Abstract:
An air filter assembly for remodel construction has a housing with a frame configured to seat against a wall and about a cold air return. A grill defining a plurality of louvers and a rim is configured to cover at least a portion of the housing outer surface. The rim extends to a depth no greater than the thickness of the housing outer surface. A filter has a frame configured to receive filtration media, the filter shaped and sized for removable insertion into the slot of the housing.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    Not applicable. 
       STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH 
       [0002]    Not Applicable. 
       BACKGROUND 
       [0003]    The invention relates to an air filter for heating and air conditioning systems, and more particularly, to an air filter assembly for use in remodel construction. 
         [0004]    Indoor air quality is increasingly becoming an important health, political, scientific, and environmental concern. Airborne contaminants, such as dust and pollen, can circulate throughout a building via heating and cooling systems. This has become a concern to homeowners, healthcare facilities, and other industries. Improving air quality by removing such particles reduces the risk of infection or other ailments that result from air pollution caused by these airborne particles. In particular, good air quality is important for those who suffer from respiratory ailments such as asthma. 
         [0005]    Heating and cooling systems typically include cleaners and filters that are positioned prior to flowing through the fan housing and into the duct system for delivery to the various areas of the building. However, these filters do not remove enough of the contaminants. Therefore, additional filtering of the airflow is needed before introduction of the air into the building. 
         [0006]    Some new constructions of buildings have begun incorporating such filtering systems and methods. However, existing buildings cannot be remodeled using the same systems and methods. Remodeling an existing building differs substantially from new construction and is often more expensive. With new construction, everything in the structure is designed from scratch and can be installed with complete access to all areas before they are blocked behind walls or other structures. In contrast, remodeling requires different equipment, materials, supplies, and techniques because of the limited access to many areas, such as behind walls, and the inability to change much of the existing structure. For example, the ducting for heating and cooling systems, including the location of cold air returns and registers, are typically located behind or within the walls of the building and are difficult to reroute once new construction is completed. 
         [0007]    Therefore, there is a need among consumers, healthcare facilities, and other industries for a cost-effective filter and grill assembly for installation in remodel construction. 
     
    
     
       DESCRIPTION OF THE DRAWINGS 
         [0008]    In the accompanying drawings which form part of the specification: 
           [0009]      FIG. 1  is a front exploded perspective view of a filter and grill assembly mounted to a cold air return for a heating and cooling system according to an embodiment of the present invention; 
           [0010]      FIG. 2  is a rear exploded perspective view of the filter and grill assembly according to an embodiment of the present invention; 
           [0011]      FIG. 3  is a front view of a grill according to an embodiment of the present invention; 
           [0012]      FIG. 4  is a rear view of the grill according to an embodiment of the present invention; 
           [0013]      FIG. 5  is a front view of a frame assembly according to an embodiment of the present invention; 
           [0014]      FIG. 6  is a rear view of the frame assembly according to an embodiment of the present invention; and 
           [0015]      FIG. 7  is a front view of a filter according to an embodiment of the present invention. 
       
    
    
       [0016]    Corresponding reference numerals indicate corresponding parts throughout the several figures of the drawings. 
       DETAILED DESCRIPTION 
       [0017]    The following detailed description illustrates the claimed invention by way of example and not by way of limitation. The description clearly enables one skilled in the art to make and use the disclosure, describes several embodiments, adaptations, variations, alternatives, and uses of the disclosure, including what is presently believed to be the best mode of carrying out the claimed invention. Additionally, it is to be understood that the disclosure is not limited in its application to the details of construction and the arrangements of components set forth in the following description or illustrated in the drawings. The disclosure 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. 
         [0018]    As shown in  FIGS. 1-8 , an embodiment constructed in accordance with the present disclosure, generally referred to as an air filter assembly  10  for remodel construction (or an existing building), includes a housing  12 , a removable filter  14 , and a grill  16 . The air filer assembly  10  seals on a wall  18  about a cold air return  20  to filter air containments from the air flow. 
         [0019]    The housing  12  is a generally rectangular prism that defines a generally rectangular prism shaped slot  22  sized and shaped to receive the filter  14 . A front face  24  of the housing  12  defines an inlet opening  26  generally corresponding to the size and shape of the filter  14 , but sized and shaped for retention of the filter within the slot of the housing. A rear face  28  of the housing  12  defines an outlet opening  30  generally corresponding to the size and shape of the filter  14 , sized and shaped for retention of the filter within the slot of the housing. For example, the perimeter of the inlet opening and outlet opening can be slightly smaller than the border of the filter to overlap the perimeter of the filter  14  for securement. The housing  12  is preferably made from aluminum, but can be made from any suitable material, including, but not limited to, metals, wood, or polymers. Insulation strips  32  are attached, such as with adhesive or fasteners, along the border of the rear face  28  to seal against the wall  18  about the cold air return  20 . The insulation strips  32  are preferably a foam material, but can be any suitable material that forms a seal between the housing  12  and wall  18 , including, but not limited to, natural materials or synthetic materials. The housing  12  defines holes  34  for insertion of fasteners  36  and securement to the wall  18 . 
         [0020]    The filter  14  is a generally rectangular frame  36  shaped and sized for placement within the slot  22  of the housing  12 . The frame  36  includes a perimeter preferably comprised of U-shaped channel sized and shaped for securement of filtration media  38 . A crossbar  40  extends between an upper portion and lower portion of the frame  36  to support the filtration material. The filtration media  38  can be any material suitable to trap airborne contaminants, including, but not limited to natural materials, synthetic materials, metal, paper, foam, organza, and the like. A tab  42  extends upwardly from the filter  14 , so that when the filter  14  resides in the housing  12 , the tab  42  extends out of the housing  12 . In this way, the tab  42  aids in removal of the filter from the housing  12 . Insulation strips  43  are attached, such as with adhesive or fasteners, along the upper edge filter frame  36  to seal against an inner surface of the housing  12 . The insulation strips  32  are preferably a foam material, but can be any suitable material that forms a seal between the housing  12  and wall  18 , including, but not limited to, natural materials or synthetic materials. 
         [0021]    The grill  16  is a generally rectangular panel  44  that is shaped and sized to generally cover the front and side surfaces of the housing  12 . The panel  44  defines a plurality of louvers  46  configured to direct airflow. A rim  48  extends generally rearwardly from the perimeter of the panel  44 . The length of the rim  48  generally corresponds to but does not exceed the width of an outer surface  50  of the housing  12 . A top portion of the rim  48  defines an opening  52  that corresponds generally to the shape and size of the slot  22  of the housing  12  so that the filter  14  can be inserted and removed from the housing  12 . The panel  44  defines holes  54  that generally aligns with the holes  34  in the housing  12  for insertion of fasteners and securement to the wall  18 . 
         [0022]    In operation, the housing  12  is positioned over the cold air return  20  with the insulation strips  32  sealed against the wall  18 . The grill  16  seats against the front face  24  of the housing  12  with the rim  48  extending to cover the outer surface  50  of the housing  12 . The opening  52  of the top portion of the rim  48  aligns with the slot  22  of the housing  12 . Fasteners  36  insert through the holes  54  of the grill and holes  34  of the housing  12  and secure to the wall  18 , preferably by insertion into studs. The filter  14  inserts into the slot  22  of the housing  12  with the tab extending out of the housing  12  for easier removal of the filter  14 . After a designated period of use, the filter  14  can be removed for cleaning or replacement. 
         [0023]    Changes can be made in the above constructions without departing from the scope of the disclosure, it is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense.