Abstract:
The invention provides a filter that can be cut-to-fit or deformed to fit a variety of differently shaped and sized intakes. The invention also provides a filter kit that allows a user to create a filter of a desired size with attaching mechanisms to secure the filter to or on the intake.

Description:
BACKGROUND OF THE INVENTION 
     The invention relates to filtration systems and, in particular, to a self-supporting filter that is readily fixed to or positioned on or in equipment intakes. 
     Clean air is important in the efficient operation of a variety of machines and systems. Forced-air cooling and heating systems, internal combustion engines, and even office equipment require clean air for proper operation. In most instances, filters are specially designed to fit into or onto an intake of the device with which the filter is used. This requires manufactures to produce a large variety of differently shaped and configured filters. For example, some filters come in numerous sizes based on width, length, and height. Of course, the near endless number of different filter sizes and configurations makes replacing filters difficult for users. In order to replace a used filter, an exact replacement filter of the correct size and style must be purchased. This is true even though the filtering media used in differently sized filters is often the same or very similar. When the exact filter needed is not available or out-of-stock, special ordering arrangements must be made. 
     SUMMARY OF THE INVENTION 
     Although current filters are functional, the system of making custom filters for each application is inefficient. The invention provides a filter that can be cut-to-fit or deformed to fit a variety of differently shaped and sized intakes. The invention also provides a filter kit that allows a user to create a filter of a desired size with attaching mechanisms to secure the filter to or on the intake. 
     The present invention is directed to a filter assembly that includes a self-supporting filter media and a plurality of attachment strips. The self-supporting filter media is configured to filter non-gaseous items from a gas flow. The attachment strips have a first portion that is attachable to the filter media and a second portion that is attachable to a housing surrounding an intake. 
     The present invention is also directed to a filter assembly that includes a filter media, a deformable frame, and attachment strips. The deformable frame is positioned around at least a portion of the filter media. The attachment strips have first sides and second sides. The first sides are attached to the deformable frame and the second sides are removably attachable to a housing surrounding an inlet. 
     The present invention is also directed to a method of mounting a filter to an intake on a housing. The method includes selecting a filter media, forming the filter media to a desired size to match the size and contours of the intake, fitting attachment strips along the periphery of the filter media, and securing the filter media to the intake with the attachment strips. 
     Other features and advantages of the present invention will become apparent by consideration of the detailed description and accompanying drawings. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a perspective view illustrating an apparatus with an air intake and a filter assembly of one embodiment of the present invention. 
     FIG. 2 is an enlarged perspective view of the filter assembly shown in FIG.  1 . 
     FIG. 3 is an exploded view of the filter assembly shown in FIG.  1 . 
     FIG. 4 is a partially-sectioned front view of the filter assembly shown in FIG.  1 . 
     FIG. 5 is a cross-sectional view taken along line  5 — 5  in FIG.  4 . 
     FIG. 6 is a perspective view illustrating an apparatus with an intake and a filter assembly of an alternative embodiment of the present invention. 
     FIG. 7 is a partially-sectioned front view of the filter assembly shown in FIG.  6 . 
     FIG. 8 is a cross-sectional view taken along line  8 — 8  in FIG.  7 . 
    
    
     DETAILED DESCRIPTION 
     Before embodiments of the invention are explained, it is to be understood that the invention is not limited in its application to the details of the construction and the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced or being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. 
     FIG. 1 illustrates an apparatus  10  such as an air conditioner or heat pump which includes a housing  12  with an air intake  14  (FIG. 2) and an air outlet (not shown). A fan (not shown) operates to draw air (creating an air or gas flow) through the air intake  14  into the housing  12  and through the air outlet. A filter assembly  16  is connected to the housing  12  and covers the intake  14  to prevent debris, contaminants, and other non-gaseous items present within the air from entering into the housing  12  through the intake  14 . 
     As shown in FIG. 3, the filter assembly  16  includes a filter  18  and attachment strips  20 . The filter  18  is detachably connected to the housing  12  around the intake  14  by the attachment strips  20 , such as VELCRO hoop and loop fastening strips. FIGS. 4 and 5 further illustrate that the attachment strips  20  are generally located around the perimeter of the filter  18 . The attachment strips  20  can be separate strips that are cut to length by scissors or the like and combined to cover the perimeter of the filter  18 . Alternatively, the attachment strips  20  could be made of a single integral piece that is cut to size by a cutting die. 
     The attachment strips  20  includes a first portion  22  that is attached to the housing  12  and a second portion  24  that is attached to the filter  18 . The first portion  22  includes an adhesive face  26  that is attachable to the housing  12  and a hook and loop face  28 . The second portion  24  includes an adhesive face  30  that is attachable to the filter  18  and a hook and loop face  32  that is removably attachable to the mating hook and loop face  28  on the first portion  22  of the attachment strip  20 . Alternatively, the second portion  24  of the attachment strip  20  could be attached to the filter  18  by stitching, stapling, gluing, taping, or the like. It should be noted that only a single portion of an attachment strip  20  could be used to attach the filter to the housing. Specifically, an adhesive face  26  of the single portion attaches to the housing  12 , and a hook and loop face  32  of the single portion fastens directly to the filter  18 . 
