Filter Lift Apparatus and Method

A filtered vent system for a return air duct in a ceiling, the vent system includes a bracket configured to mount to the ceiling. A vent frame mounts to the bracket to fix the frame to the ceiling. A vent plate carries an air filter. A hoist arrangement is mounted to the vent frame and is connected to the vent plate. A hoist arrangement is actuable through an aperture in the vent frame to move the vent plate from a first state in contact with the vent frame to a second state free from contact with the vent frame and spaced apart from the vent frame a distance permitting removal of the air filter.

FIELD OF THE INVENTION

This invention generally relates to air return vents and more particularly to filtered vent systems for the return air in commercial buildings and residential homes with heating, ventilation, and air conditioning systems.

BACKGROUND OF THE INVENTION

Residential homes and commercial buildings typically have HVAC (heating, ventilation, and air conditioning) systems to regulate the home or building's internal air temperature as well as to improve indoor air quality. HVAC systems draw in air, referred to as return air, from the home or building through filtered air return vents. The filtered air return vents are typically located in the ceilings of the homes or buildings.

Depending on the size of the filtered air return vent, typically, it is recommended that the air filters in the return vents be checked monthly to see if they have accumulated an amount of particulate that prevents them from permitting sufficient air flow therethrough (a dirty filter). When too much particulate accumulates in the air filter, air flow slows or stops and thereby prevents the HVAC system from operating efficiently or at all.

When the HVAC system is operating with a dirty filter in the air return vent, air within the home or building may not be sufficiently filtered to provide for the desired healthy, “quality” clean air in the home or building. Because of this, manufacturers of the HVAC systems may recommend that the air filters be checked at least monthly and/or changed out monthly to ensure the HVAC system operates efficiently with proper filtered air flow to sufficiently filter the air and to properly cool, ventilate, and heat the home or building while maintaining healthy air within the home or building.

Far too often, the air filters in the air return vents are not checked nor changed out regularly because of the imposition it requires, namely having to access the ceiling of a home or building where the filtered air vent is located. Indeed, to change the air filter in the air return vent, a ladder is required to reach the return vent located in the ceiling. However, dragging a ladder, reaching above one's head to open a cover of the filter housing while also holding the replacement air filter, swapping out the dirty air filter with a new air filter, and then carefully descending a ladder while holding a dirty air filter is simply cumbersome and fraught with issues of safety and cleanliness.

FIG.12illustrates a user300on a ladder with his arms over his head attempting to change out an air filter302located in a return air duct304of a home. The air filter302is located in a vent return housing306and covered by a grille308that is connected via hinges to the vent return housing306mounted in the ceiling310. This is a problem, especially for an aging population relying on clean air but lacking the full physical strength, mobility, and endurance to climb up on a ladder on a regular basis and clean or replace the existing air filter302in the vent return housing306.

To date, prior art efforts to address the problem of changing out air filters in return vents installed in ceilings have not solved the problems discussed above. For example, U.S. Pat. No. 9,127,856 to Joseph W. Cole entitled, “Method and System for Replacing Air Filter” and its family of patents (hereinafter, “the Cole patents), U.S. Pat. Nos. 10,960,339; 10,520216; 10,520,216; 10,527,315; 10,376,827; and U.S. Publication No. 2021/021338 have not overcome the foregoing problems.

While Cole seeks to provide for retrofitting current return vents, the system requires users to completely remove the permanently installed vent return housing and grille intake before installation. Cole's system is installed within the ceiling and retrofitted to current size airduct return. With Cole's system, the user must pull the filter housing down under tension against a biasing force. The filter housing is pulled down with a pole that is rotated in reverse while the housing is pulled back up into place using the pole. Thus, while the user is pulling down the filter housing of Cole, the pole can unexpectedly disconnect resulting in its filter housing retracting into the ceiling and possibly injuring the user.

Cole's system includes a control tool base that is large and includes a dolly, requiring more storage space. Cole's control tool pole is cumbersome and not user friendly because it requires the user to synchronize multiple places on its pole to rotate for length and locking, as well as to raise and lower. Cole's system is unsteady with the control tool attached to the moveable filter housing, as a user could mistakenly kick or knock into the pole which would cause the filter housing to unsafely sway on its cables. Cole's retrofit installation requires complete removal of the old system, with potential for requiring drywall and paint repair for the ceiling. Thus, Cole's design is best understood as a design for new construction and not a retrofit that can be used with existing return vents.

