System and method for filtering inlet air in an air conditioner air handler

A system for filtering inlet air of an air conditioner air handler, and method of filtering inlet air without a conventional filter, said system is a structure comprising: an air inlet, an air directing structure, a water chamber, positioned within an internal cavity, a structure for directing condensate from an air handler into said water chamber, a drain positioned to impart a maximum water level of water accumulated in said first water chamber; a second air directing structure configured to direct air from said first internal cavity towards an outlet that is affixed to the inlet of an air conditioner air handler.

BACKGROUND OF THE INVENTION

Air conditioner air handlers require regular care and maintenance. One are of care involves the continual changing of an inlet air filter. Filters are changed typically every one to six months. However, many persons fail to change their filters and there is often damage to the air handler.

A system and method is contemplated where an air handler n loner requires a filter.

BRIEF SUMMARY OF THE INVENTION

In one embodiment, the present invention is a system for filtering inlet air of an air conditioner air handler, said system is a structure comprising:

an air inlet;

an first air directing structure configured to act in concert with said air inlet to direct air from said air inlet into a first internal cavity;

a first water chamber, said water chamber positioned within said first internal cavity such that inlet air passing through said air directing structure directs air above a water level of said first water chamber;

a structure for directing condensate from an air handler into said water chamber;

a drain positioned to impart a maximum water level of water accumulated from said condensate in said first water chamber;

a second air directing structure configured to direct air from said first internal cavity towards an outlet that is affixed to the inlet of an air conditioner air handler.

The system has an air inlet configured to draw in ambient air through a negative pressure differential formed from an inlet fan of an air conditioner air handler.

The system has an air constricting structure incorporated within said first air directing structure.

The system also has a second water chamber positioned above the first water chamber.

The second water chamber is positioned in an airflow stream between the first water chamber and the system outlet where air exits the system and enter the air handler.

Also contemplated is a method of removing particulate from an air conditioner air handler inlet comprising:

providing a structure of claim1;

arranging said structure to connect said structure outlet to an air conditioner air handler inlet in order that said arranging is accomplished with substantially all air exiting the structure entering the air handler;

activating said air conditioner air handler, said activating imparting negative pressure in said structure an drawing ambient air into said inlet;

directing said ambient air through said first internal cavity and across an upper surface of water in said first water chamber;

further directing said ambient air from said first internal cavity to said second air directing structure configured to direct air from said first internal cavity towards an outlet that is affixed to the inlet of an air conditioner air handler;

said method removing particulate from said ambient air before said ambient air is directed to said outlet, removal of particulate having efficiency substantially similar to air filtered by a conventional air conditioner air handler filter

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

The present invention includes an assembly10that is utilized with existing air conditioner air handlers. The system has a configuration that interacts with the components of an air conditioner air handler. Ambient air70is drawn into system10through a cavity formed by front frame14and lower vertical baffle plate36. As air is drawn in, it is directed into air constriction area74by virtue of air constriction deflector72. Ambient air is forced into inlet cavity96and contacts water92positioned in lower water chamber76. Air continues to flow within the interior portion of lower vertical baffle plate36into cavity97and over upper water chamber78contacting water94located in upper water chamber78. Air flows along first deflecting baffle34into cavity98and second deflecting middle baffle plate32below cavity99. Upper baffle plate30directs air into upper chamber84defined by upper wall28. Airflow continues from the apparatus into the air conditioning air handler as indicated in airflow direction by arrow inFIG. 5. Water positioned in each of lower water chamber76and upper water chamber78is supplied to the apparatus utilizing condensate water84created by the air conditioner air handler and fed by pipe42to upper water chamber78. Upper water chamber78fills until exceeding upper water chamber water level82. Once water exceeds upper chamber water level82, water travels gravitationally to lower water chamber76. As water exceeds lower chamber water level80, water drains through waist water drain90and is further directed from the system through drain connector44that directs water outward through waist water pipe54. As previously stated, water travels into the apparatus as is normally collected in an air conditioner air handler condensate.

Article10is constructed and arranged to be positioned next to and work with an existing air conditioner air handler. Air handler58interfaces with article10at gasket54which seals the opening and prevents air passing through article10from escaping. All air is directed into the air handler. A filter bracket56is used to position article10. Article10obviates the need for air handler filters. Support rails22support upper perimeter walls28. A cross brace16further provides support to article10. Inlet hose50collects condensate from the air handler and directs collected condensate water84into article10through inlet tube42. A lower brace20supports the inlet assembly which is formed of inlet frame14. Ambient air70flows into article10through an opening as best seen inFIG. 5.

An additional feature in the present invention provides for indication of malfunction the system cease to function properly.

In an embodiment where the lower water chamber76fails to drain properly, water92rises to a level at or above constrictor72. Ambient air70is prevented from traveling thorough the intended air route in article10. In such situations, the air handler will freeze due to a lack of inlet air. When the air handler freezes, the air conditioner will cease cooling and an operator will inspect the cause of the malfunction.

