to mount flush against the intake face in surrounding fashion around the opening, thereby avoiding side admittance of particles or other contaminants from bypassing the filter or screen covering, and as the load exerted on the progressively contaminated filter screen applied over the intake opening reaches the point in which the intake airflow begins to bypass the screen around its outer perimeter edges. The invention includes a plurality of fasteners (such as without limitation any of twist lock or toggle lock fasteners) slidably installed over an exterior of each of the tracks prior to inter-assembly, and as opposed to being interiorly installed in prior art filter screen assemblies and in which their rotatable portions project upwardly through elongated slots formed in the tracks (this again shown in varying example in each of Simmons U.S. Pat. Nos. 9,561,456, 9,827,521, 9,827,522, 10,040,149).

The configuration of the tracks in the present design further include opposite side exterior rail locations which oppose tabs configured into interior facing locations of the fasteners so that the fasteners are adjusted along the opposite sides of the tracks, thereby permitting the underside of each track section to be flush mounted to the intake surface. The filter, screen or covering further includes a plurality of perimeter spaced apertures for securing to upward projecting and engaging portions of the fasteners, upon pre-positioning each of the fasteners and aligning locations along the tracks, this in order to mount the filter, screen or covering to the intake face in extending fashion over the intake opening.

Additional features include the rail locations in the tracks extending along opposite side edges. The tracks each further include a base surface flush mounting to the intake face. A linear recess notch is configured in a top of each of the track sections for seating a mating interior projection configured upon a roof underside of each of the fasteners.

A plurality of corner connectors are provided for interconnecting opposing ends of each of the tracks. The corner connectors each include an “L” shaped body having first and second receiving pockets, each of the track sections further including a rectangular extending tongue dimensioned to resistively fit within the receiving pockets configured into each of the corner connectors.

The filter, screen or covering further includes a reinforced location established around an outer edge perimeter and further including any of a ring or grommet for defining each of the perimeter spaced apertures. The engaging portion of each of the fasteners further include any of twist lock or toggle lock portions. A plurality of intermediate “T” shaped connectors are provided for interconnecting opposing intermediate ends of each of horizontal and vertical extending sections of the tracks.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

With reference toFIG.1of the attached drawings, the present invention discloses a kit and assembly for surface mounting a perimeter defining track flush against an intake face surrounding an intake opening. The present invention further seeks to overcome the deficiencies in the prior art, and by which the progressive fouling of an intake screen or filter covering (also termed as a load exerted on the filter) will cause a path of least resistance to, in response to such fouling, draw air through any gap existing between the intake surface surrounding the opening and the perimeter mounted track, thereby bypassing the screen.

As will be individually described in further detail, the kit includes each of an attachable screen, filter or other covering (in each instance depicted at10). A plurality of elongated tracks are provided as shown at12,14,16and18for establishing a perimeter defining arrangement assembly and for flush mounting against the intake face via the use of any suitable fasteners including screws or adhesives.

Other kit components include corner connectors20(typically four) for engaging ends of the track sections to define a closed perimeter frame of the assembled track when secured upon the intake face. Finally, a plurality of fasteners22are provided and which, as will be further described, each include a lower car portions which slidably install over the ends of the individual track sections12-18, prior to assembly of the corner connectors20) and so that the fasteners are linearly adjustable along opposite exterior side rails configured in the tracks to aligning positions allowing for upward extending portions (such as without limitation twist or toggle lock portions) for engaging through perimeter defined grommets or the like for retaining the screen. Each of the track sections, corner connectors and exterior slide on fasteners are constructed of any suitable material not limited to metal or durable polymer. The screen or covering can further include any flexible material not limited to a mesh, fabric or the like.

FIG.2is an exploded view illustrating a rectangular frame construction dimensioned to cover an intake opening of an air handling unit (not shown) and once secured to the intake face. The frame includes both longer sections of track (again at12and14) defining top and bottom of the frame, and shorter sections of track (again at16and18) defining first and second sides. Without limitation, the track sections12-18can be mounted to the intake face of the equipment using any of screws, adhesives (such as peel and stick), or magnets.FIG.2also depicts the corner connector and fasteners ofFIG.1in arrayed fashion prior to assembling to the intake face.

FIG.2Ais an alternated exploded view toFIG.2and depicting a variant of the kit incorporating intermediate “T” type connectors21positioned along with subdivided lengths of the upper12and lower14extending track sections, these along with an intermediate vertical extending track section17for providing additional filter/covering support. The “T” connectors21are otherwise similar in construction as the corner connectors20and provide additional intermediate interior support to the associated filter or covering10.

