Patent Abstract:
Contaminants present in air ducts or other components of HVAC systems may be carried by moving air passing through the HVAC system and ultimately delivered as air contaminants to rooms in which such contaminated air may be breathed in by humans. An air filter system is described for removing air contaminants from moving air passing through a register or grille between an air duct of a HVAC system and a room. The air filter system includes one or more air filters within an interface housing or secured by a frame that is attached or adhered to the register or grille so that the air filter removes at least some of the air contaminants in the moving air passing from the air duct through the register or grille before it enters the room. Methods for assembling and manufacturing air filter systems are also described.

Full Description:
FIELD OF THE INVENTION 
       [0001]    The present specification relates generally to air filters and more specifically relates to a system for removing air contaminants from moving air at an interface between a duct of a heating, ventilating and air conditioning (HVAC) system and a room. 
       BACKGROUND OF THE INVENTION 
       [0002]    Today, more than 50 million Americans suffer from allergies and 10-12 million Americans suffer from asthma. It has been suggested that one of six people suffer from allergies because of the fungi and bacteria in the air duct system of their residence and workplace. Moreover, the level of some contaminants in indoor air may be as high as 70 times the level found in outdoor air. It has been put forward that as many as half of all illnesses may be caused or aggravated by contaminants in indoor air. Furthermore, children and the elderly may be particularly susceptible to indoor air quality issues. 
         [0003]    Because most people spend about 60 percent to 90 percent of their time indoors, good indoor air quality is important to one&#39;s health. Air filters are known and used in establishments to improve indoor air quality by removing air contaminants such as dust, bacteria, pollen, carpet fibers, mold, smoke and pet dander from the air. A furnace filter is a common type of air filter, and is used to remove air contaminants at the interface between an air duct and the furnace so as to reduce or prevent air contaminants from entering into the furnace. However, most commercially available fiberglass filters are less than 7% efficient in removing airborne contaminants from indoor air. 
         [0004]    Despite the filtering of airborne contaminants entering a furnace, it is known that, over time, contaminants accumulate inside of the air ducts of a HVAC system as well as other components of a HVAC system. Typically, HVAC components such as furnaces and air conditioners may be serviced by a service technician, who, among other things, cleans out any build-up of contaminants that have accumulated in the furnace or air conditioner since it was last serviced. In the case of air ducts, air duct cleaning services may be available, but for large buildings, such as apartment buildings, such duct cleaning services may be costly and as a result the air ducts may not be cleaned regularly or at all. Moreover, a resident in a building may not be available to authorize air duct cleaning services for the building, and therefore may not be able to bring about the removal of any build-up of contaminants in the building air ducts leading to the rooms in their particular apartment or suite. Without regular air duct cleaning and furnace and air conditioner maintenance, individuals with respiratory health conditions, environmental allergies or sensitivities to allergens may find the indoor air quality to be problematic for them. 
         [0005]    Registers or grilles are typically used at the interface between air ducts and a room in a building. A register has moving components that allow a user to restrict air flow through the openings in a register, while a grille has the same openings to allow air flow there though as a register without the moving parts that allow a user to restrict the air flowing from them. Registers or grilles are not designed to accommodate air filters and at this time only rudimentary cut-to-fit polyester filter sheets are sold for air vents without an accompanying securing mechanism. 
         [0006]    Accordingly, there remains a need for improvements in the art. 
       SUMMARY OF THE INVENTION 
       [0007]    In accordance with an aspect of the invention, there is provided an air filter system for securing to an interface between an air conduit in a HVAC system and a room, the system for removing at least some air contaminants from moving air passing through the interface between the air conduit in the HVAC system and the room so as to improve the indoor air quality in the room. 
         [0008]    According to an embodiment of the invention, the present invention provides an air filter system for securing to an interface between an air conduit in a HVAC system and a room, the system for removing at least some air contaminants from moving air passing through the interface between the air conduit in the HVAC system and the room, the system comprising: at least one air filter; and a securing mechanism for attaching the air filter to the interface such that the at least one air filter removes at least some air contaminants from the moving air before the moving air enters the room. 
         [0009]    According to a further embodiment, the present invention provides a method for assembling an air filter system for securing to an interface between an air conduit in a HVAC system and a room, the system for removing at least some air contaminants from moving air passing through the interface between the air conduit in the HVAC system and the room, the method comprising: removing one or more release sheets covering adhesive on two or more flaps of a frame securing at least one air filter; and adhering the flaps to the interface between the air conduit and the room so as to place the at least one air filter between moving air from the air conduit and the room so as to allow the at least one air filter to remove at least some air contaminants from the moving air before it enters the room. 
         [0010]    According to a further embodiment, the present invention provides a method of manufacturing an air filter system for securing to an interface between an air conduit in a HVAC system and a room, the system for removing at least some air contaminants from moving air passing through the interface between the air conduit in the HVAC system and the room, the method comprising: folding and cutting a cardboard sheet into a frame for securing at least one air filter, the frame including a right side panel, a left side panel, a rear side panel, a front side panel and at least two sealing flaps; adhering the frame to the at least one air filter so as to secure the at least one air filter to the frame; applying an adhesive to the at least two sealing flaps, the adhesive being sufficiently strong so as to allow the frame to be secured to a register or grille; and covering the adhesive with one or more removable release sheets. 
         [0011]    According to a further embodiment, the present invention provides an air filter system for securing between an air conduit in a HVAC system and a room, the system for removing at least some air contaminants from moving air passing through the interface between the air conduit in the HVAC system and the room, the system comprising: a frame capable of being secured around an opening between the air conduit in the HVAC system and the room; an interface at least partially releasably secured to the frame; and at least one air filter for positioning between the interface and the air conduit. 
         [0012]    According to a further embodiment, the present invention provides an air filter housing for positioning at least one air filter between an air conduit in a HVAC system and a room, the housing comprising: a frame capable of being secured around an opening between the air conduit in the HVAC system and the room; and an interface at least partially releasably secured to the frame; wherein at least one air filter may be positioned between the interface and the air conduit. 
         [0013]    Other aspects and features according to the present application will become apparent to those ordinarily skilled in the art upon review of the following description of embodiments of the invention in conjunction with the accompanying figures. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0014]    Reference will now be made to the accompanying drawings which show, by way of example only, embodiments of the invention, and how they may be carried into effect, and in which: 
           [0015]      FIG. 1  is a perspective view of an air filter system according to an embodiment as secured to a register between a duct of a HVAC system and a room; 
           [0016]      FIG. 2  is an exploded view of an air filter system, register and air duct according to an embodiment; 
           [0017]      FIG. 3  is an exploded view of a register and air filter system according to an embodiment; 
           [0018]      FIG. 4A  is a front view of an air filter according to an embodiment,  FIG. 4B  is a side view of the air filter of  FIG. 4A , and  FIG. 4C  is a top view of the air filter of  FIG. 4A ; 
           [0019]      FIG. 5  is a view of an unassembled cardboard frame for securing around one or more air filters according to an embodiment; 
           [0020]      FIG. 6  is a perspective view of a second embodiment of an air filter system which is secured to a ceiling of a room and is shown in an open position for inserting or replacing an air filter; and 
           [0021]      FIG. 7  is a cross-sectional side view of the air filter system of  FIG. 6  after the air filter has been loaded. 
       
    
    
       [0022]    Like reference numerals indicate like or corresponding elements in the drawings. 
       DETAILED DESCRIPTION OF THE EMBODIMENTS 
       [0023]    According to embodiments as shown in  FIGS. 1, 2, 3, 4A, 4B, 4C, and 5 , an air filter system  400  may be secured to an interface, such as a register  500  or grille, in a floor, ceiling or wall of a room  900 . Such interfaces are already existing in buildings and are generally found positioned between an air conduit, such as air duct  700 , in a HVAC system (not shown) operating in the building and the particular room  900 . The air filter system  400  may include at least one air filter  110  which may remove at least some air contaminants from the moving air passing through the interface, such as register  500 , between the air conduit, such as air duct  700 , in the HVAC system and the room  900 . According to an embodiment, the air filter system  400  may comprise at least two air filters  110 . Since a dirty air filter may cause greater reduction of air flow through the air filter  110  than a clean or new air filter, the air filter  110  should be cleaned, if possible, or replaced at regular intervals to limit any reduction in air flow into the room  900  that may be caused by the presence of air filter  110 . 
         [0024]    According to embodiments as shown in  FIGS. 3 and 5 , the air filter system  400  may comprise a frame  600 , which may be made of cardboard or any other suitable material for securing to an air filter. The frame  600  may comprise a sealing tab  170 , a right side flap  140 , a left side flap  160 , a rear side flap  150 , a front side flap  130 , a right side panel  200 , a left side panel  180 , a rear side panel  190  and a front side panel  210 . 
         [0025]    According to embodiments as shown in  FIGS. 3 and 5 , an inner surface of the sealing tab  170 , the right side flap  140 , the left side flap  160 , the rear side flap  150  and the front side flap  130  may comprise an adhesive placed thereon as shown by sealing tab adhesive  260 , a right side flap adhesive  230 , a left side flap adhesive  250 , a rear side flap adhesive  240  and a front side flap adhesive  220 , respectively. The adhesives on the flaps may be covered by removable release sheets that may prevent the adhesives from adhering to anything other than the release sheet prior to the release sheet being removed when the air filter system  400  is ready to be installed. Then, for use, the air filter system  400  may be assembled by the purchaser by removing the one or more release sheets covering the adhesive and adhering the flaps to the interface, such as register  500 . 
         [0026]    According to an embodiment as shown in  FIG. 5 , the sealing tab  170  may be an extension of the left side panel  180 . The sealing tab  170  may be positioned onto an outer surface of the front side panel  210  and adhered by the sealing tab adhesive  260  so as to create an assembled frame  600 . The at least one air filter  110  may be placed inside the frame  600  after it is assembled or alternatively the frame  600  may be assembled around the perimeter of the at least one air filter  110 . The frame  600  may be adhered to the at least one air filter through the use of glue or another adhesive, or by any other suitable means for securing the at least one air filter  110  to the frame  600 . According to an embodiment, a lower portion of an inner surface of the right side panel  200 , the left side panel  180 , the rear side panel  190  and the front side panel  210  may comprise a right side panel adhesive  290 , a left side panel adhesive  270 , a rear side panel adhesive  280  and a front side panel adhesive  300 , respectively. 
         [0027]    According to an embodiment, the air filter system  400  may be attached to a bottom or rear surface of an interface such as register  500  by positioning two or more flaps with adhesive thereon onto the bottom or rear surface of the interface. According to a further embodiment, the air filter system may be attached to the top or front of the interface such as register  500  or a grille. While attaching the air filter system  400  to the bottom or rear surface will generally obscure it from view and therefore be more aesthetically appealing, attaching the air filter system to the front of the register or grille may be functionally equivalent and may be more suitable where the grille is not removable or at least not easily removed by the occupant of the room. 
         [0028]    According to a further embodiment, the frame  600  may be secured to the interface, such as register  500 , using one or more clips, which may be made from plastic or metal or another suitable material. The clips would attach to the interface either through two attaching openings in the register or grille or around perimeter edges of the grille or register  500 . According to an embodiment, at least two clips may be used to ensure secure engagement of the frame  600  with the interface. Such a clip may be made integral with the frame or separate and attachable by the user. 
         [0029]    According to an embodiment, the air filter system may be manufactured by first folding and cutting a cardboard sheet into frame  600 . Then the frame  600  may be adhered to the at least one air filter  110  such as with the use of glue or another suitable adhesive or attached by another securing mechanism. Further, an adhesive may be applied to two or more of the flaps and then covered with one or more removable release sheets. According to an embodiment, the adhesive may be sufficiently strong so as to allow the frame  600  to be secured to a register  500  or grille. 
         [0030]    According to a further embodiment, at least one air filter  110  may be mounted or received inside a housing of an interface, for example, a specially-configured register or grille. Such a specially configured register may be made of plastic or metal or any other suitable material for the particular indoor use. 
         [0031]    According to an embodiment as shown in  FIGS. 6 and 7 , an air filter system  400   a  may comprise an interface housing  910  which may comprise an interface, such as a register or grille  505 , which may connect at a pivot  950  to a frame  920  that may be secured to a ceiling  930 , wall or floor, and inside which interface housing  910  at least one air filter  110  may be housed or positioned so that the at least one air filter  110  is situated between the interface and the air conduit. The air filter system  400   a  may be used in place of, or to replace, a standard interface in a building. 
         [0032]    According to an embodiment, a gasket  910  may optionally be used with air filter system  400   a . Optional gasket  910  may be made from material that acts as a seal and allows for compression, such as foam, and may be seated on the side of the frame  920  that is adjacent to the air conduit and shaped so as not to impede air flow between the air conduit and the at least one air filter  110 . 
         [0033]    According to an embodiment, the frame  920  may be configured so as to be capable of being placed generally flush with a flat surface such as a ceiling  930 , wall or floor, and secured to the surface using two or more screws  940  or other suitable securing mechanisms. 
         [0034]    According to an embodiment as shown in  FIGS. 6 and 7 , the frame  920  may also include one or more releasable clips  960 . The clips  960  may be unclipped to allow the interface to pivot about pivot  950  and permit the at least one air filter  110  to be inserted or replaced within the interface housing  910 . According to an embodiment, the interface housing  910  may be configured to receive the at least one air filter  110  and allow it to be mounted or at least partially secured or impeded from movement such as through ridges  965  on the register or grille  505  which are sized so that they may impede the at least one air filter  110  from shifting movement while the air filter system  400   a  is in use filtering moving air. Once the at least one air filter  110  has been replaced or inserted, the register or grille  505  may be pivoted closed and then held in place by securing the clips  960 . Further, other mechanisms for partially or fully releasably securing the interface may be employed so long as they allow the at least one air filter  110  to be inserted or replaced as needed. 
         [0035]    The present invention may be embodied in other specific forms without departing from the spirit or essential characteristics thereof. Certain adaptations and modifications of the invention will be obvious to those skilled in the art. Therefore, the presently discussed embodiments are considered to be illustrative and not restrictive, the scope of the invention being indicated by the appended claims rather than the foregoing description and all changes which come within the meaning and range of equivalency of the claims are therefore intended to be embraced therein.

Technology Classification (CPC): 5