Cole's system does not use the existing frame in its retrofit and has multiple elements, for example its mounts for its cables that must be attached inside the ceiling on the filter housing. This makes for difficult installation as the user must access and find suitable locations if any inside the ceiling. Cole's biased cables, in connection with its pole to raise and lower its filter, are not user friendly and are awkward to use, and therefore discourage the user from making the required filter checks for change out.

BRIEF SUMMARY OF THE INVENTION

Improving air quality can be achieved by changing the air filters that filter a home or building's air more often. Doing so, however, requires a retrofit adjustment to the current return air filtered vent system in a ceiling.

The invention provides such a filtered vent system and method for its installation that allows for the existing frame in the ceiling to remain in place while only the existing vent plate of the existing return air vent system is removed. These and other advantages of the invention, as well as additional inventive features, will be apparent from the description of the invention provided herein.

In one aspect, the invention provides a filtered vent system for a return air duct in a ceiling. The vent system includes a bracket configured to mount to the ceiling. A vent frame is configured to be mounted to the bracket to fix the frame to the ceiling. A vent plate carries an air filter. A hoist arrangement is mounted to the vent frame and connected to the vent plate. The hoist arrangement is actuable through an aperture in the frame to move the vent plate from a first state in contact with the frame to a second state free from contact with the frame and spaced apart from the frame a distance permitting removal of the filter.

In an embodiment, the bracket is a pair of brackets configured to mount on opposite sides of the air duct.

In an embodiment, each one of the pair of brackets includes a bracket body. A plurality of arm members extend away from the bracket body in a direction generally perpendicular to the bracket body and the ceiling. The plurality of arm members are spaced apart from one another in parallel relation. Each one of the plurality of arm members includes a first portion in contact with the bracket body and a mounting portion free from contact with the mounting portion.

In an embodiment, the mounting portion includes a plurality of detent members. The frame includes a plurality of apertures. Each one of the detent members is received into a respective one of the plurality of apertures of the frame so as to mount the frame to the bracket.

In an embodiment, the frame is configured to surround the air duct without any portion thereof extending into the air duct.

In an embodiment, the actuator extends through the aperture to actuate a gear assembly of the hoist arrangement mounted to the frame.

In an embodiment, the actuator rotates in a first actuation direction to actuate the gear assembly to turn in a first direction to rotate a plurality of pulleys in a pulley system of the hoist arrangement to move the vent plate from the first state to the second state.

In an embodiment, the actuator moves in a second actuation direction, opposite the first actuation direction to actuate the gear assembly to turn in a second direction opposite the first direction to rotate the plurality of pulleys in the pulley system to move the vent plate from the second state to the first state. In the first state, the vent plate is in contact with the frame.

In an embodiment, the pulley system includes ropes connected to the vent plate in an unbiased state.

In an embodiment, simultaneously the ropes are unwound or wound about the plurality of pulleys so as to lower or raise, by rotation of the plurality of pulleys, the vent plate from the first position to the second position and from the second position to the first position.

In an embodiment, the actuator is mounted to a crank pole. The crank pole with the actuator defines a first length of the crank pole. Rotation of the crank pole in a first rotational direction to actuate the actuator does not change the first length of the crank pole as the vent plate moves from the first position to the second position.

In an embodiment, the first length does not change with rotation of the crank pole in a second rotational direction, opposite the first rotational direction, to move the vent plate from the second position to the first position.

In an embodiment, the vent plate has a vent body having four side walls surrounding a slotted face of the vent body. The side walls are in contact with the frame in the first state.

In an embodiment, the actuator is located on the end of a crank pole.

In an embodiment, the actuator includes a torque limiter.

In an embodiment, the crank pole is moveable between a first longitudinal length and a second longitudinal length.

In an embodiment, the frame does not move as the vent plate moves from the first state to the second state and from the second state to the first state.

In another aspect, the invention provides a method for replacing an existing vent return plate and existing air filter in an existing frame for a filtered return air vent in a ceiling duct. The method includes the steps of removing the existing vent return plate while the existing frame surrounding the vent return plate remains fixed to the ceiling. The method includes the step of removing the existing air filter from the filtered air return vent. The method includes the step of fastening a bracket on a portion of the ceiling surrounding the existing frame. The method includes the step of mounting a new frame carrying a new vent plate with a new air filter to the bracket and over the existing frame. The new vent plate is moveable relative to the new frame between a closed state in contact with the frame to an open state wherein the vent plate is free from contact with the frame.