FIG.3depicts the screen or covering10in an intermediate attached configuration to the frame construction inFIG.2. In this depiction, the individual fasteners22are positioned so that projecting twist or toggle lock portions (see twist lock version depicted at24also inFIG.7et seq.) and which are inserted through any type reinforced location established around an outer edge perimeter of the cover or screen, these further defining any of a ring, grommet or the like (see at26) at spaced apart locations around the outer perimeter of the covering10.FIG.4is a succeeding illustration toFIG.3and depicting the screen completely attached to the frame construction. Beyond that shown, it is understood that the arrangement of the linearly adjustable fasteners22upon the track sections12-18, as well as the configuration of the reinforcing edge defined rings or grommets26, can be modified from that shown to accommodate any desired mounting arrangement and can include relocating at any point from the respective corner locations of the screen and frame.

Proceeding toFIG.5, an exploded perspective is shown of a first non-limiting configuration of surface mounting track and corner connectors according to an embodiment of the present invention for establishing a flush mount against the intake surface. The corner connectors area again as shown at20inFIGS.1-4, with each including an “L” shaped body having first and second receiving pockets (see rectangular shaped pocket shaped profiles at28and30corresponding to first and second angled sides).

The flush mount track sections12-18can be shaped according to any modified cross sectional configuration and, as shown inFIG.5, are depicted by corner connecting lengths of track sections at12′ and18′. Each of the track sections includes a rectangular extending tongue or projection end portion (see tongue at32for reconfigured track shown at12′ and further by tongue34for reconfigured track14′), and which are dimensioned to resistively fit within reciprocal mating the receiving pockets28and30configured into the corner connector. Alternatively, any of adhesives or mechanical fasteners can be employed for engaging the ends of the track sections into the corner connectors and the present invention further envisions a reciprocal arrangement by which the corner connectors can be redesigned to exhibit similar shaped projecting tongues for seating within mating recesses which can be designed into the ends of further redesigned track sections.

FIG.5Ais a related exploded perspective toFIG.5according to a second non-limiting configuration of the surface mounting track sections12-18and corner connectors20, and in which the tongue portions32are relocated to extend instead from the corner connector20. As further shown, the recess28originally shown as interior pockets in the corner connector20ofFIG.5is shown in the variant ofFIG.5Aat28′ (in comparison narrowed as compared to at28) and formed within an entire interior extending length of the track section (again shown by example by interior recess28′ in track section12′ and corresponding interior recess30′ in track section14′, both of the track sections also shown in reduced length depiction). In this fashion, the individual sections of track (such as which are typically provided as eight foot lengths) can be sectioned (resized) by the installer according to any reduced length during installation upon a given piece of equipment and over an intake opening and in order to be resistively engaged to the given projecting tongue of the corner connector20.

FIG.6largely repeats much of the structure previously described and shown inFIG.5and by which the a modification20′ of the corner connectors each again include an “L” shaped body having first28and second30receiving pockets (see rectangular shaped pocket shaped profiles corresponding to first and second angled sides). Horizontal track section12″ includes an end-projecting tongue portion32′, with vertical track section14″ a corresponding end-projecting tongue portion14″ for resistively engaging within the corner connector recessed pockets28and30.

FIG.6Ais an exploded perspective illustration of the “T” shaped intermediate connectors21depicted inFIG.2Aaccording to a non-limiting configuration of surface mounting track and corner connectors according to the present invention for again establishing a flush mount against the intake surface2. In this illustration, a variant of the sub-divided horizontal track sections are again shown at12′, along with a likewise reconfiguration of the intermediate vertical track, see as shown at17, these corresponding to the cross sectional track sections14′ depicted inFIG.5and including a projecting tongue34′.

The track sections are designed to exhibit a flat bottom surface (see as best shown at36as shown for track12′ inFIG.5). Each of the track sections12′ and14′ further exhibit a cross sectional profile for slidably receiving the corresponding fasteners, which can be suitably reconfigured from the generic version depicted at22inFIG.1and, in the instance of the track sections12′ and14′, are depicted at22‘inFIGS.7-9.

The fasteners22’ each depict a slidable engaging profile which, in the perspective ofFIG.7, is shown by side located and inwardly angled tabs38and40, these further being configured (upon being slidably installed over an end of the track section) to mate with outwardly side facing and opposing configured rails, these depicted as opposite exterior side facing and linear extending recess slots at42and44. The slots42/44are configured within each track section (as further depicted by track section12′ inFIG.8). Additional guiding support for the slidable attachable fasteners22′ can be provided by a linear recess notch (see at46configured in a top of each track section as shown at12′), this seating a mating interior projection48configured upon a roof underside of the fastener22′.