     As best shown in FIG. 5, the filter  18  is a washable, semi-rigid, three-dimensional type, synthetic media filter. In the illustrated embodiment, the three-dimensional type filter is a corrugated weave filter as opposed to a flat woven screen or other two-dimensional type filter. Three-dimensional type filters generally include a thickness component that increases the effectiveness of the filter and provides the filter with increased stability compared to the two-dimensional type filters. In contrast to typical filters that are mounted inside of equipment, the illustrated filter  18  is mounted to the exterior of equipment, and, therefore, the synthetic media is UV protected and is protected from degradation due to exposure to sunlight and hostile environments (e.g. rain, chemicals, oil, etc.). The filter  18  has a permanent electrostatic charge to facilitate the pickup of dust and other airborne contaminants. The filter  18  is self-supporting and is therefore capable of maintaining its shape under the pressure of its own weight. The filter  18  is, however, easily deformable to match the contours of the surface of the housing  12 . 
     In the illustrated embodiment, the filter  18  includes a corrugated layer  34  and a base layer  36 , each made of woven synthetic polymer fibers. The corrugated layer  34  is woven together with the base layer  36  and a top layer  38  such that the corrugated layer  34  is between the base layer  36  and the top layer  38 . The top layer  38  includes a plurality of threads that extend transversely to the corrugation direction of the corrugated layer  34 . 
     It can be seen that a custom-sized filter assembly  16  can be easily constructed by an individual on site with minimal materials. A filter kit, including bulk rolls or amounts of filter material and attachment strips, is all that would be necessary for an individual to create a filter assembly  16  to fit over almost any sized intake  14  opening. For example, the filter material could easily be cut by a pair of scissors to form a filter  18  that would cover an intake  14  opening. Next, attachment strips could be cut to length from the bulk roll so that the attachment strips  20  would substantially outline the perimeter of the filter  18 . After adhering the adhesive side  26  of the first portion  22  around the intake  14  of the housing  12  and the adhesive side  30  of the second portion  24  around the filter  18 , the hook and loop sides  28 ,  32  of the first and second portions  22 ,  24  could be removably attached to each other such that the filter  18  covers the intake  14  opening in the housing  12 . 
     FIG. 6 illustrates an apparatus  10  that includes an intake  14  and a filter assembly  40  of an alternative embodiment of the present invention. The apparatus  10  includes a housing  12  with the air intake  14  and an air outlet (not shown). A fan (not shown) operates to draw air in through the air intake  14  into the housing  12  and through the air outlet. The filter assembly  40  is connected to the housing  12  and covers the intake  14  to prevent debris and contaminants in the air from entering into the housing  12  through the intake  14 . 
     As shown in FIGS. 7 and 8, the filter assembly  40  includes a filter  42 , a support structure  44 , a frame  46 , and attachment strips  48 . The filter  42  and the support structure  44  are supported within the frame  46  such that the filter  42  and the support structure  44  are adjacent to each other. The filter  42  can be any known filter media and is prevented from substantial movement in one direction by the support structure  44 . The support structure  44  is a thin metal screen that is an expanded metal media designed to support the filter  42  and allow air flow through the filter. The support structure  44  is typically manufactured by cutting offset slits into a sheet of the metal material and pulling the metal sheet in a direction that is perpendicular to the direction of the slits. 
     The frame  46  includes multiple C-shaped and thin-walled metal channels  50  that are assembled to enclose and support the support structure  44  and the filter  42 . The metal frame  46  and support structure  44  are substantially rigid, however they are also semi-flexible such that the frame  46  and support structure  44  can be formed to match the contours of the housing  12  to which it is attached. In addition, the frame  46  allows slight flexing to effectively seal against a flat surface that is not perfectly planar. Alternatively, the support structure  44  and the frame  46  could be made from an easily flexible polymer material such as polypropylene, polyester, polyethylene, or the like. 
     The frame  46  is attached to the housing  12  by the attachment strips  48 , such as magnetic strips. The attachment strips  48  include adhesive sides  52  which are attached to the frame  46  and magnetic sides  54  that are detachably attached to the metal housing  12  around the intake  14  opening. Alternatively, the attachment strips  48  could be glued to the frame  46  or the frame  46  itself could be magnetized to facilitate the connection with the housing  12 . 
     As can be seen from the above, the invention provides, among other things, a filter assembly  40  and/or filter kit that can be (i) cut to fit a variety of intake  14  openings; (ii) simply placed over the intake  14  opening with the attachment strips  20 ,  48  to conveniently and reliably filter air flowing into the housing  12  through the  30  intake  14 ; and (iii) formed to match irregularities that are present in the housing  12  of different apparatuses  10  to which the filter assembly  16 ,  40  can be attached. Various features and advantages of the invention are set forth in the following claims.