Room air treatment system
O
Umted States Patent 1191
1111 Patent Number:
Kudirka et al.
[45]
[54] ROOM AIR TREATMENT SYSTEM
[75] Inventors= Paul J- Kudirka, Grand Rapids;
3,932,432 V1372 Rudin .................................. .. 55/499
,93 ,2 4 2/1
M so
55/485 X
3,971,877 7/1976 Leae
55/491 X
Date of Patent:
Gregory T. Grochoski, Ada; Robert
4,252,547 2/1981 Johnson .
W. Hamilton, Grand Rapids, all of
4,350,504 9/1982 Diachuk
Mich.
4,629,479 12/1986
[73] Assignee: Amway Corporation, Ada, Mich.
4,737,173
Apr. 12, 1988
..... .. 55/234
55/217
Cantoni ........................... .. 55/485 X
OTHER PUBLICATIONS
[21] Appl. No.: 881,702
[22] Filed:
Jul. 3, 1986
1985 'l‘eledyne Water Pik Brochure, “Instapure Air
oslyggesrgs, 1730 East Prospect Street, Fort
[51] Int. Cl.‘ ............................................ .. B01D 50/00
[52] US. Cl. ...................................... .. 55/276; 55/316;
Teledyne Water Pik Brochures, Form No. 2AF12~R35,
Part No. 26925-3, 1730 E. Prospect, Fort Collins, Col.
55/470; 55/471; 55/472; 55/485; 55/502;
80525.
55/507- 55/511
.
[58] Field of Search
351067’ 355101’ 425.7%
’
[56]
_
’
’
’
DeWitt & Litton
[57]
U'S' PATENT DOCUMENTS
galdlwm .
oyan
3/1966
through a large particle pre?lter, a ?rst carbon ?lter, a
ss/sn
second dual honeycomb matrix carbon ?lter in which
55/483
igleatlilglfggonmb cells ,1“ adlacem mamces at? oflset
................................ ..
3,177,637 4/1965 Davis ...... ..
3,242,656
ABSTRAC1.
A room air treatment system in which air is drawn
1,288,027 12/1918 Kern ._.............................. .. 55/485 X
,
.
Attorney, Agent, or Firm-—Price, Heneveld, Cooper,
’
References Cited
,
.
Primary Exammer-Kathleen J. Prunner
Murphy, Jr. . . . . . .
-
55/485 X
55 /276
.. 210/485
...... .. 55/316
3,727,384 4/1973 Feldman
'
e another, a blower mounted on vlbratlon
.
1t.
t
d.
11d b
th
bl
,
15° 31°“ mu“ 5 an ,15 631” e
Y e Owe‘ ""O 3
plenum from when it exlts upwardly through a ?ne
particle HEPA ?lter and ?nally out through a ?nal
?lter which is a combination ?ne particle ?lter and
. . . . . . .. 55/500
3,299,620 1/1967 Hollingworth
3,375,640 4/1968 pelosi’ Jr. ____ __
3,392,846 7/1968 Getzin ..... ..
3,577,710 5/1971 Feldman
-
55/316 X
carbon ?lter. A ?lter change warning system is pro
31745175o
7/ 1973
Afff - - - s - - -
- - - - - - -- 55/102
vided which includes a 3500 hour ?lter change indica
3,802,l68
4/ 1974
Deckas . . . . . .
. . . . . . .. 55/473
tor’ an every 7000 hour ?lter change indictor, a back_up
3304942 4/1974 Kato. et a1‘ ‘
55/276 X
,8l2,370
5/1974 LaV10lette
warning indicator, a mute button for muting the warn
.... .. 250/527
.
. d.
t
d
3,828,530
8/1974 Peters
55/473
mg m m or an
3,861,894
1/1975
55/316
hour count
Marsh .......... ..
3,925,043 12/1975 Matrone et al.
55/276
3,928,008 12/ 1975 Petersen .............................. .. 55/472
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US. Patent
Apr. 12,1988
lg4.?‘1mm4040)
(up
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1.