This particular system provides for a method of removing impurities such as dirt, dust, allergens and the like from entering a typical air conditioner and air handling system. The system and method of the present invention provides efficiency equal to or greater than conventional fiber filters. As air enters the system, heavier particles such as dust, dirt and allergens contact water in several different locations. These particles when in contact with water will remain in the water and be drawn out of the air flowing through the system. As the water levels accumulate, they eventually collect in the lower most water chamber, which is lower water chamber76. As the water level in lower water chamber76exceeds in lower water chamber80, water is drained through coupling48and water drain90eventually to be removed from the system. As will be noted from test results below, the system is shown to greatly reduce dirt, dust and allergens from air transported there through.

The present invention further relates to a method for removing particulate from inlet air traveling into the inlet of an air conditioning air handler.

Typically, filters are utilized for the removal of particulates from air inlet.

The filters need to be changed and have significantly variable levels of efficiency.

A test was performed an air handler with a standard filter against an air handler without a filter in which the apparatus is utilized.

Both tests were performed using Surface Microscopy analysis with an Allergen Screen Check kit.

The test results appear below:

Air Handler with Conventional Filter.

Particle Identification Opaque Particles Skin Cell

Fragments Insect Biodetritus Total Fibers

Manmade Fibers

Total Pollen

Total Fungal Elements/SporesCurvulariaspecies

Particles Black Particles

The results in this report apply only to the sample(s) specifically listed above and tested at Environmental Diagnostics Laboratory. Unless otherwise noted, samples were received in good condition. Laboratory prepared Quality Control (OC) samples are analyzed with the samples routinely; however, unless a blank (control) is received, the result for the control is not compared. Quantitative data is based on 3 significant figures; Grand Total may not equal 100% due to rounding.

Opaque Particles Identified from Tape Prep Assays

Opaque Particles

These particles may originate from inorganic or organic sources in nature. However, it appears opaque when observed under light microscopy. It has various shape and sizes. It may be regular or irregular in shape. On an average it can be measured less than one micron to well over fifty microns with some exceptions. Commonly these particles include but are not limited to dust & debris, paint, combustions, emission, ash, silica and others.

These particulates are significant from a health/allergy point of view especially in case of respiratory disorder.

Fibers Identified from Tape Prep AssaysMan-made fibers may come from natural raw materials like cellulose or from synthetic chemicals like rayon, nylon, etc. In indoor environments, some important sources of man made fiber include carpet. cellulose based building materials, clothing, paper and paper products, etc. Size of these fibers varies from a few microns to a few millimeters; however, an average size range may be 1 micron to over 500 microns. Health implications of these particles are not well described. however some of the man-made fibers are important from an allergy point of view especially for dermal allergy.
Spores I Fungal Elements Identified from Tape Prep Assays
CurvulariaSpeciesCurvulariaspecies are found worldwide and are very common. The hyphae, conidiophores, and conidia are pigmented olivaceous-brown (dematiaceous). They can be isolated from the air, plants (especially grasses), sand dune soil, and soil. Rarely, they can be an opportunist human pathogen causing allergic reactions, eye (corneal) infections, mycetoma, and infections in immunocompromised patients.

Other Material Identified from Tape Prep Assays

These are thin disk-like particles of variable size range (10 to 50 micron), It may be organic or inorganic in nature. In indoor environment these particles mainly come from cornmeal, other grain flour, talcum powder etc. Some of these particles may adversely influence the health of dweller (example talcum powder).
Black ParticlesThese microscopic particles may originate from an organic source material. They greatly vary in their shape and sizes depending on their origin. However, an average size ranges between 1-micron to 5 micron with some exceptions. It may be regular or irregular in shape. In the indoor environment some important source/cause of these particles includes but are not limited to combustion, burning of oil & candles, chimney shoot, automobile exhaust, neoprene (rubber compound that applied to the inside surface of fiber glass duct liner), and other organic materials emitted by copier machines, printers, abraded paints etc. These particles may influence health and hygienic condition of dwellers.
Reddish-Brown ParticlesThese microscopic particles may originate from inorganic or organic source materials. In indoor environments these particles mainly come by rusting, coarse, weathering of materials etc. They may also be released into the environment due to deterioration of wood or wood products, art and sculpture work etc. These particles greatly vary in their shape and sizes. It can be measured from a few micron to over 100-microns. This particle may be the indicator of moisture problem in indoor environment.The health implications of this material are not well established however; it may be significant from a health and hygiene point of view.

Table 1 andFIGS. 6 and 7show significant particulate detected in the inlet air.

The experiment was repeated utilizing the system of the present invention in an air handler with no filter in place.