In an embodiment, the method includes the step of inserting an actuator through the new frame to actuate a hoist arrangement having a gear assembly mounted to the frame and connected to a pulley system connected to the vent plate to lower the vent plate from the closed state to the open state.

In an embodiment, the method includes the step of attaching the actuator to a crank pole to allow a user to insert the actuator through the frame while standing on a floor below the ceiling without the crank pole changing length as the vent plate moves between the closed and open state and between the open and closed state.

DETAILED DESCRIPTION OF THE INVENTION

With respect toFIG.1, according to the teachings of the instant invention, a top view of a filtered vent system100for a return air duct304(FIG.12) in a ceiling306(FIG.

12) is illustrated. The filtered vent system100is shown surrounding a preexisting frame306(FIG.12) that would be in the ceiling310(FIG.12) that surrounds the return air duct304(FIG.12). The filtered vent system100is in a first state, that is a closed state.

FIG.2illustrates a bottom view of the filtered vent system100in the closed state as typically seen by a user on a floor looking up at the ceiling.

With respect toFIGS.1and2, in the closed state, return air flows from the from the home or building through a vent plate106that has a plurality of openings108, that may be formed by louvres109of the vent plate106. The vent plate106is received into a frame110of the filtered vent system100in the closed state. The frame110surrounds the air duct304(FIG.12) without any portion thereof extending into the return air duct304(FIG.12). After passing through the plurality of openings108, the return air is filtered through an air filter112carried by the vent plate106. The air filter112may be of any known filter media for home and business commonly used to filter return air. After passing through the air filter112, the return air enters the return air duct304(FIG.12).

The filtered vent system100includes a pair of brackets114,116that are fastened, for example, via screws to the ceiling (not illustrated).FIG.3illustrates a partial view of the frame110, namely the brackets114,116that mount to the ceiling on opposite sides of the preexisting vent frame306. Thus, it should be readily appreciated that the filtered vent system100is easy to install because the preexisting vent frame306does not have to be removed. The preexisting vent frame306remains fixed in place while only its louvered vent plate308(FIG.12) and air filter302(FIG.12) are removed in order to install the filtered vent system100. While a pair of brackets114,116is illustrated, a single bracket, or more than two brackets, could be used to mount the frame110of the filtered vent system100to the ceiling. Typically, the brackets114,116are of metal.

FIG.4is a partial assembly view illustrating the brackets114,116as if mounted to the ceiling (not illustrated) on opposed sides of the preexisting frame306with the frame110positioned below the preexisting frame306with the vent plate106(FIG.2) carrying the air filter112inside the frame110in position to be mounted to the brackets114,116. Once the frame110is mounted to the brackets114,116, the frame110is fixed in place. The vent plate106(FIG.2) carrying the air filter112is not part of the frame110. The vent plate106(FIG.2) carrying the air filter112is moveable between the first state, that is the closed state, where the vent plate106(FIG.2) is in contact with the frame110to a second state, that is an open state (SeeFIG.7), wherein in the vent plate106(FIG.2) carrying the air filter112is outside the frame110. The frame110and the vent plate106are typically made of metal.

FIG.5illustrates a partial assembly view of the frame110. Frame110includes a main frame member118spaced apart from another main frame member120which is shown in assembly view. An endcap122connects the main frame member118and main frame member120at first ends124,126, and another endcap128connects the main frame member118and main frame member120at second ends130,132. The main frame members118,120may be connected by any known fastener means, for example, screws. The main frame members118,120and the end caps122,126may be considered the four walls of the frame110that are in contact with the vent plate106in the closed state and which are not in contact with the vent plate106when the filtered vent system100is in the open state.

Main frame member118includes a through hole133(FIG.2) which is an opening for receiving an actuator136(FIG.7) therethrough. Main frame member118include an inner flange134. Main frame member120includes an inner flange136. Each inner flange134,136is structured the same, and therefore only inner flange136is discussed with the understanding that the same structures and relationship therebetween is present on flange134.

The inner flange136includes a plurality of through holes138that are apertures that mount via reception therein by a plurality of detents144located on the brackets116. Bracket116is structured the same as bracket114, and therefore only bracket116is discussed.

FIG.6better illustrates the plurality of detents144of the bracket116and the plurality of through holes138,140,142of the inner flange136. Bracket116includes a bracket body150and a plurality of arm members152extending away from the bracket body150in a direction generally perpendicular to a planar surface158of the bracket body150. In other words, when bracket116is mounted to the ceiling the arm members152extend in a direction away from the ceiling. By generally, it is meant within plus or minus five degrees. The plurality of arm members152are spaced apart from one another in parallel relation. Each one of the plurality of arm members152has a first portion154in contact with the bracket body150and a mounting portion160free from contact with the bracket body150.

