Filter frame and assembly

A filter frame including a panel having a plurality of V-shaped elements disposed on the first side thereof. Each V-shaped element includes a pair of slots each configured to receive and orient a filter element. A portion of the panel disposed between adjacent pairs of V-shaped elements has an opening form therein to define a handle for carrying the filter frame.

BACKGROUND OF THE INVENTION

The invention relates generally to filter element supports, and in particular to a filter frame assembly for supporting a plurality of filter elements and including a handle for carrying.

Prior art filter assemblies are known. For example, U.S. Pat. No. 4,193,780, issued to Cotton, Jr. et al., describes a plurality of separate V-shaped wire mesh members arranged and connected in side-by-side relationship to provide a plurality of V-shaped cells disposed across an air stream. A stabilizer bar extends across and attaches to the exposed edges of the V-shaped cells to support the cells in a proper relation and retain the filter media in place. Additionally, the stabilizer bar stabilizes the frames to decrease vibration and rattle when the system is operating. No handle is provided for carrying the filter assembly.

U.S. Pat. No. 2,016,033, issued to Christofferson, describes an air filter, which has filter media disposed between a pair of V-shaped support members. A plurality of the V-shaped filters may be arranged side-by-side in a filter array. Each of the V-shaped filters is independently removable and replaceable. A handle or pair of handles are provided and extend into the central portion of the V-shaped area to facilitate insertion and removal of the filter with respect to the array. No handle is provided for carrying the array.

One disadvantage of the above and other prior art designs is that because of the size of the filter assemblies/arrays often used in large commercial or industrial applications, the filter arrays are difficult to carry and position for installation. Usually, an installer grasps the filter assembly/array at one of the vertex points of the V-shaped members. The palm of the installer is disposed at the vertex of the V-shape and the installers fingers grasp the filter media. As a result, the filter media is usually damaged. Christofferson provides handles for removing individual filter elements. However, these handles are not useful when moving or installing the filter array.

Therefore, there is a need for a filter frame having a convenient handle that is relatively easy to manufacture, low cost, light weight and may be used with another filter frame to define a filter frame assembly.

The filter frame assembly of the present invention is primarily for use in air filtration systems. In one principal aspect of the present invention, a filter frame includes a panel including a plurality of V-shaped elements disposed on a first side of the panel. Each V-shaped element includes a pair of slots. The slots are each configured to receive and orient a filter element. A portion of the panel disposed between adjacent pairs of V-shaped elements has an opening formed therein to define a handle for carrying the filter frame.

In one embodiment, a rib is disposed on the first side of the panel between the slots of each V-shaped element extending along the line passing through a vertex of the V-shaped element and normal to a base of the panel for reinforcing the panel. In another embodiment, a rail is disposed on a second side of the panel at a base thereof having an extent greater than the base. In still another embodiment, a connector is disposed at each end of the rail extending toward the first side of the panel. In yet another embodiment, each slot is defined by a plurality of flanges extending from the first side of the panel. In still yet another embodiment, the slots of each V-shaped element are disposed at a relative angle of less than 180 degrees. In a still yet further embodiment, the handle further includes a support element normal to the panel and extending toward the first or second side of the panel between the V-shaped elements. In yet another still further embodiment, the slots of each V-shaped element are configured to define a continuous channel.

In another principal aspect of the present invention, a filter frame includes a generally W-shaped panel including a pair of V-shaped elements disposed on the first side of the panel. Each V-shaped element includes a pair of slots configured to receive an oriented pair of filter elements. A portion of the panel extending between the adjacent V-shaped elements has an opening formed therein which defines a handle for carrying the filter frame.

In one embodiment, a rib is disposed on the first side of the panel between the slots of each V-shaped element extending along the line passing through a vertex of the V-shaped element and normal to a base of the panel for reinforcing the panel. In another embodiment, a rail is disposed on a second side of the panel at a base thereof having an extent greater than the base. In still another embodiment, a connector is disposed at each end of the rail extending toward the first side of the panel. In yet another embodiment, each slot is defined by a plurality of flanges extending from the first side of the panel. In still yet another embodiment, the slots of each V-shaped element are disposed at a relative angle of less than 180 degrees. In a still yet further embodiment, the handle further includes a support element normal to the panel and extending toward the first or second side of the panel between the V-shaped elements. In yet another still further embodiment, the slots of each V-shaped element are configured to define a continuous channel. In another embodiment, each slot of each V-shaped element is defined by four flanges extending from the first side of the panel configured as a trapezoid.

Another principal aspect of the present invention is directed to a filter assembly including a pair of filter frames engaging opposite ends of a plurality of filter elements. Each filter frame includes a panel including a plurality of V-shaped elements disposed on a first side of the panel. Each V-shaped element includes a pair of slots where each slot is configured to receive and orient one end of a filter element. A portion of the panel disposed between each adjacent pair of V-shaped elements has an opening formed therein to define a handle for carrying the filter frame. A pair of transverse members space and interconnect the filter frames.