TABLE 2RawTotal CountPercent ofParticle IdentificationCount(Cts/cm2)Total CountOpaqueParticles22188490.9%Skin Cell Fragments4161.65%Insect BiodetritusBDLBDLN/ATotal Fibers140.412%Manmade Fibers140.412%Total PollenBDLBDLN/ATotal Fungal Elements/Spores140.412%Curvulariaspecies140.412%Total “Other”16646.58%“Talc-Like” Particles280.82%Reddish-Brown Particles3121.23%Black Particles11444.53%Total Counts:243972100%BDL = Below Detection Limit: No particles were reported from the microscopically observed area on the specimen slide (at 10 × 10 or 10 × 40 magnification).
Surface Microscopy (Tape Prep Assays)
Opaque Particles Identified from Tape Prep Assays
Opaque ParticlesThese particles may originate from inorganic or organic sources in nature. However, it appears opaque when observed under light microscopy. It has various shape and sizes. It may be regular or irregular in shape. On an average it can be measured less than one micron to well over fifty microns with some exceptions. Commonly these particles include but are not limited to dust & debris, paint, combustions, emission, ash, silica and others.

These particulates are significant from a health/allergy point of view especially in case of respiratory disorder.

Fibers Identified from Tape Prep Assays

Man-made fibers may come from natural raw materials like cellulose or from synthetic chemicals like rayon, nylon, etc. In indoor environments, some important sources of man made fiber include carpet. cellulose based building materials, clothing, paper and paper products, etc. Size of these fibers varies from a few microns to a few millimeters; however, an average size range may be 1 micron to over 500 microns.

Health implications of these particles are not well described. however some of the man-made fibers are important from an allergy point of view especially for dermal allergy.

Spores I Fungal Elements Identified from Tape Prep Assays

Curvulariaspecies are found worldwide and are very common. The hyphae, conidiophores, and conidia are pigmented olivaceous-brown (dematiaceous). They can be isolated from the air, plants (especially grasses), sand dune soil, and soil. Rarely, they can be an opportunist human pathogen causing allergic reactions, eye (corneal) infections, mycetoma, and infections in immunocompromised patients.
Other Material Identified from Tape Prep Assays
“Talc-Like” ParticlesThese are thin disk-like particles of variable size range (10 to 50 micron), It may be organic or inorganic in nature. In indoor environment these particles mainly come from cornmeal, other grain flour, talcum powder etc. Some of these particles may adversely influence the health of dweller (example talcum powder).
Black ParticlesThese microscopic particles may originate from an organic source material. They greatly vary in their shape and sizes depending on their origin. However, an average size ranges between 1-micron to 5 micron with some exceptions. It may be regular or irregular in shape. In the indoor environment some important source/cause of these particles includes but are not limited to combustion, burning of oil & candles, chimney shoot, automobile exhaust, neoprene (rubber compound that applied to the inside surface of fiber glass duct liner), and other organic materials emitted by copier machines, printers, abraded paints etc. These particles may influence health and hygienic condition of dwellers.
Reddish-Brown ParticlesThese microscopic particles may originate from inorganic or organic source materials. In indoor environments these particles mainly come by rusting, coarse, weathering of materials etc. They may also be released into the environment due to deterioration of wood or wood products, art and sculpture work etc. These particles greatly vary in their shape and sizes. It can be measured from a few micron to over 100-microns. This particle may be the indicator of moisture problem in indoor environment.The health implications of this material are not well established however; it may be significant from a health and hygiene point of view.

As seen from the reported results, an air handler without a filter would be expected to have significant increase in particulate.

This was not the case. The congruity of results indicates that the system of the present invention provides particulate filtration similar to filtration results when using an air filter.

In one embodiment, an additive is added to system10. Additives include, but are not limited to materials such as, aromatic, antimicrobial, anti fungal, anti-mole, anti-spore, or combinations thereof.

One embodiment adds the additive to at least one water chamber. The additive can be a solid, semi solid or liquid.

One embodiment provides an additive as a solid in which the additive is released over an extended period of time being 1-90 days.

In one embodiment, addition of anti-mold materials is a step in a method to clean mold from duct work.

The method includes the steps of

providing a an article/system of the present invention;

adding a mold killing or remediation component to the water chamber of the article;

running the air conditioner such that the mold killing component is carried through the system, into the existing air handler;

dispersing the mold killing component through the air conditioning ductwork;

wherein the method is carried out for 1-90 days until mold is killed and no longer in the ductwork.

This method can be used to sterilize and deodorize air ducts. The method is not limited to distribution of a single additive and can be used with a plurality of additives.

The present invention has an additional feature in that there is no need to clean or change the water in any water chamber.

Particulate in the inlet air70is directed into water in a water chamber. Air pressure from the system circulates water in all water chambers such that particulate is not able to settle or accumulate. The particulate circulates in the water. As water levels rise above the aforementioned drainage heights, particulate is carried out of the article10and ultimately deposited outside article10though drain48.

While the invention has been described in its preferred form or embodiment with some degree of particularity, it is understood that this description has been given only by way of example and that numerous changes in the details of construction, fabrication, and use, including the combination and arrangement of parts, may be made without departing from the spirit and scope of the invention.