Patent Abstract:
A filter-fan unit has a housing, at least one fan arranged in the housing, and at least one filter connected to the housing. The housing is transferable from a transport/storage position into a position of use, wherein the transport/storage position is significantly smaller than the position of use. The housing is foldable from the transport/storage position into the position of use. The housing has a housing frame and one or more sidewalls connected with one side to the housing frame.

Full Description:
BACKGROUND OF THE INVENTION 
   The invention relates to a filter-fan unit comprising a housing in which at least one fan is arranged and which comprises at least one filter. 
   Filter-fan units have a housing made from sheet metal or plastic material in which the fan, optionally a soundproofing device and/or at least one suspended particle filter are installed fixedly. The filter-fan units are rigid and are transported in their assembled state and size, mounted on a filter or mounted, including the filter, in a ceiling grid. For mounting a unit that has a square contour from the cleanroom side, the ceiling has profiled section with insertion strips because the unit when it has a certain height can no longer be pushed diagonally through the opening of the ceiling grid. Storing and transporting such filter-fan units is complex and expensive because of the large size. In particular, the space required for storage and transport is significant. 
   SUMMARY OF THE INVENTION 
   It is an object of the present invention to configure a filter-fan unit of the aforementioned kind such that it can be easily stored and/or transported and/or mounted. 
   In accordance with the present invention, this is achieved in that the housing can be transferred from a transport/storage position having a small size into a position of used having a large size. 
   In the filter-fan unit according to the invention, the housing can have a small size during transport and/or when stored. At the site where the filter-fan unit is to be mounted, the housing is transferred from the transport/storage position into a position of use. In the position of use the housing has its final predetermined size. The housing of the filter-fan unit is thus no rigid component but has a foldable or collapsible construction that can be comprised of different materials, for example, sheet metal, plastic material, fabric and the like. Since the housing can be transferred into a small size for transport and/storage, the filter-fan unit requires only a small space. Once delivered to the site where it is to be installed, the housing is transferred into the large final size. Accordingly, the housing can be unfolded, for example, once it is located in the cleanroom or the supply air plenum, the open edges can be connected and the filter-fan unit formed in this way can be placed onto the filter. Likewise, mounting of the fan can also be realized in the cleanroom or the supply air plenum. 
   The filter-fan unit can have the soundproofing elements that obtain their full size and efficiency only upon unfolding of the housing. Such sound-proofing elements can be, for example, open-pore foam material, micro-porous films and the like. 
   In a first embodiment, the filter, the housing, and the fan each are an independent component whose housing can be, for example, folded or collapsed. However, it is also possible that the filter and the housing together form a module and that the fan is a separate component. It is also possible that the housing and the fan together form a module and that the filter is a separate component. Finally, the filter, the housing, and the fan can formed a module. 
   Since the housing can be folded or collapsed to a small size (to a size or height much smaller or significantly smaller than the housing in its position of use—theoretically it can be reduced to a height that corresponds to the thickness of the sidewalls and the housing frame or the lid), a very small transport/storage size results. When filter and housing form a module, during transport and/or storage the size of the module is not larger than that of the filter or only insignificantly larger. Advantageously, the housing can be folded to be flat. The housing can be combined with filters of different manufacturers. 
   In contrast to known filter-fan units, an inventive filter-fan unit having a square contour can be mounted from the cleanroom side without requiring insertion strips. This is so because the housing when in the flat, folded or collapsed state can be pushed diagonally through the opening in the ceiling grid. 
   Each component of the filter-fan unit, i.e., the filter, the housing, and the fan can be delivered separately to the construction site. Intermediate transports, for example, transporting the fan to the manufacturer of the housing, are not required. Also, the required space during installation in the cleanroom at the customer site is significantly reduced because of the configuration in accordance with the invention. Also, the installation, in particular, in cleanrooms with high ceilings is significantly simplified because of the reduced size of the collapsed housing. 
   The housing can be produced from any suitable material, for example, sheet metal, plastic material or fabric in particular flame resistant canvas material. 
   When the housing walls are supported in a pivotable way, it is possible to employ weakened portions in the material as predetermined bending locations, hinges or strap hinges as a pivotable connection. When the housing is made from fabric, it is possible to connect the tailored sections of the fabric by means of a zipper or a hook-and-loop fastener. 
   The connection of the fan or the fan unit and the housing can be realized in any suitable way, for example, by placing the fan unit onto an angled portion of the housing wall, by gluing with a double-sided adhesive tape or, for example, by connecting with snap-fit closures. 