Each mounting portion160includes one of the plurality of detents144. Each one of the detents144is received into one of the through holes138of the inner flange136of the frame110(FIG.5) so as to mount the frame110(FIG.5) to the bracket116.

FIG.7illustrates a second state of the filtered vent system100with the brackets114,116(FIG.1) removed for the purposes of illustration. The second state is an open state wherein the vent plate106carrying the air filter112has been lowered out of the frame110via a hoist arrangement170that includes a gear assembly172(FIG.8), ropes174,176,178,180and pulleys182,184,186,188. In the open state, the vent plate106carrying the air filter112has been lowered a distance190sufficient to permit a user to view the air filter112for cleanliness and to remove the air filter112for either further inspection or to change it out with a new air filter112. By “sufficient distance”190, it is meant a distance between the frame110and the vent plate106carrying the air filter112that allows for a user to easily remove the air filter112from the vent plate106. The distance will typically allow a user standing on the floor to easily remove the air filter112from the vent plate106.

The air filter112is held in place by a pair of retaining members144,146located on opposite sides of the air filter112and permitting the air filter112to be slid into and out of the retaining members144,146. While a pair of retaining members192,194are shown, any number of known retaining devices can be used, for example, only one of the retaining members192,194, or a latch or plurality of latches that can be rotated to cover a portion of the air filter112or rotated to uncover the portion of the air filter112so as to permit removal of the air filter from the vent plate106.

In order to move the vent plate106from the closed position (FIG.1) to the open position a user holds a crank pole196having an actuator198(FIG.8) attached at an engagement end200of the crank pole196and a handle portion201at the opposite end202of the crank pole196. The actuator198(FIG.8) is inserted through the hole133(FIG.8) in the main frame member118. However, the other frame member120or end caps122,124could provide the opening133(FIG.8). A user turns the handle portion201to turn the actuator198so as to impart a rotational force204that may be clockwise in a first direction and counterclockwise in a second direction opposite the first direction as desired to actuate the hoist arrangement170.

The actuator198is inserted into a frame opening202to actuate a gear assembly204of the hoist arrangement170(FIG.8).FIG.8is a vertical cross taken through the main frame member118, inner flange134and including bracket114(not present inFIG.7) at line8-8ofFIG.7. A stepped channel206is defined by the main frame member118and the inner flange134. The gear assembly172is mounted inside the stepped channel206of the frame110. The gear assembly172converts the rotational force204of the actuator198from rotation about a first axis205defined by the longitudinal axis of the actuator198to a second axis208defined by a longitudinal axis of an axle212connecting a first central pulley214to another central pulley216(FIG.7) located on frame member120(FIG.7). The gear assembly172comprises a first beveled gear218driven by the actuator198that turns a second beveled gear220which turns the first central pulley214and axle212and the second central pulley216. Other gear assemblies172are possible, for example, the gear assembly172may be a worm gear250(FIG.11) driven by the actuator198that turns gear252(FIG.11) which turns the first central pulley and axle212and the second central pulley216.

The first central pulley214and second central pulley216are each dual spool (FIG.9) and can spool two of the ropes174,176,178,180simultaneously based on their wound direction. Thus, the first central pulley214includes rope174and rope176spooled thereon. (FIG.9) Rope174extends over pulley182mounted at the second end130of the main frame member118. An end222of the rope174connects to vent plate106at a first corner224. Rope176extend over pulley184at the first end124of the main frame member118. An end226of the rope176connects to the vent plate106at a second corner228.

The second central pulley216mounted on main frame member120has ropes178and180spooled thereon. Rope178extends over pulley186mounted on the second end132of main frame member120. An end230of the rope178connects to the vent plate106at a third corner232of the vent plate106. Similarly, rope180extends over pulley188mounted on the first end126of the main frame member120. An end234of the rope180connects at a fourth corner236of the vent plate106. Axle238connects pulleys182and184, while axle240connects pulleys186,188.

It can now be readily appreciated that the actuator198actuates the hoist arrangement170to either lower or raise the vent plate106as desired. The hoist arrangement170is not biased to either keep the vent plate106in the closed position (FIG.1) or the open position (FIG.7). Sufficient length of the ropes174,176,178,180,182is provided to permit a user standing on the floor to lower the vent plate106to a height above the floor and at a sufficient distance190from the frame110to permit the user to easily reach the air filter112carried by the vent plate106without having to use a ladder or reach overhead. The pulleys174,176,180,182and ropes174,176,178,180and axles212238,240together make up pulley system242of the hoist arrangement170.