FIG.6Bis a related exploded perspective toFIG.6Aaccording to a second non-limiting configuration of the surface mounting track with “T” shaped connectors21and (similar toFIG.5B), and again in which the tongue portions32are relocated to extend from each connecting interface of the “T” connector, with the recesses (again at28′ as depicted inFIG.5A) instead being formed within an entire interior extending length of each track section, such permitting the track to again be sectioned (or resized) to any reduced length during installation and then resistively engaged to the given projecting tongue of the “T” connector.

FIG.7Ais a perspective view of an exteriorly and linearly adjustable toggle style fastener23according to a further non-limiting configuration. The toggle fastener is similar in construction and operation as the twist lock style fastener variants previously shown at22and22′ and includes a toggle element25rotatable about a horizontal axis (as opposed to the twist lock element which rotates about a vertical axis extending through the fastener). A pair of spaced apart and upwardly extending support plates27and29are affixed to the upper surface of the fastener23for supporting the rotation of the toggle element.

In this manner, and as best depicted inFIGS.8-9, each of perspective and end views are provided of the fastener and track and better depicting the surface mounting aspect of the support track (this depicted in9again by underside surface36of track which can be secured to a surface2such as which can surround an intake opening of an air handling unit) with side configured engagement rails, along which adjusts the exterior supported fasteners22′ in a manner which does not interfere with the surface mount to the intake surface. In this manner, the track sections are flush mounted to the intake surface along their entire lengths, with this mounting aspect of the track not interfering with the ability to adjust the exterior supported fasteners along the individual tracks during installation of the given screen, filter or other covering10.

It is also envisioned and understood that the fasteners22, according to any of the disclosed variants herein, can be dimensioned relative to the supporting track sections, so as to be frictional-adjusted when linearly adjusts along the exterior of each of the track sections. Other locking mechanism (such as utilizing without limitation and of cams, screws or the like) can also be incorporated into the opposing interface established between each fastener and associated track section12-18for pre-adjusting the positioning of the fasteners before installation of the screen or covering.

Without limitation, the opposing seating configurations established between the fastener and track can be dimensioned so that a selected plurality of individual fasteners are initially installed in end fashion along each track section, prior to interconnection of the track sections with the end connectors. The fasteners are further dimensioned such that they linearly adjust along each of the inter-assembled sections of track, and which can again include either of a tight dimensioning between the track and fasteners for providing for a frictional/resisting linear adjustment without the need for separate connectors or anchors, as well as a looser dimensioning in which the fasteners can be more easily slid along the track sections and, upon being positioned at an aligning location for engaging the cover, can additionally again include a separate cam or screw (not shown) for tightening or locking the fastener in position along a given track section.

As again depicted inFIG.9, the twist or toggle lock portions each again include an uppermost adjustable portion as again shown at24, this being adjustable relative to a post or base portion50(see as best shown inFIG.12). As indicated, alternate versions can include a toggle portion or other portion for engaging through the ring or grommet configured into the edge perimeter of the screen or covering. Although not shown, other variants contemplate redesigning the fasteners to incorporate any type of compressible or deflectable portion for engaging the ring or grommet location of the cover.

FIG.9Ais an alternate end view of the twist lock fastener and track shown inFIG.9, and depicting the toggle style fastener23(as described inFIG.7A) in place of the twist lock fastener). The cross sectional configuration shown inFIG.9Aalso reconfigures the cross sectional profile12′ of the track section inFIG.9by narrowing the thickness of bottom wing sections (at31/33) of the track, these seating the inwardly angled side tabs38/40of the fastener base23in a manner which more closely spaces the bottom edges of the fastener with the intake surface2(this depicted by a minimal spacing35(this can be decreased to zero between the fastener underside and the intake surface) depicted between the underside of the side tabs38/40and the opposing intake surface2. With subsequent reference toFIG.12, a similar close tolerance surface dimensioning is depicted between the underside of the traversable fasteners22″ and the intake face2, it being understood that any amount of spacing or dimensioning can be designed into the construction of the surface mounted track sections and the exteriorly traversable fasteners.

Proceeding toFIG.10, a perspective view is shown of an alternately configured exteriorly and linearly adjustable fastener22″ according to a further non-limiting configuration and which largely matches the construction of the fastener22′ inFIG.7, with the exception of the dimensioning of the angled side tabs being reconfigured at38′ and40′ (see alsoFIG.12) from that shown at38/40in the fastener variant22′ inFIG.9. The track section is further redesigned, at12″ inFIGS.11-12from that shown at12′ inFIGS.8-9and so that the opposite side facing rails are reconfigured by underside recessed edges42′/44′ which replace the recessed side slots42/44in rail12′.