   
     BRIEF DESCRIPTION OF THE DRAWING 
       FIG. 1  is a schematic side view illustration of a folded housing of a filter-fan unit according to the invention. 
       FIG. 2  is a schematic illustration of a suspended particle filter of the filter-fan unit according to the invention. 
       FIG. 3  is a plan view onto the folded housing according to  FIG. 1 . 
       FIG. 4  is a schematic illustration of a fan insert of the filter-fan unit according to the invention. 
       FIG. 5  shows the housing according to  FIG. 1  in the unfolded state. 
       FIG. 6  shows the suspended particle filter according to  FIG. 2 . 
       FIG. 7  is a plan view of the unfolded housing according to  FIG. 5 . 
       FIG. 8  shows a side view of the mounted filter-fan un it with unfolded housing, the suspended particle filter, and the inserted fan insert. 
       FIG. 9  shows the filter-fan unit according to  FIG. 8  in a plan view. 
       FIG. 10  is a side view showing schematically a second embodiment of a suspended particle filter of the filter-fan unit according to the invention. 
       FIG. 11  is a plan view of a second embodiment of a filter-fan unit according to the invention showing the folded housing in which the filter insert is mounted. 
       FIG. 12  is a side view of the folded housing with fan insert according to  FIG. 11 . 
       FIG. 13  shows the unfolded housing with fan insert. 
       FIG. 14  is a plan view onto the unfolded housing according to  FIG. 13 . 
       FIG. 15  is a side view of the finish-mounted filter-fan unit with attached suspended particle filter. 
       FIG. 16  is a plan view onto the filter-fan unit according to  FIG. 15 . 
       FIG. 17  is a side view of a fan insert of a further embodiment of a filter-fan unit according to the invention. 
       FIG. 18  is a schematic side view illustration of a further embodiment of the filter-fan unit according to the invention showing a folded housing that is provided on a suspended particle filter. 
       FIG. 19  is a plan view onto the folded housing according to  FIG. 18 . 
       FIG. 20  shows the unfolded housing of  FIG. 18 . 
       FIG. 21  shows a plan view onto the unfolded housing according to  FIG. 20 . 
       FIG. 22  is a schematic side view illustration of another embodiment of the filter-fan unit according to the invention showing an unfolded housing that is provided on a suspended particle filter 
       FIG. 23  shows the filter-fan unit according to  FIG. 22  in a plan view. 
       FIG. 24  is a plan view onto a further embodiment of a folded housing of a filter-fan unit according to the invention. 
       FIG. 25  is a side view of the folded housing according to  FIG. 24 . 
       FIG. 26  is an end view of the folded housing according to  FIG. 24 . 
       FIG. 27  shows the folded housing according to  FIG. 24  in which the folded sidewalls are folded down. 
       FIG. 28  shows the housing according to  FIG. 24  in which the folded-down sidewalls are unfolded. 
       FIG. 29  is a representation in accordance with  FIG. 28  showing a further step of unfolding the sidewalls of the housing. 
       FIG. 30  shows the completely unfolded sidewalls of the housing. 
       FIG. 31  shows the insertion of a connector for connecting the unfolded sidewalls of the housing. 
       FIG. 32  shows the housing according to  FIG. 31  with the lid in the closed position. 
       FIG. 33  is a schematic side view illustration of the folded state of the housing of another embodiment of the filter-fan unit according to the invention. 
       FIG. 34  shows a reinforcement element of the housing according to  FIG. 33 . 
       FIG. 35  is a plan view onto the housing according to  FIG. 33 . 
       FIG. 36  shows the unfolded housing according to  FIG. 33  in a side view. 
       FIG. 37  shows a section along the section line XXXVII-XXXII of  FIG. 36 . 
       FIG. 38  is a plan view onto the housing according to  FIG. 36 . 
       FIG. 39  show a first pivot connection between neighboring housing sidewalls. 
       FIG. 40  shows a second pivot connection between neighboring housing sidewalls. 
       FIG. 41  shows a third pivot connection between neighboring housing sidewalls. 
       FIG. 42  shows a fourth pivot connection between neighboring housing sidewalls. 
   

   DESCRIPTION OF THE PREFERRED EMBODIMENTS 
   Filter-fan units are used advantageously in clean rooms in the ceiling area. The filter-fan units are comprised essentially of three components, i.e., at least one fan  1 , at least one suspended particle filter  2 , and a housing  3 . The suspended particle filter  2  is preferably a HEPA filter (High Efficiency Particulate Air) but can also be any other suitable filter in accordance with the specific requirements of the application. The filter-fan units according to  FIGS. 1 through 9  are characterized in that the housing  3  can be folded ( FIGS. 1 and 3 ). The housing  3  therefore requires little space during transport. The housing  3  is unfolded once at the site where it is to be installed. Thereafter, the fan  1  and the suspended particle filter  2  are mounted on the unfolded housing  3 . Since the housing  3  is foldable or collapsible, it requires only very little space during transport. 
   In the embodiment according to  FIGS. 1 through 9 , the housing  3  has four sidewalls  4  to  7  that are positioned at a right angle to one another. The housing sidewalls  4 ,  5 ,  6 ,  7  each are trapezoidal in shape and have the same size. As shown in  FIG. 1 , the sidewalls  4 ,  5 ,  6 ,  7  are provided at their inner side or face with a soundproofing layer  8  that is advantageously comprised of an open-pore foam material. 
   The sidewalls  4  through  7  are connected to a narrow circumferential rim  9  having a height that corresponds approximately to the thickness of the soundproofing layer  8 . The circumferential rim  9  projects at a right angle from the bottom housing frame  10  that has a square contour, for example. 
   As shown in  FIG. 3 , the sidewalls  4  through  7  taper in a direction away from the rim  9  so that in the folded state the free edges  11  through  14  are spaced from one another. In order to complete the filter-fan unit, first the housing  3  is unfolded such that the sidewalls  4  to  7  are positioned with their slanted lateral edges against one another ( FIG. 7 ). The adjoining lateral edges of the sidewalls  4  to  7  are connected in a suitable way fixedly and tightly to one another. The sidewalls  4  to  7  are positioned at an acute angle relative to the rim  9  of the housing  3  and converge starting at the rim  9 . Because the soundproofing layers  8  are attached to the inner side of the sidewalls  4  through  7 , the soundproofing layers  8  are moved into their final mounted position when folding upwardly the sidewalls  4  to  7 . The housing  3  in the unfolded state has the shape of a square pyramid. The free edges  11  through  14  of the sidewalls  4  through  7  delimit in the illustrated embodiment a square mounting opening  15  into which the fan  1  can be inserted. The fan  1  is part of a fan insert  16  that has a baseplate  17  on which the fan  1  is mounted in a way known in the art. The baseplate  17  is connected by means of vertical supports  18  to a mounting plate  19  that is connected to the free edges  11  to  14  of the sidewalls  4  to  7  with its edge  20 , as shown in  FIG. 8 . The mounting plate  19  has a central opening  21  through which the fan  1  sucks in air. The mounting plate  19  is advantageously connected with its edge  20  air-tightly to the housing  3  so that the clean air which is sucked in by the fan  1  can flow out only through the filter  2 . 
   At the bottom side of the unfolded housing  3  the suspended particle filter  2  is mounted. The filter  2  has a circumferential filter frame  22  that projects upwardly past the suspended particle filter  2  and is connected with this projecting part to the rim  9  of the housing  3 . 
   The collapsible housing  3  can be comprised of sheet metal or a suitable plastic material. The plastic material can be polyamide, polyethylene, polypropylene, or polyvinyl chloride as a thermoplastic material. It is also possible to employ a thermosetting material, for example, polyester or polyurethane. Finally, it is also possible to produce the housing, for example, from epoxy resin, polyester resin, Styrofoam® (polystyrene), Macrolon® (polycarbonate), acrylic glass, and the like. The housing  3  has in any case a sufficient stability and strength in order to support the fan insert  16  and the suspended particle filter  2 . 
   The pivot connection between the sidewalls  4  to  7  and the rim  9  can be designed in different ways. Examples of different configurations will be explained in more detail in connection with  FIGS. 39 to 42 . 
     FIGS. 10 through 16  show a fan unit in which the foldable housing  3  is attached already to the mounting plate  19  of the fan insert  16 . After folding out the sidewalls  4  to  7  of the housing  3 , it is no longer necessary to connect the fan insert  16  in a separate working step to the housing  3 . The sidewalls  4  to  7 , in contrast to the preceding embodiment, are rectangular in shape ( FIG. 11 ) and extend between the oppositely positioned parallel extending circumferential edges  23 ,  24 ,  25 ,  26  of a housing lid  27  (compare  FIGS. 11 and 14 ). The lid  27  is of a plane configuration and has in the illustrated embodiment approximately a square contour. It is centrally provided with a mounting opening  28  for the fan insert  16 . The mounting plate  19  of the fan insert  16  is attached to the edge of the mounting opening  28  in a way known in the art. 
   In the folded state, the sidewalls  4  to  7  rests against the housing lid  27 ; the sidewalls  4  to  7  are pivotably connected to the edges  23 ,  24 ,  25 ,  26  of the lid  27 , respectively. 
     FIG. 13  shows the situation when the sidewalls  4  to  7  are folded down. The bottom edges of the sidewalls  4  to  7  are connected to the projecting edge of the filter frame  22 . As shown in  FIG. 15 , the upwardly projecting edge of the filter frame  22  extends past the bottom edges of the sidewalls  4  to  7 . It is also possible that the bottom edges of the sidewalls  4  to  7  are positioned outwardly relative to the upwardly projecting edge of the filter frame  22 . The filter frame  22  and the sidewalls  4  to  7  can be connected to one another in a suitable way so as to be airtight. 
   Advantageously, in the area between the sidewalls  4  to  7  and the lid  27  a micro-porous film  29  is provided as a sound-proofing element. Upon folding out the housing  3 , the film  29  is moved into a stretched position as illustrated in  FIG. 15 . 
   The filter-fan unit according to  FIG. 17 to 23  is similar to the embodiment according to  FIGS. 1 through 9 . The difference is that the sidewalls  4  to  7  are connected to the projecting edge of the filter frame  22 . The folded housing  3  and the suspended particle filter  2  thus form a module. The sidewalls  4  to  7  are folded onto the suspended particle filter  2  ( FIG. 18 ) so that this module comprised of housing  3  and suspended particle filter  2  requires only minimal space during transport. For completing the filter-fan units, the sidewalls  4  to  7  are folded upwardly and are connected fixedly to one another at their edges. The free edges  11  to  14  of the trapezoidal sidewalls  4  to  7  define the mounting opening  15  ( FIG. 21 ) for the fan insert  16  ( FIG. 17 ). The fan insert  16  is connected with its mounting plate  19  in the way described in connection with  FIGS. 1 through 9  to the unfolded housing  3 . In this embodiment, the suspended particle filter  2  must not be mounted separately so that the installation of the filter-fan unit is possible in a simple and quick way. Since the sidewalls  4  to  7  of the housing  3  are folded onto the suspended particle filter  2 , the module of suspended particle filter  2  and folded housing  3  requires only minimal space. 
   With the aid of  FIGS. 24 to 32  a housing  3  is described whose sidewalls  4  to  7  have a rectangular cross-section ( FIG. 30 ). The housing  3  has a lid  30  that has a rectangular contour. At the longitudinal bottom edge of the lid  31  illustrated in  FIG. 24  the sidewalls  4  to  7  are pivotably connected and, in turn, are pivotably connected to one another and are placed on top one another. The height of the sidewalls  4  to  7  is smaller than the width of the lid  30 . 
   In order to build the housing  3 , the folded sidewalls  4  to  7  are first folded about the longitudinal edge  31  of the lid  30  (compare  FIG. 24  and  FIG. 27 ). Subsequently, the sidewalls  4  and  5  resting against one another are folded outwardly ( FIG. 28 ). The sidewall  4  is connected with one narrow side  32  to the narrow side  33  of the sidewalls  7  that is hidden from view in  FIG. 28 . To the other narrow side  34  of the sidewall  4 , the narrow side  35  of the sidewall  5  is connected in a pivotable way (compare  FIG. 28  and  FIG. 29 ). This sidewall  5 , as illustrated in  FIG. 29 , is then folded about the lateral edges  34 ,  35 . The sidewall  6  is connected with its narrow side  36  to the narrow side  37  of the sidewall  7  in a pivotable way. The sidewall  6  is unfolded finally about pivot axis  36 ,  37  ( FIG. 30 ). By means of a connecting member  38  ( FIG. 38 ) that is embodied as an angle member, the neighboring narrow sides  39 ,  40  of the sidewalls  5 ,  6  are tightly connected to one another. 
