Abstract:
The present invention relates to an add on filter for a packaged air handling unit, such as a heating, ventilation and/or air conditioning unit, and method incorporating an add on filter for applying ultraviolet light to an environment to create oxidizing agents for killing microbes, such as bacteria, mold, and viruses, and for destroying odors. The add on filter may be coupled to the blower housing of existing packaged heating, ventilation and/or air conditioning units. The add on filter includes an ultraviolet light source for emitting a broad spectrum of ultraviolet light and a catalytic target structure mechanically coupled to the ultraviolet light source. The system and method result in the production of Hydroxyl Radicals, Super Oxide ions and Hydro Peroxide for killing microbes.

Description:
TECHNICAL FIELD 
       [0001]    The present invention relates generally to the field of air filtration and, more particularly, to an add on filter for an air handling unit and a method for applying the same. The add on filter is mounted to a blower in an air handling unit and applies ultraviolet light to an environment to create oxidizing agents for killing microbes, such as bacteria, mold, and viruses, and for destroying odors. 
       BACKGROUND 
       [0002]    Traditional air filtration systems are not effective for treating many types of microbials (e.g., bacteria, germs, viruses, fungi, spores and mold) and gases (e.g., benzene, formaldehyde, chloroform, hydrogen sulfide, ammonia). Hydroperoxides are very effective at destroying harmful microbials in the air and on surfaces through a process called cell lysing or by changing its molecular structure. Hydroperoxides are also effective at rendering gases harmless by changing their molecular structure. The present invention treats microbials and gases in package air handling units, such as a heating, ventilation and/or air conditioning unit. 
       SUMMARY 
       [0003]    Particular embodiments of the present invention are directed to an add on filter and method incorporating such an add on filter for applying ultraviolet light to an air handling unit for killing microbes, such as bacteria, mold, and viruses, and for destroying odors. 
         [0004]    According to particular embodiments of the present invention, an add on filter for a packaged heating, ventilation and/or air conditioning unit including a blower and a blower housing comprising a filter housing is provided. The add on filter also includes a first mounting unit coupled to the filter housing and a first magnet to couple the first mounting unit to the blower housing. The add on filter further includes a second mounting unit coupled to the filter housing and a second magnet to couple the second mounting unit to the blower housing. The distance between the first magnet and the second magnet is adjustable. The add on filter also includes a device disposed in the filter housing for the formation of advanced oxidation product. The device for formation of advanced oxidation product includes an ultraviolet light source for emitting a broad spectrum of ultraviolet light and a first catalytic target structure mechanically coupled to the ultraviolet light source. 
         [0005]    In some embodiments, the first mounting unit is approximately V-shaped and the second mounting unit is approximately V-shaped. Each of the first mounting unit and the second mounting unit includes at least two magnets. Each magnet of each mounting unit is independently adjustable relative to the respective mounting unit. In some embodiments, the first mounting unit is shaped to be mounted on a plurality of blower housings, wherein each of the plurality of blower housings includes a different curvature of radius. 
         [0006]    In some embodiments, the first mounting unit includes a first rail and a portion of the first magnet is positioned in the first rail. The second mounting unit includes a second rail and a portion of the second magnet is positioned in the second rail. The first magnet is slidable relative to the first rail, and the second magnet is slidable relative to the second rail. In some embodiments, the first mounting unit includes a third rail and a portion of a third magnet is positioned in the third rail, and the second mounting unit includes a fourth rail and a portion of a fourth magnet is positioned in the fourth rail. The third magnet is slidable relative to the third rail, and the fourth magnet is slidable relative to the fourth rail. When the add on filter is mounted to the blower housing, the first magnet is fixed relative to the first rail, the second magnet is fixed relative to the second rail, the third magnet is fixed relative to the third rail and the fourth magnet is fixed relative to the fourth rail. 
         [0007]    In some embodiments, the filter housing includes a first protrusion and a second protrusion. The first protrusion forms a first rail with the first mounting unit and a portion of the first magnet is positioned in the first rail. The second protrusion forms a second rail with the second mounting unit and a portion of the second magnet is positioned in the second rail. 
         [0008]    In some embodiments, the filter housing includes a plurality of openings in a portion of the filter housing surrounding the device for formation of advanced oxidation product. The portion of the filter housing including a plurality of openings forms a second catalytic target structure. 