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Sheet 10f 5
4,737,173
US. Patent
Apr. 12,1988
Sheet 3 of5
4,737,173
52
US. Patent
Apr. 12, 1988
FIG. 6
Sheet 4 of 5
4,737,173
US. Patent
Apr. 12,1988
Shee‘et 5 0f 5
250
240
I
I
I0 S‘ECOND
DELAY
‘
F“ MUTE INPUT
260
I
290
|
REGISTER
24 HOUR
RESET
MUTE HOLD
a»
2l|0
REGISTER
ALARM
REGISTER
I
,
RESET CYCLE
-)
l
3600 HOUR
300
3500 HOUR
280
I
~
I»
i___
270
CLOCK
220
4,737,173
COUNTER
3|O
1
FILTER 2
'P
I 2310
FILTER ‘I
INDICATOR
FIG. 9
INDICATOR
200'
1
4,737,173
2
FIG. 5 is a broken, perspective view of the second
ROOM AIR TREATMENT SYSTEM
carbon ?lter;
FIG. 6 is a broken, perspective view of the blower
assembly mounted on the floor of the cabinet;
BACKGROUND OF THE INVENTION
The present invention relates to room air treatment
FIG. 7 is a cross-sectional view of an isolation mount
systems. Such systems typically comprise a cabinet in
used to mount the blower assembly;
FIG. 8 is a broken, perspective view of the rear of the
air treatment system; and
FIG. 9 is a functional schematic diagram of the ?lter
which are mounted a large particle pre?lter, a ?ne ?lter
and a fan which pulls air through the ?lters and blows
it back into the room. Such systems are relatively inef?
cient, noisy and generally not effective against chemical
contaminants in the air.
,. . 0
change warning system of the air treatment system.
'
DESCRIPTION OF THE PREFERRED
EMBODIMENT
Some systems incorporate carbon ?lters in order to
eliminate odorous and chemical contamination. The
carbon is often bonded to some type of ?brous material.
Some systems use carbon ?lters in which carbon
granules are contained in a honeycomb support matrix.
\ In the preferred embodiment, the air treatment sys
tem 1 of the present invention includes a large particle
pre?lter 10, a ?rst carbon ?lter 20, a second carbon
?lter 30, a blower assembly 40, a ?ne particle HEPA
?lter 70 and a ?nal ?lter 80 (FIG. 1) arranged in the
indicated order in a cabinet 100 (FIG. 2). By arranging
blower assembly 40 between pre?lter 10 and carbon
The honeycomb matrix comprises a plurality of cells,
each of which contains carbon granules. It is dif?cult to
pack each cell full and consequently, there is an air
space above the carbon. This leads to air passing over
the carbon rather than through it.
One prior art system draws air into a blower through
a large particle pre?lter and a carbon ?lter, and then
forces it out through a ?ne particle high ef?ciency par
ticulate air (HEPA) ?lter and out into the room1 How
ever, as the HEPA ?lter accumulates aerosol particles
?lters 20 and 30 on one side and HEPA ?lter 70 and
?nal ?lter 80 on the other side, blower noise is muffled
on both sides of blower assembly 40. Pre?lter 10 re
moves large objects, dust, lint and the like from the air,
carbon filters 20 and 30 remove chemical impurities
which give rise to unpleasant odors, HEPA ?lter 70
and odor bearing entrained particles, the associated
removes very ?ne particles entrained in the air and ?nal
?lter 80 comprises a combination of ?brous material and
gases eventually are carried off the ?lter and are con
veyed into the room.
carbon to ?nally trap any particles and gaseous materi
als which have passed through the prior ?lters or which
lU.S. Pat. No. 3,812,370 to Fred G. LaViolette, issued May 21, 1974 and
entitled “Low Cost Portable Room Air Cleaner."
have for one reason or another broken free of the earlier
Indeed, one serious drawback to many room air treat
ment system is knowing when to change the ?lters.
Dirty ?lters can become breeding grounds for prob
?lters after having been previously entrapped.
to change ?lters would be desirable.
12 ?-TIG. 1). Foam sheet 11 comprises a material typi
cally used in room air treatment system pre?lters. It is
Large particle pre?lter 10 comprises an open cell
lems. A satisfactory control system for warning a user 35 polyurethane foam sheet 11 having end securing strips
SUMMARY OF THE INVENTION
approximately %" thick and has approximately 30 pores
per square inch. It is intended only to trap larger parti
The room air treatment system of the present inven
tion comprisesa large particle pre?lter, carbon ?lter
40 cles such as lint and larger particles of dirt and dust. It
means, a blower, a ?ne ?lter, and a ?nal ?lter compris
ing a combination ?ne ?lter and carbon ?lter, all ar
is easily removed, washed and replaced after drying.
ranged in the order indicated. Most preferably, the
ferent contaminants.
In a most preferred aspect of the invention, a carbon
having a plurality of looped threads 13 projecting there
from (FIG. 3) which facilitates securing pre?lter 10 in
position by engagement with a mating tape having a
plurality of loop engaging projections. Located at op
posite ends and on opposite sides of each securing strip
?lter is employed having two honeycomb support ma
trices, each with plural carbon containing cells therein,
separate securing strip 12 from its mounting strip (FIG.
carbon ?lter means comprises at least two layers of
carbon, treated differently so as to be attractive to dif 45
End securing strip 12 comprises a piece of fabric tape
12 is a pull tab 15 which a user can grasp and pull to
1).
wherein the cells in one layer are offset laterally from
those in another layer so that air passing over carbon in
an individual cell in one layer will pass through carbon
First carbon filter 20 comprises an internal honey~
comb support matrix 21 (FIGS. 2 and 4). Matrix 21
in an individual cell in a next layer.
comprises a cross section of corrugated cardboard,
These and other objects, advantages and features of
approximately one inch thick, de?ning a plurality of
the invention will be more fully understood and appre 55 individual cells 22. The individual cells can be of any
ciated by reference to the written speci?cation and
con?guration, but in the preferred embodiment are
appended drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective, exploded view of the various
?lter elements and blower assembly arranged in opera
tional order;
FIG. 2 is a cross-sectional view of the air treatment
triangular having a height of approximately three
eighths inch.
Each cell 22 of honeycomb support matrix 21 con
tains activated carbon. The preferred carbon blend
comprises a 50/50 mixture of activated coconut shell
carbon and urea impregnated activated coconut shell
carbon. The untreated activated carbon acts as a gen
system of the present invention;
eral purpose absorber while the urea impregnated acti
FIG. 3 is a fragmentary, cross-sectional view of the 65 vated carbon is reported to preferentially remove form
edge of the pre?lter;
FIG. 4 is a broken, perspective view of the ?rst car
bon ?lter;
aldehyde and other aldehydes. The carbon particles are
of a 7 by 12 US Screen mesh size, as determined by
ASTM D2862.
3
4,737,173
Carbon particles are held in place within honeycomb
support matrix 21 by retention screens 23 adhered to the
opposite sides of honeycomb matrix 21. Each retention
screen 23 is made of nylon yarn of 15 pound denier. The
screen is of a sufficiently ?ne mesh that the carbon
4
important in that the activated carbon granules in each
individual cell tend to settle to the bottom, allowing air
to pass over the top of the collection of granules, rather
than through them. By staggering the cells in the two
different adjacent honeycomb support matrices, air
passing over the activated carbon in the ?rst layer will
have to pass through the activated carbon in the second
The screen covered, carbon containing honeycomb , layer and vice versa. This action is further enhanced by
orienting the matrices such that the rows of cells in one
matrix 21 is encased in an outer envelope 24 comprising
a dust ?ltering layer of white, non-woven polyester. 10 matrix are at right angles to the rows in the adjacent
The envelope is sealed on three sides prior to framing.
matrix (FIG. 5).
Carbon ?lter 30 comprises three layers of nylon re
The non-woven polyester material comprises 65% by
tention screen 35. Each layer is as retention screen 23
weight of 6 denier fabric and 35% by weight of a suit
described above. One layer is on the outer surface of
able binder such as polyvinyl chloride. It has a density
particles will not pass through it, while the flow of air is
substantially unrestricted.
of 0.36 ounces per square foot.
The entire envelope is then contained in a 28 gauge
honeycomb matrix 31, the second layer is between hon
aluminum frame 25. Frame 25 is generally U-shaped in
surface of honeycomb support matrix 33. The retention
cross section and is preferably made in one piece with
mitered corners. The ends are joined with a manually
screens are all bonded in place, as described above.
eycomb matrices 31 and 33 and the other is on the outer
As with ?rst carbon ?lter 20, the assembly of reten
operated tab fastener or the like (not shown) while the 20 tion screen layers 35 and carbon containing honeycomb
edges of the U channel are hemmed to provide addi
layers 31 and 33 are contained within a white, non
woven polyester envelope as described above. This in
tional structural strength.
Projecting from one side of frame 25 is a perimeter
turn is contained within a generally U-shaped (in cross
foam gasket 26. Foam gasket 26 is made of a relatively
section) aluminum frame 37 which is constructed in the
soft, compressible foam. It extends completely around 25 manner of frame 25. Finally, frame 37 is covered on one
the perimeter of one face of frame 25 so that when ?lter
side by a perimeter foam gasket 38 which corresponds
to foam gasket 26 described above.
20 is seated, its edge is sealed. The possibility of air
by-passing ?lter 20 is minimized.