   The lid  30  has a prependicularly projecting rim  30   a  which extends along three sides of the lid  30 . Only at the longitudinal side  31  where the sidewall  7  is pivotably attached the rim  30   a  is not provided. When the housing  3  is in the folded state, the sidewalls  4  to  7  that are folded onto one another are located within the rim  30   a . The rim  30   a  is advantageously only so tall that the folded sidewalls  4  to  7  do not project or project only slightly past the rim  30   a . It is advantageous that the rim  30   a  has approximately the same height as the thickness of the folded sidewalls  4  through  7 . When the lid  30  is closed ( FIG. 32 ) the rim  30   a  projects past the upper longitudinal edge of the sidewalls  4  to  6 . As shown in  FIG. 32 , the longitudinal edge  31  serving as the pivot axis is positioned at the level of the free edge of the lid rim  30   a . In the lid  30  there is centrally a mounting opening  28  that has a rectangular contour in the illustrated embodiment but, depending on the configuration of the fan insert  16 , can also have different contour shapes. The fan insert  16  is mounted in the mounting opening  28  of the housing  3  according to  FIG. 32 . Subsequently, the housing  3  that is open in the downward direction is placed onto the suspended particle filter  2  and is fixedly connected thereto. The suspended particle filter  2  closes off the bottom side of the housing  3 . 
   The housing according to  FIGS. 33 to 35  has a shape-stable housing frame  41  with an angled circumferential rim  41   a . The housing  3  is attached to the rim  41   a . The housing is comprised of a fabric  42  that is flame resistant. As a reinforcement, centrally within the fabric a rectangular reinforcement frame  43  is attached into which the fan insert  16  is inserted. 
   In order for the housing  3  that is made from fabric to keep its shape, profiled sections  44  are provided as reinforcement. They are arranged in the corner areas of the housing frame  41  in such a way that the fabric will keep taut the unfolded housing  3 . On the inner side of the fabric  42  along the seams  45  ( FIG. 38 ) receptacles  46  for the reinforcing profiled sections  44  are provided. The receptacles  46  can extend across the entire length of the seams  45  but can also be arranged along the seams at a spacing from one another. The reinforcing profiled sections  44  are, for example, round elastically bendable rods that are supported with their first end in receptacles (not illustrated) in the corner area of the housing frame  41  and with their second end in receptacles in the corner area of the reinforcement frame  43 . The fabric  42  is tailored such that the rods  44  are bent about their length when they are positioned with their ends in the receptacles of the two frames  41 ,  43 . The fabric  42 , as shown in  FIG. 36 , is curved outwardly and is kept in a stretched position. 
   The fabric  42  forming the housing is comprised advantageously of four trapezoidal tailored sections  47  to  50  which are connected to one another at their abutting edges by seams  45 . The seams  45  can be formed also by a zipper or by a hook-and-loop fastener. 
     FIGS. 39 to 42  finally show possible configurations of the pivot connections as they are provided in all disclosed embodiments. 
     FIG. 39  shows that the parts to be pivotably connected to one another are connected by a hinge  51  in a pivotable way. As is known in the art, the hinge fittings  52 ,  53  are attached to the parts that are pivotable relative to one another. The pivot direction is indicated by arrow  54 . 
     FIG. 40  shows the possibility of providing the pivot connection  55  by a portion of reduced or weakened material between the parts to be pivoted relative to one another. This portion of reduced material thickness forms a predetermined bending location. 
     FIG. 41  shows the possibility of providing on the parts to be pivotable relative to one another shaped pivot elements  56 ,  57  that are curved approximately like a part of a circle and that engage one another. The shaped pivot elements  56 ,  57  are attached to the end faces of the corresponding parts that are pivotable relative to one another and can extend about the entire length of these end faces. It is also possible to provide individual pivot elements across the length of the end faces. The pivot elements  56 ,  57  engage one another in such a way that in the pivot direction they cannot be detached from one another. The two parts that are pivotably connected to one another can be detached from one another only by sliding in the direction of the pivot axis. As is shown in  FIG. 41 , the pivot elements  56 ,  57  are curved in such a way that their free ends engage or mesh with one another and their curved areas  58 ,  59  rest against the respective neighboring part to be pivoted when they are in the parallel position illustrated in  FIG. 41 . 
     FIG. 42  finally shows the possibility of connecting the two parts pivotable relative to one another by a profiled section  60  that has the shape of an H. The two parts to be connected to one another project into the profiled section and are separated from one another by the transverse web  61  of the profiled section  60 . The profiled section  60  extends also advantageously across the length of the corresponding edges of the parts to be connected. 
   In the described embodiments, the different parts can be connected to one another at their abutting locations in ways known in the art. 
   The specification incorporates by reference the entire is closure of German priority document 10 2005 062 523.1 having a filing date of 19 Dec. 2005. 
   While specific embodiments of the invention have been shown and described in detail to illustrate the inventive principles, it will be understood that the invention may be embodied otherwise without departing from such principles.

Technology Classification (CPC): 5