         [0009]    According to particular embodiments of the present invention, a system for filtering air in a packaged heating, ventilation and/or air conditioning unit comprising a blower and a blower housing includes an add on filter coupled to the blower housing to produce an oxidation agent. The add on filter comprises a filter housing. The add on filter also includes a first mounting unit coupled to the filter housing and a first magnet to couple the first mounting unit to the blower housing. The add on filter further includes a second mounting unit coupled to the filter housing and a second magnet to couple the second mounting unit to the blower housing. The distance between the first magnet and the second magnet is adjustable. The add on filter also includes a device disposed in the filter housing for the formation of advanced oxidation product. The device for formation of advanced oxidation product includes an ultraviolet light source for emitting a broad spectrum of ultraviolet light and a first catalytic target structure mechanically coupled to the ultraviolet light source. 
         [0010]    In another aspect, certain embodiments of the present invention are directed to a method for filtering air in a packaged heating, ventilation and/or air conditioning unit including a blower with a blower housing. The method includes a step of providing an add on filter including a first mounting unit with a first magnet and a second mounting unit with a second magnet. The method also includes a step of adjusting a distance between the first magnet and the second magnet such that the distance between the first and second magnets is not greater than a length of the blower housing. The method further includes a step of mounting the add on filter to the blower housing via the first magnet and the second magnet. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0011]    The accompanying drawings, which are incorporated herein and form part of the specification, illustrate various embodiments of the present disclosure and, together with the description, further serve to explain the principles of the disclosure and to enable a person skilled in the pertinent art to make and use the embodiments disclosed herein. In the drawings, like reference numbers indicate identical or functionally similar elements. 
           [0012]      FIG. 1  Illustrates a perspective view of a packaged air handling unit, such as a heating, ventilation and/or air conditioning unit, known in the art. 
           [0013]      FIG. 2  illustrates a perspective view of an add on filter mounted on a blower housing in accordance with exemplary embodiments of the present invention. 
           [0014]      FIG. 3  illustrates a side view of an add on filter mounted on a blower housing in accordance with exemplary embodiments of the present invention. 
           [0015]      FIG. 4  illustrates a perspective view of an add on filter in accordance with exemplary embodiments of the present invention. 
           [0016]      FIG. 5  illustrates a perspective view of an add on filter in accordance with exemplary embodiments of the present invention. 
           [0017]      FIG. 6  illustrates a perspective view of an add on filter in accordance with exemplary embodiments of the present invention. 
           [0018]      FIG. 7  illustrates a base of an add on filter in accordance with exemplary embodiments of the present invention. 
           [0019]      FIG. 8  illustrates a detailed view of a mounting unit of the add on filter in accordance with exemplary embodiments of the present invention. 
           [0020]      FIG. 9  illustrates a detailed view of a mounting unit of an add on filter in accordance with exemplary embodiments of the present invention. 
           [0021]      FIG. 10  illustrates a perspective view of a device for formation of advanced oxidation product without the housing and a base of an add on filter in accordance with exemplary embodiments of the present invention. 
           [0022]      FIG. 11  illustrates a top view of a device for formation of advanced oxidation product without the housing and a base of an add on filter in accordance with exemplary embodiments of the present invention. 
           [0023]      FIG. 12  illustrates a perspective view of a device for formation of advanced oxidation product of an add on filter without the housing in accordance with exemplary embodiments of the present invention. 
           [0024]      FIG. 13  illustrates a perspective view of a device for formation of advanced oxidation product and a housing of an add on filter in accordance with exemplary embodiments of the present invention. 
       
    
    
     DETAILED DESCRIPTION 
       [0025]    As required, detailed embodiments of the present invention are disclosed herein; however, it is to be understood that the disclosed embodiments are merely exemplary of the invention, which can be embodied in various forms. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art. Further, the terms and phrases used herein are not intended to be limiting; but rather, to provide an understandable description of the invention. 
         [0026]    According to particular embodiments of the present invention, an add on filter for a packaged air handling unit, such as a heating, ventilation and/or air conditioning unit, includes a device for formation of an advanced oxidation product, such as a PHI cell. The add on filter may be coupled to the blower housing of a packaged air handling unit. The device for formation of an advanced oxidation product includes an ultraviolet light source for emitting a broad spectrum of ultraviolet light and a catalytic target structure mechanically coupled to the ultraviolet light source. The target catalytic structure comprises a multi-metallic catalytic and hydrophilic material, and the hydrophilic surface attracts and absorbs moisture from the surrounding air. The broad spectrum ultraviolet light includes multiple bands of ultraviolet light at about 185 nm, 254 nm, 320 nm, 365 nm, 380 nm, 400 nm and 480 nm wavelength. The ultraviolet energy at 254 nm and above strikes the target structure and activates production of Hydroxyl Radicals, Super Oxide ions and Hydro Peroxide on the surface. The ultraviolet energy at 185 nm is sufficient to split oxygen molecules to form ozone gas. These ozone molecules in the air are then reduced back to oxygen via decomposition process initiated by the 254 nm ultraviolet light energy, which results in the production of Hydroxyl Radicals, Super Oxide ions and Hydro Peroxide similar to the surface reaction. This process is described in further detail in co-owned U.S. Pat. No. 7,988,932, the entire disclosure of which is herein incorporated by reference. 