In one embodiment, a rib is disposed on the first side of the panel between the slots of each V-shaped element extending along the line passing through a vertex of the V-shaped element and normal to a base of the panel for reinforcing the panel. In another embodiment, a rail is disposed on a second side of the panel at a base thereof having an extent greater than the base. In still another embodiment, a connector is disposed at each end of the rail extending toward the first side of the panel. In yet another embodiment, each slot is defined by a plurality of flanges extending from the first side of the panel. In still yet another embodiment, the slots of each V-shaped element are disposed at a relative angle of less than 180 degrees. In a still yet further embodiment, the handle further includes a support element normal to the panel and extending toward the first or second side of the panel between the V-shaped elements. In yet another still further embodiment, the slots of each V-shaped element are configured to define a continuous channel. In another embodiment, each slot of each V-shaped element is defined by four flanges extending from the first side of the panel configured as a trapezoid.

FIG. 1is a first side perspective view of the filter frame10of an embodiment of the present invention. The filter frame10includes a panel12having a first side14and a second side16(seeFIG. 2). A plurality of V-shaped elements18are disposed on the first side14of panel12. In this embodiment, the panel12is generally W-shaped. It will be recognized that the panel12may take any shape or form such that the plurality of V-shaped elements18may be disposed thereupon.

Each V-shaped element18includes a pair of slots20. Each slot20is defined by a plurality of flanges22,24,26,28extending from the first side14of the panel12. The slots20of each V-shaped element18are disposed at a relative angle γ of less than 180 degrees. It will be recognized that the relative angle γ between each of the V-shaped elements20may be configured as desired for certain applications.

A rib21disposed on the first side14of the panel12between the slots20of each V-shaped element18extending along a line42passing through a vertex44of the V-shaped element18and normal to a base32of the panel12for reinforcing the panel12.

FIG. 2is a second side perspective view of the filter frame ofFIG. 1. The panel12has a second side16. A rail30is disposed on the second side16of the panel12at a base32(see alsoFIG. 1) thereof and has an extent34greater than the extent36of the base32. A connector38is disposed at each end40of the rail30, beyond the extent36of the base32, and extends toward the first side of the panel12.

FIG. 3is a first side elevation view of the filter frame ofFIG. 1andFIG. 4is a detailed view of a highlighted portion indicated as No. 4 onFIG. 3. A portion46of the panel12disposed between adjacent pairs of V-shaped elements18has an opening48formed therein to define a handle50for carrying the filter frame10. The handle50includes a support element52normal to the panel12and extending toward the first side14of the panel between the V-shaped elements18. It will be recognized that the support element52may also extend toward the second side of the panel between the V-shaped elements and provide identical functionality.

The slots20of each V-shaped element18may be configured to define a continuous channel, as shown inFIGS. 1 and 3. It will be recognized that such configuration increases the ease of manufacture. Alternatively, each slot20of each V-shaped element18is defined by four flanges22,24,26,28extending from the first side of the panel12configured as an enclosed area, such as a trapezoid, parallelogram, rectangle or any other suitable form.

FIGS. 5 and 6are, respectively, top and bottom perspective views of a filter frame assembly60of one embodiment of the present invention. A filter assembly60includes a pair of filter frames10engaging opposite ends of a plurality of filter elements62. The structural elements and the configuration thereof for each filter frame10are as described above. A pair of elongated members64space and interconnect the filter frames10. Each end66of the filter element is received within a slot20which positions and orients the filter element62. The filter elements62include a filter media68and a frame70. It will be recognized by those of skill in that art that the filter media68may be, of any suitable design and composition. For example, the filter media68may be accordion-fold of a standard filtering material, such as wet-laid fiberglass paper or any other suitable material.

The elongated member64may be configured as a square tube having a through bore which engages the connecters disposed on the ends of the rail in a conventional manner. It will be recognized by those of skill in the art that the elongated members may take any structural and functional configuration which cooperatively engages the connectors to retain the filter frames10in a spaced and interconnected relationship. For example, the elongated member64may be configured as a round tube, a solid bar, a flat bar or any other suitable structural configuration made of any material as desired.

As shown in the disclosed embodiment, the filter frame and filter assembly of the present invention provides a structural configuration for carrying the filter assembly which is inexpensive and easy to manufacture.

The invention is not limited to the details of the apparatus depicted and other modifications and applications may be contemplated. For example, the relative angle between the V-shaped elements may be changed as desired. For further example, additional filter elements may be added to the filter assembly. Also, the size, shape and position of the opening may be altered as desired to suit particular applications. Certain other changes may be made in the above-described apparatus without departing from the true spirit and scope of the invention here involved. It is intended, therefore that the subject matter of the above depiction shall be interpreted as illustrated and not in a limiting sense.