It is important that second carbon ?lter 30 is just
Second carbon ?lter 30 is similar to ?rst carbon ?lter
slightly smaller in rectangular dimensions than ?rst
v3,20 but comprises ?rst and second adjacent honeycomb 30 carbon ?lter 20 (FIG. 2). In this way, ?lters 20 and 30
can be arranged adjacent one another without ?lter 20
-support matrices 31 and 33 (FIGS. 2 and 5). Each hon
~ eycomb support matrix corresponds generally in con
sealing against the frame 37 of ?lter 30. Rather, the
struction to honeycomb support matrix 21, except that
foam gasket 26 of frame 20 seals against its own, ?rm,
sealing surface, rather than against another ?lter mem
_;the sections are somewhat thinner, being approximately
one half inch thick each.
35 ber which may have a tendency to move relative to
First honeycomb matrix 31 contains in its cells a
foam gasket 26 in use.
V blend of 40% urea impregnated coconut shell activated
Blower assembly 40 comprises a motor 44 with a
carbon and 60% by weight non-impregnated coconut
squirrel cage fan 60 on either side thereof mounted on a
shell activated carbon. The mesh size of this blend is 7
“by 12, US Screen mesh, as determined by ASTM
molded, structural plastic platform 41 (FIG. 6). Plat
M-5D2862. The blend further enhances removal of alde
mounting stanchions 42, reinforced by stanchion rib 43,
. --;-»;.hydes and other undesirable odors.
- The activated carbon in the cells of honeycomb ma
on either side of motor 44. Motor 44 is capped by a
form 41 includes a pair of upwardly projecting motor
generally U-shaped radiator 45 which includes a plural
trix 33 comprises a blend of 40% by weight copper
ity of projecting radiator ?ns 48. Radiator 45 is made of
oxide impregnated activated coconut shell carbon, 40% 45 aluminum or the like so as to radiate heat generated by
by weight potassium hydroxide impregnated activated
motor 44.
coconut shell carbon and 20% by weight of non
Blower assembly 40 is mounted to the bottom wall
impregnated activated coconut shell carbon. Again, the
102 of cabinet 100 in spaced relationship thereto
particle size distribution is the same as for the previ
through six rubber grommets 50 which serve as vibra
ously described carbon blends. The copper oxide im 50 tion isolation mounts. Each grommet 50 comprises an
pregnated carbon tends to remove amines and other
annular rim 51 with an annular peripheral groove 52
basic gases. The potassium hydroxide impregnated acti
therein and an inner cylindrical barrel 54 joined to rim
vated carbon tends to remove acid gases such as sulfur
51 by means of a web 53 (FIG. 7). The foregoing are
dioxide. The non-impregnated carbon is, as above, a
integrally molded of a vibration absorbing rubber mate
general purpose gas absorbant.
55 rial. Groove 52 ?ts over and embraces the edge of an
Because this combination of impregnated carbons
aperture in blower assembly platform 41. A screw re
preferentially absorbs certain contaminants it is impor
ceiving ferrule 55 having a rim 56 ?ts inside cylindrical
tant that it not become overloaded with other contami
barrel 54 and receives a bolt which passes through fer
nants which are equally or even preferentially attracted
to non-impregnated carbons or differently impregnated
carbons. Hence, it is important that this layer be down
stream from the non-impregnated, urea impregnated
rule 55 and is threaded into a T-nut embedded in bottom
wall 102. Grommet 50 is oriented so that ferrule rim 56
rests on bottom wall 102 to hold platform 41 in spaced
relationship with respect to bottom wall 102. As a re~
carbon combinations so that aldehydes and other gen
eral contaminants are removed prior to reaching this
sult, vibration generated by blower assembly 40 tends to
be absorbed by rubber grommet 50 before reaching
acid/base attractant layer.
Referring to FIG. 2, it can be seen that honeycomb
matrices 31 and 33 are offset, so that their individual
cells are staggered with respect to each other. This is
65 bottom wall 102 of cabinet 100.