The redesigned side tabs38′/40′ are dimensioned so that they seat against a narrowed cross sectional base portion (see in contact with the bottom track surface36′) of the selected track section12″ depicted inFIG.12. As further again shown inFIG.12, the surface mounting aspect to the intake2corresponds to that inFIG.9and by which the fasteners12″ can adjust along the individual interconnected sections of track without interference from the flush mount of the track bottom surface36′ to the intake face. Additional guiding support is again provided for the slidable attachable fasteners22″ provided by a linear recess notch (see at46′ configured in a top of each track section as shown at12″), this seating a mating interior projection48′ configured upon a roof underside of the fastener22″ in each ofFIGS.10-12.

FIG.13is a perspective view of a further alternately configured exteriorly adjustable fastener, see at22′″ in each ofFIGS.13-15according to a further non-limiting configuration and which can represent either the same or another possible reconfiguration of the fasteners22generically represented in the kit views ofFIGS.1-4. The fasteners22′″ generally mimic those depicted at22″ and again include reconfigured angled sides38″/40″ which align with further redesigned underside rail ledges42″/44″ configured in the further redesigned version of the tracks (see selected track section by example at12′″).

As with the versions depicted in each ofFIGS.9and12, the sliding interface between the fasteners and tracks are such that the fasteners can be slidably attached over the ends of the redesigned tracks in a manner which permits them to be adjusted along the tracks (seeFIG.15) without interfering with the surface mounting (via base surface36″) of the tracks to the intake surface2. Without limitation, the track sections can be designed to include any cross sectional profile adaptable for slidably receiving the fasteners in a fashion which does not interfere with the surface mounting of the tracks to the intake face. By this construction, the assembled depiction of the kit assembly inFIG.4prevents the side-admittance of debris or other contaminants underneath the inter-assembled track sections.

Having described my invention, other and additional preferred embodiments will become apparent to those skilled in the art to which it pertains, and without deviating from the scope of the appended claims. This can, in certain applications, include the redesigning of both the tracks and fasteners to exhibit other and varying configurations which are envisioned to cover both surface mount and, in given instances, non-surface mounting variants. Other variants envision incorporating corner connections directly into the track sections in order to further reduce part count and simplify assembly.

The detailed description and drawings are further understood to be supportive of the disclosure, the scope of which being defined by the claims. While some of the best modes and other embodiments for carrying out the claimed teachings have been described in detail, various alternative designs and embodiments exist for practicing the disclosure defined in the appended claims.

In the foregoing specification, the disclosure has been described with reference to specific embodiments. However, as one skilled in the art will appreciate, various embodiments disclosed herein can be modified or otherwise implemented in various other ways without departing from the spirit and scope of the disclosure. Accordingly, this description is to be considered as illustrative and is for the purpose of teaching those skilled in the art the manner of making and using various embodiments of the disclosure. It is to be understood that the forms of disclosure herein shown and described are to be taken as representative embodiments. Equivalent elements, materials, processes or steps may be substituted for those representatively illustrated and described herein. Moreover, certain features of the disclosure may be utilized independently of the use of other features, all as would be apparent to one skilled in the art after having the benefit of this description of the disclosure. Expressions such as “including”, “comprising”, “incorporating”, “consisting of”, “have”, “is” used to describe and claim the present disclosure are intended to be construed in a non-exclusive manner, namely allowing for items, components or elements not explicitly described also to be present. Reference to the singular is also to be construed to relate to the plural.

Further, various embodiments disclosed herein are to be taken in the illustrative and explanatory sense, and should in no way be construed as limiting of the present disclosure. All joinder references (e.g., attached, affixed, coupled, connected, and the like) are only used to aid the reader's understanding of the present disclosure, and may not create limitations, particularly as to the position, orientation, or use of the systems and/or methods disclosed herein. Therefore, joinder references, if any, are to be construed broadly. Moreover, such joinder references do not necessarily infer that two elements are directly connected to each other.

Additionally, all numerical terms, such as, but not limited to, “first”, “second”, “third”, “primary”, “secondary”, “main” or any other ordinary and/or numerical terms, should also be taken only as identifiers, to assist the reader's understanding of the various elements, embodiments, variations and/or modifications of the present disclosure, and may not create any limitations, particularly as to the order, or preference, of any element, embodiment, variation and/or modification relative to, or over, another element, embodiment, variation and/or modification.