FIG.10illustrates the actuator198mounted on crank pole196. Actuator198may include a torque limiter244to prevent over torque of the gear assembly172(FIG.8). However, as can be readily appreciated, the crank pole196may be of many different designs provided that it can be easily extended or contracted by the user to read the gear assembly172(FIG.8) and while a torque limiter244may provide known advantages, it does not have to be present on the actuator198as the user can use their experience to prevent over-torque of the gear assembly172(FIG.8).

Returning toFIG.7andFIG.8, crank pole196has a changeable longitudinal length. By way of non-limiting examples, the crank pole196may be collapsible and expandable or a telescoping pole which permits the user to extend the crank pole196to reach the frame110while the user stands on the floor. It can be readily appreciated at this point in the disclosure that a user can rotate the crank pole196in a first rotational direction to rotate the actuator198to turn the gear assembly172which turns the pulleys174,176,180,182to unspool and extend the ropes174,176,178,180to lower the vent plate106carrying the air filter112. Rotating the crank pole196in a second rotational direction opposite the first rotational direction spools and thereby retract the ropes174,176,178,180to raise the vent plate106carrying the air filter to the closed state. (FIG.1). The ropes in the pulley system242are in an unbiased state. When the gear assembly172stops its rotation, the distance190remains fixed until rotation begins again.

At this point in the disclosure, it can be readily appreciated that a user having a home or building with a preexisting vent frame306(FIG.12) in an intake of existing return air duct304no longer has to endure the inconvenience of using a ladder to reach overhead to remove the louvered vent plate308or try to balance the vent plate308as they try to swing it open or lower it in some fashion. Instead, the user can install the filtered vent system100by removing the existing louvered vent plate308while the preexisting frame306remains fixed to the ceiling.

The user then merely has to fasten, with screws in most instances, the pair of brackets114,116(FIG.3) on a portion of the ceiling310(FIG.12) surrounding the preexisting vent frame306. Once the brackets114,116(FIG.3) are installed, the user mounts the new frame110(FIG.1) carrying a new vent plate106(FIG.2) with a new air filter112(FIG.1) to the brackets114,116(FIG.1) and over the preexisting vent frame306(FIG.1).

The user may thereafter use a crank pole196(FIG.7) that has an actuator198(FIG.8) on its end. The actuator198(FIG.8) is placed to extend through the opening133(FIG.8) in the main frame member118(FIG.8) of the new frame110(FIG.8) to actuate the hoist arrangement170(FIG.8) to lower the vent plate106(FIG.7) carrying the air filter112(FIG.7) from the frame110(FIG.7) to the desired height above the floor. Once at the desired height, the user can easily remove the air filter112(FIG.7) from the vent plate106(FIG.7) for inspection or replacement. Once inspected or replaced, the user uses the crank pole196(FIG.7) to actuate the actuator198(FIG.8) to raise the vent plate106(FIG.7) carrying the air filter112(FIG.7) to its closed position (FIG.1) wherein the vent plate106(FIG.2) is again in contact with the frame110(FIG.2).

The vent plate106(FIG.7) is adjustable between a plurality of positions between the closed state (FIG.1) and the open state (FIG.7) as determined by the length of the ropes174,176,178,180and the distance between the teeth of the gears of the gear assembly172(FIG.8) while such adjustability therefore is not infinite, it may be said to be continuous between the open and closed positions. (FIG.1andFIG.7). Actuation of the hoist arrangement170turns all the pulleys174,176,178,180, and thus spools or unspools all the ropes174,176,178,180simultaneously depending on the actuation direction.

FIG.11shows filtered vent system100with main frame member118(FIG.7) removed to illustrate another hoist arrangement246that may be used instead of hoist arrangement170(FIG.7). Hoist arrangement246is the same as hoist arrangement170(FIG.7) except for the differences described here. Actuator198actuates gear assembly248which is made up a worm gear250which transfers the rotational force of the actuator198to gear252. Rotation of gear252in a first rotational direction unspools rope254from the first central pully214. Rotation of gear252in a second rotational direction spools rope254on the first central pulley214. Thus, unlike hoist arrangement170(FIG.7) only one rope254instead of two ropes174,176(FIG.7) is spooled to the first central pulley214. Likewise, only one rope256is spool on the second central pulley216instead of two ropes178,180(FIG.7).