Each of the squirrel cage fans 60 is driven by a drive
axle 61 extending from motor 44 (FIG. 6). Each of the
squirrel cage fans comprises a vane rotor 62 located
5
4,737,173
within a generally cylindrical housing 63 having an inlet
64 on each side and a tangential outlet 65. As can be
6
Carbon-bonded ?lter medium 82 is arranged in corru
gated fashion and is held in that con?guration by means
seen by reference to the air flow pattern arrows in FIG.
of a mesh wire support 83 to which carbon-bonded
1, air ?ows into each central inlet 64 on each side of
?lter medium 82 is bonded. A thin piece of non-woven
each squirrel cage fan 60 and then passes out through 5 fabric 84 extends across the top opening of box 81. A
each of the outlets 65. Each outlet 65 includes a lip on
foam gasket 85 around the perimeter of the bottom of
which is mounted a foam rubber gasket 66 to seal outlet
box 81 serves to seal ?nal ?lter 80 against HEPA ?lter
65 in position in cabinet 100 as described below and
70.
prevent air from leaking around the edges thereof.
The foregoing ?lters and blower assembly are ar
These foam gaskets also serve to minimize the transfer
ranged in cabinet 100 in the order indicated (FIG. 2).
of vibration from blower assembly 40 to cabinet 100.
Cabinet 100 is made of wood particle board or other
Blower assembly 40 is located upstream of HEPA
construction material and comprises a top wall 101, a
filter 70 so that any carbon particles which may be
bottom wall 102, spaced sidewalls 103 and a short, up
carried from carbon ?lters 20 and 30 are trapped in
wardly projecting front wall 104. A central divider wall
HEPA ?lter 70. In addition, the airstream leaving
blower assembly 40 is forced to undergo a 90 degree
turn in plenum 120 located downstream of it in cabinet
105 separates the front compartment of cabinet 100
from the back compartment.
100 (FIG. 2), thereby insuring that sharp carbon parti
plastic back panel 110 which includes a locator flange
111 along the bottom and side edges thereof to seat
against the interior of cabinet 100. Suitable fastening
cles will not be blown directly into HEPA ?lter 70.
Such action could conceivably damage the delicate
HEPA ?lter media. Larger carbon particles will tend to
simply settle out in plenum 120 rather than entering and
clogging HEPA ?lter 70.
Fine particle ?lter 70 is a HEPA ?lter (FIG. 2). So
The open back of cabinet 100 is closed by a molded
holes are provided whereby screws can be threaded
into cabinet 100 to hold back panel 110 in place.
called HEPA ?lters, high ef?ciency particulate air ?l
Back panel 110 includes integrally molded cord
wrap/standoffs 112, each including a projecting base
portion 113 and a laterally projection wing 114 (FIGS.
ters, are capable of removing extremely ?ne particles
2 and 8). The electric cord 125 for the unit can be
from the air. At a flow rate of about 150 cubic feet per
minute, HEPA ?lter 70 removes between about 95 and
wrapped around standoff bases 113, behind projection
wings 114. Standoff/cord wraps 112 project rearwardly
from back panel 110 approximately two inches. They
100% of all particles of a size of 0.1 micron or larger.
The HEPA ?lter is contained in a molded, structural
plastic box 71 made of structural foam polystyrene or
the like (FIG. 1). The top and bottom of box 71 are
open, and are covered by a molded plastic grill 72
prevent air treatment system 1 from being pushed so
tightly against a wall as to restrict air ?ow into the unit.
Back panel 110 includes a large central opening cov
being separated by relatively thin, corrugated aluminum
ered by an integrally molded grill 119 and framed by
three successive stepped, recessed ledges 115, 117 and
118 (FIGS. 2 and 8). Each of the ledges is generally
rectangular in con?guration. First recessed ledge 115 is
dividers 74. These pleats and corrugations extend across
recessed a distance suf?cient to approximately accom
the width of box 71, though are shown broken away in
FIG. 2 for convenience.
modate the thickness of pre?lter 10 and is faced along
its top and bottom surfaces by a piece of fabric tape
which allows air to pass therethrough (FIGS. 1 and 2).
HEPA ?lter medium 73 is pleated with separate folds
The pleats of HEPA ?lter medium 73 are parallel to 40 having a plurality of projections which hook into the
loops of the end securing strips 12 on pre?lter 10 (see
- end by a suitable adhesive to prevent air from bypassing
FIG. 2). In this manner, pre?lter 10 is held in place and
the HEPA medium. A soft ?brous pad (not shown) is
stretched across the opening de?ned by ?rst recessed
the length of the face of box 71 and are sealed at each
located on the inside of each end wall of box 71 so that
ledge 115.
the side edges of the HEPA paper 73 are embedded in 45
Second recessed ledge 117 de?nes a slightly smaller
opening than ?rst recessed ledge 115 and is recessed
inwardly from recessed ledge 115 a distance suf?cient
the soft ?brous pads, thereby minimizing air bypass
around the edges of HEPA paper 73.