         [0027]      FIG. 1  illustrates a packaged air handling system, such as a heating, ventilation and/or air conditioning unit, known in the art. The air handling system  100  includes a blower  102 , which includes a blower housing  104 . The blower  102  is configured to move air through the air handling unit  100 . The blower housing  104  surrounds the blower  102  and is composed of a metallic material. The air handling system  100  also includes a condenser fan  106 , condenser coils  108 , a compressor  110 , a resistance heater  112  and a circuit board  114 . 
         [0028]      FIGS. 2 and 3  illustrate an add on filter  200  mounted on a blower housing  104  of an air handling unit according to particular embodiments of the present invention. The add on filter  200  includes a filter housing  202  surrounding a device for formation of an advanced oxidation product or PHI cell  204  which treats microbials and gases. The housing  202  is configured to allow air to move through the add on filter  202  and be treated by the PHI cell  204 . The add on filter  200  is mounted on the blower housing  104  by magnets on a first mounting unit  206  and a second mounting unit  208  (see  FIG. 4 ), which will be discussed in further detail below. The add on filter  200  is positioned on the blower housing  104  such that air traveling through the air handling unit  100  is treated with the advanced oxidation product. 
         [0029]      FIGS. 4-6  illustrate an add on filter  200  according to particular embodiments of the present invention. The add on filter  200  includes a filter housing  202 , a PHI cell  204 , a first mounting unit  206 , a second mounting unit  208 , a base  210  and a plurality of openings in the filter housing  212 . The PHI cell  204  is positioned within the filter housing  202  such that the plurality of openings  212  surround the cell  204 . The plurality of openings  212  allow air to pass through the add on filter  200  and be treated by the PHI cell  204 . In an embodiment of the present invention, the PHI cell  204  is mounted to the base  210 , as described in further detail below with reference to  FIGS. 10 and 11 . The first mounting unit  206  includes a first rail  400  and a second rail  402 , and the second mounting unit  208  includes a third rail  408  and a fourth rail  410 . Each rail is an opening in its respective mounting unit. The first mounting unit  206  also includes a first magnet  404  configured to engage the first rail  400  and a second magnet  406  configured to engage the second rail  402 . The second mounting unit  208  includes a third magnet  412  configured to engage the third rail  408  and a fourth magnet  414  configured to engage the fourth rail  410 . Each magnet  404 ,  406 ,  412  and  414  is approximately I-shaped, and each magnet is positioned in its respective rail  400 ,  402 ,  408  and  410  such that the narrow middle portion of the magnet is positioned in the rail. Each magnet  404 ,  406 ,  412  and  414  is slidable relative to its respective rail  400 ,  402 ,  408  and  410  over the length of the rail. 
         [0030]    Each mounting unit  206  and  208  is approximately V-shaped, i.e., the portion between the rails is concave. The shape of each mounting unit  206  and  208  and the position of the rails  400 ,  402 ,  408  and  410  in their respective mounting unit allow the add on filter  200  to be mounted on blower housings  104  with different curvatures of radius. In particular, each of the magnets  404 ,  406 ,  412  and  414  is strong enough to pull itself, its respective rail and the mounting unit surrounding it towards the surface of the blower housing  104 . The strength of the magnets  404 ,  406 ,  412  and  414  allows for the mounting units  206  and  208  to adapt to different curvatures of radius. Also, the strength of the magnets  404 ,  406 ,  412  and  414  is such that it creates friction with the portion of the mounting units  206  and  208  surrounding the rails  400 ,  402 ,  408  and  410  sufficiently strong to prevent the magnets from sliding relative to the rails, i.e., when the add on filter  200  is mounted to a blower housing  104 , the magnets  404 ,  406 ,  412  and  414  become locked in place. In contrast, when the add on filter  200  is not mounted to a blower housing  104 , each of the magnets  404 ,  406 ,  412  and  414  are easily moved relative to its respective rail  400 ,  402 ,  408  and  410 . Prior to mounting the add on filter  200  on a blower housing  104 , the position of each of the magnets  404 ,  406 ,  412  and  414  may be adjusted relative to its respective rail  400 ,  402 ,  408  and  410  such the distance between the magnets of the first mounting unit  206  and the magnets of the second mounting unit  208  may be adjusted to allow the add on filter  200  to be mounted on blower housings  104  of various lengths. 