A peripheral gasket 75 extends around the bottom of
to accommodate the thickness of ?rst carbon ?lter 20.
box 71 to seal HEPA ?lter 70 when it is seated in cabi
The foam gasket 26 on ?rst carbon ?lter 20 seats snugly
net 100. This minimizes air bypass around HEPA ?lter 50 against second recessed ledge 117.
70.
Third recessed ledge 118 de?nes a still smaller open
Final ?lter 80 sits on top of HEPA ?lter 70 and com
prises a paperboard box 81 containing an activated car
ing and is spaced further inwardly from recessed ledge
bon coated ?lter medium 82 (FIGS. 1 and 2). HEPA
filter 70 is very ef?cient at removing liquid aerosols.
?lter 30. Foam gasket 38 of second carbon ?lter 30 seats
against recessed ledge 118. Each of the carbon ?lters 20
and 30 seats snugly within the recesses de?ned by re
Such aerosols, along with solid particles having at
117 a distance suf?cient to accommodate second carbon
tached odor molecules, will collect on the upstream
face of the HEPA ?lter medium 73. In time, some of
these gaseous substances will be carried through the
HEPA ?lter by the airstream. These escaping gaseous
substances are absorbed onto the carbon in ?nal ?lter
cessed ledges 117 and 118, and is held in place by pre?l
ter 10 being secured along its top and bottom securing
end strips 12 engaging the mating securing strips 116 on
?rst recessed ledge 115.
80, thus preventing them from exiting air puri?er 1.
the rear compartment of cabinet 100 in the manner
The activated carbon is bonded to the non-woven
medium web so that carbon particles cannot be blown
previously described. Blower outlets 65 are securely
?tted within openings at the bottom of central divider
Blower assembly 40 is mounted on bottom wall 102 in
into the air by air passing through ?nal ?lter 80. The 65 wall 105 so that air is drawn from the rear compartment
bulk of gaseous removal has already been accomplished
of cabinet 100 and blown into the front compartment.
by carbon ?lters 20 and 30 so ?nal ?lter 80 is satisfac
Air leaving blower assembly 40 is blown into plenum
tory for the above described purpose.
120 which is molded of plastic and is located in the
7
4,737,173
bottom of the front compartment of cabinet 100. Ple
num 120 comprises an inlet 121 which receives air from
8
A unique feature of the control system of the air
treatment system of the present invention comprises the
blower assembly 40 and an outlet 122 de?ned by a pe
?lter change warning system 200 shown functionally
rimeter lip 123 upon which is seated the foam gasket 75
of HEPA ?lter 70 (FIG. 2). Final ?lter 80 seats on top
schematically in FIG. 9. A clock module 210 drives a
of HEPA ?lter 70 as heretofore described and both ?nal
bale 130 described below (FIG. 2). Positioned above
?nal ?lter 80 is baffle 140, which is molded of plastic
hours activates ?lter 1 warning indicator 230. Filter 1
warning indicator 230 comprises a readout on control
panel 170. When it lights up, the user knows that carbon
?lters 20 and 30 should be discarded and replaced.
Upon doing so, the user can recycle the 3500 hour
and includes a curved back wall 142 which extends
register 220 by depressing the mute input button 240 for
?lter 80 and HEPA ?lter 70 are held in place by the
combination of a hold down frame 90 and a hold down
3500 hour register 220 which upon expiration of 3500
between spaced sidewalls 141 (FIG. 2). Depending
10 seconds. This overrides a 10 second delay circuit 250
downwardly from each sidewall 141 is a reinforcing rib
and activates the register reset function 260. It will be
143 including an opening 144 in the front end thereof.
noted that register reset function 260 requires input not
Opening 144 facilitates removably mounting a front 15 only from depression of the mute input button for more
panel 160 on air treatment system 1 in the manner de
than 10 seconds, but also from the ?lter l indicator
scribed below. A front louver 150 is pivotally mounted
circuit. If ?lter 1 indicator 230 is not energized, depres
at the front of baf?e 140 and comprises the point at
sion of mute input button 240 for more than 10 seconds
which air exits air treatment system 1.
will not activate register reset 260.
Hold down frame 90 comprises a vertical perimeter 20 In the event the user fails to change the ?lters and
wall 91 with an inwardly projecting, horizontal perime
effect reset at 3500 hours, clock 210 will eventually
ter ?ange 92 (FIG. 1). Vertical wall 91 seats over box 81
activate 3600 hour register 270 which in turn will set off
.of ?nal ?lter 80 and horizontal ?ange 92 rests on top
another indicator, alarm 280. Alarm 280 is preferably an
thereof. A pair of ribs 93 extend across frame 90, each
intermittently
beeping device, preferably beeping every
including notches 94 in the top edge thereof. Hold 25 30 seconds. If alarm ‘280 goes off at an undesirable time,
down bale 130 is a generally U-shaped member pivot
the user can deactivate it by momentarily depressing
ally mounted at each end in the sidewalls 141 of upper
mute input 240. This activates 24 hour mute hold circuit
baf?e 140. When bale 130 is pivoted downwardly, its
290 which in turn deactivates alarm 280 for 24 hours.
-__ bite portion slides into and engages the notches 94 in
After 24 hours, alarm 280 is again automatically ener
ribs 93 of hold down frame 90 to thereby secure ?nal
gized. It will be noted that when mute input button 240
J ?lter s0 and HEPA ?lter 70 in position.
is depressed for more than 10 seconds so as to override
A front panel 160 made of wood particle board, and
10 second delay circuit 250 and activate register reset
_ preferably covered with fabric or the like, is removably
260, 3600 hour register 270 is reset along with 3500 hour
mounted over the opening which contains HEPA ?lter 35 register 220, provided register reset 260 is receiving
70 and ?nal ?lter 80. Front panel 160 includes a com
input from ?lter 1 indicator circuit 230.
pressible fastener 161 at each corner. The bottom com
Warning system 200 also includes means for indicat
pressible fasteners 161 ?t into a hole 104A in front wall
ing the need to change HEPA ?lter 70 and ?nal ?lter
; 104 of cabinet 100. The top compressible fasteners 161
80. Reset cycle counter 300 counts the odd and even
"git-?t into holes 144 in the downwardly depending ribs 143 40 numbered times 3500 hour register 220 is recycled. On
“non baffle 140. Each compressible fastener 161 comprises
even numbered counts, reset cycle counter 300 ener
a post with a pair of wings projecting from the sides
gizes ?lter 2 indicator circuit 310. Thus, each even
- thereof in a ball con?guration which can be forced into
numbered time that ?lter 1 indicator is energized, i.e.,
the respective openings 104A and 144 and which
approximately every 7000 hours, ?lter 2 indicator 310 is
thereby snugly retain front panel 160 in position.
45 also energized. Thus, at approximately 7000 hour inter
Located above baffle 140 is the control panel 170.
vals, the user is warned that he or she must replace not
Electric cord 125 provides power in. Wiring 171 lead
only carbon filters 20 and 30, but also HEPA ?lter 70
ing away from control panel 170 provides power to
and ?nal ?lter 80.
blower assembly 40 and wiring 171A feeds power to an
The foregoing functions or circuits are programmed
electrical outlet 172 located at the top of rear panel 110.. 50 or hard wired into a microcomputer mounted on con
Quick release connector means 173 connects wiring
trol panel 170, which in turn is connected to the associ
171A to outlet 172. In a similar manner, quick release
ated mute input button and ?lter change indicators.
connectors 174 facilitate disconnection of wiring 171. A
Power is provided through the 120 volt power input
similar quick disconnect connector 175 is located at
cord 125, and also preferably through a battery in the
blower assembly 40. By removing back panel 110 and 55 event of power failure. The presence of the battery
disconnecting connector 175, blower assembly 40 can
prevents system reset in the event of power failure.
be readily removed for repair or replacement simply by
The preferred embodiment air treatment system is
unscrewing the six screws in isolation mount grommets
50.
relatively quiet and extremely ef?cient. Even at high
speed ?ow rates of 150 cubic feet per minute, air treat
Another quick disconnector 176 facilitates disconnec 60 ment system 1 of the present invention generates only
tion of the main power cord 125 from control panel 170.
about 5l decibels at l meter in front of the unit. Typical
Quick disconnect connector 177 also facilitates rapid
percentage particle removal for particles even as small
disconnection of wiring from control panel 170.
as 0.100 micron is in excess of 96%. Typical percentage
Through the use of quick disconnect connectors 176
particle removal for particles larger than 1 micron is
and 177, one can readily disassemble control panel 170 65 about 99%.
from cabinet 100 by simply removing the two screws
Of course, it is understood that the foregoing is
which hold it in place and disconnecting quick discon
merely a preferred embodiment of the invention and
nect connectors 176 and 177.
that various changes and alterations can be made with
4,737,173
9
10
out departing from the spirit and broader aspects
a plurality of cells, each containing activated carbon
thereof.