         [0031]      FIGS. 7-9  illustrate detailed views of mounting units  206  and  208  of an add on filter according to particular embodiments of the present invention. The mounting units  206  and  208  are coupled to the base  210  of the filter housing. Each mounting unit  206  and  208  includes an inner member  700 , a transverse member  702  and outer members  712  and  714 . It should be understood that while the description below is directed to the first mounting unit  206 , the components described are the same in both mounting units  206  and  208 . The inner member  700  is positioned in between the outer members  712  and  714  and the transverse member  702  is coupled to the outer members  712  and  714  such that it extends across the inner member  700 . In an embodiment of the present invention, the transverse member  702  may be bent towards the inner member when assembled, which allows for fitting the curvature of the blower. The inner member  700  includes a first angled member  704 , a center member  706  and a second angled member  708 . The first and second angled members  704  and  708  are coupled to opposite sides of the center member  706 , and each of the angled members  704  and  708  extend from the center member  706  at an angle away from the base  210 . The first angled member  704  forms a rail  400  with the outer member  714 . The transverse member  702  forms a first end of the rail  400  and a protrusion extending from the outer member  714  and a protrusion extending from the first angled member  704  form a second end of the rail  400 . Similarly, the second angled member  708  forms a rail  402  with the outer member  712 , and the ends of the rail  402  are defined by the transverse member  702  and protrusions extending from the second angled member  708  and the outer member  712 . 
         [0032]    The mounting units  206  and  208  are coupled to base  210 . The inner members  710  of the mounting units  206  and  208  may be coupled to the base  210  via coupling members (e.g., screws or bolts) engaged with openings  710  and corresponding openings in the base  210 . The transverse members  702  may be coupled to the outer members  712  and  714  via a coupling member (e.g., screws or bolts), and the coupling members may extend into the base  210 . The outer members  712  and  714  may be welded to the base  210 . In another embodiment of the present invention, the inner member  700 , the transverse member  702 , and the outer members  712  and  714  may be a single unit coupled to the base  210 . 
         [0033]      FIGS. 10-13  illustrate a device for formation of an advanced oxidation product  204  without the housing according to particular embodiments of the present invention. The device for formation of an advanced oxidation product or PHI cell  204  includes an ultraviolet light source  1000 , a target structure  1002 , a connector  1004 , a ballast  1006  and a cord  500 . The PHI cell  204  is coupled to the base by coupling member  108 , such as clips configured to engage the ends of the PHI cell  204 . The ultraviolet light source  1000  is a cylindrical bulb. The target structure  1002  surrounds the light source  1000  provides a surface area to be contacted by the ultraviolet light emitted by the source  1000 . The ultraviolet light source  1000  emits ultraviolet light at multiple bands: about 185 nm, 254 nm, 320 nm, 365 nm, 380 nm, 400 nm and 480 nm wavelength. The target catalytic structure  1002  comprises a multi-metallic catalytic and hydrophilic material, and the hydrophilic surface attracts and absorbs moisture from the surrounding air. The ultraviolet energy at 254 nm and above strikes the target structure  902  and activates production of Hydroxyl Radicals, Super Oxide ions and Hydro Peroxide on the surface. The ultraviolet energy at 185 nm is sufficient to split oxygen molecules to form ozone gas. These ozone molecules in the air are then reduced back to oxygen via decomposition process initiated by the 254 nm ultraviolet light energy, which results in the production of Hydroxyl Radicals, Super Oxide ions and Hydro Peroxide similar to the surface reaction. The ultraviolet light source  1000  is supplied energy by the ballast  1006  via the cord  500 . The ballast  1006  is connected to the ultraviolet light source  1000  via the connector  1004 . 
         [0034]    In an embodiment of the present invention, the portion of the filter housing  102  surrounding the PHI cell  204  and including a plurality of openings  212  is also a target structure. This portion of the filter housing  102  comprises a multi-metallic catalytic and hydrophilic material, and the hydrophilic surface attracts and absorbs moisture from the surrounding air. 
         [0035]    While various embodiments have been described above, it should be understood that they have been presented by way of example only, and not limitation. Thus, the breadth and scope of the present disclosure should not be limited by any of the above-described exemplary embodiments. Moreover, any combination of the above-described elements in all possible variations thereof is encompassed by the disclosure unless otherwise indicated herein or otherwise clearly contradicted by context. 
         [0036]    Additionally, while the processes described above and illustrated in the drawings are shown as a sequence of steps, this was done solely for the sake of illustration. Accordingly, it is contemplated that some steps may be added, some steps may be omitted, the order of the steps may be re-arranged, and some steps may be performed in parallel.