The embodiments of the invention is which an exclu
sive property or privilege is claimed are de?ned as
particles;
follows.
said second ?lter comprising ?rst and second adja
cent honeycomb support matrices, each compris
ing a plurality of cells containing activated carbon
'
particles;
l. A room air treatment system comprising:
a cabinet having an air inlet and an air outlet;
said ?rst ?lter containing a ?rst type of activated
carbon, said ?rst honeycomb support matrix of said
a large particle pre?lter located generally at said
inlet;
second ?lter containing a second type of activated
carbon and said second honeycomb support matrix
of said second ?lter containing yet a third type of
activated carbon.
carbon ?lter means located in said cabinet down
stream from said pre?lter for absorbing odorous
and other chemical gases;
blower means located in said cabinet downstream
from said carbon ?lter means for drawing air
7. The air treatment system of claim 6 in which said
?rst type of activated carbon in said ?rst ?lter com
through said pre?lter and said carbon ?lter means;
?ne particle ?lter means located in said cabinet down
prises a blend of approximately 50% by weight acti
vated carbon and 50% by weight activated carbon im
stream from said blower means in air flow commu
nication therewith whereby said blower means
forces air through said ?ne particle ?lter means;
and
,
pregnated with a material attractive to aldehydes;
said second type of activated carbon comprising a
20
a ?nal ?lter comprising a combination carbon ?lter
blend of approximately 60% by weight activated
carbon and 40% by weight activated carbon im
pregnated with a material attractive to aldehydes;
said third type of activated carbon comprising a blend
and ?ne particle ?lter whereby odorous and other
chemical gases and particles passing through or
of approximately 20% by weight activated carbon,
40% by weight activated carbon impregnated with
escaping earlier entrapment in said ?ne particle
?lter means are entrapped by said ?nal ?lter.
2. The air treatment system of claim 1 in which said
carbon ?lter means comprises at least two separate
a base attractant material and 40% by weight acti
vated carbon impregnated with an acid attractant
material.
8. The air treatment system of claim 7 in which said
layers of carbon of different types, whereby different
types of contaminants are attracted differentially to said
30 cells in said ?rst honeycomb support matrix of said
two carbon layers.
second ?lter are offset from said cells in said second
3. The air treatment system of claim 2 in which said
honeycomb matrix of said second ?lter whereby air
two carbon layers are arranged serially as an upstream
passing over carbon particles settled in a cell in one of
layer and a downstream layer, said downstream layer of
said matrices will pass through the carbon in an adja
carbon being more preferentially attractive to speci?c 35 cent but offset cell in the other of said honeycomb ma
contaminants than said upstream layer of carbon,
trices.
whereby a broader range of contaminants will be ab
9. The air treatment system of claim 6 in which said
sorbed by said upstream carbon layer and will thereby
air inlet of said air treatment system is framed by at least
not contaminate said downstream carbon layer and
two stepped, recessed ledges, recessed inwardly away
interfere with its preferential absorption of said speci?c
from the exterior of said cabinet, the ?rst of said ledges
contaminants.
being recessed a distance approximately equal to the
4. The air treatment system of claim 3 in which said
thickness of said ?rst carbon ?lter, said ?rst carbon
upstream layer of carbon comprises a combination of
?lter being seated against said ?rst ledge;
activated carbon and activated carbon impregnated
with an aldehyde attracting composition;
said downstream layer comprising a blend of acti
vated carbon treated with an acid attracting sub
45
stance and activated carbon treated with a base
attracting substance.
5. The air treatment system of claim 4 in which said
carbon ?lter means comprises ?rst and second adjacent
honeycomb support matrices, each comprising a plural
ity of cells;
carbon particles of said upstream carbon layer being
said second recessed ledge being recessed from said
?rst ledge a distance approximately equal to the
thickness of said second carbon ?lter and being
stepped inwardly to narrow said inlet opening rela
tive to said ?rst ledge, said second carbon ?lter
being smaller in perimeter dimensions than said
?rst carbon ?lter and being seated on said second
ledge.
10. The air treatment system of claim 9 in which each
of said ?rst and second carbon ?lters includes a foam
gasket perimeter seal which seats against its respective
contained in said cells in the upstream one of said 55 one of said ?rst and second ledges.
honeycomb support matrices and carbon particles
11. The air treatment system of claim 10 in which said
of said downstream carbon layer being contained
?rst type of activated carbon in said ?rst ?lter com
in the downstream one of said honeycomb support
prises a blend of approximately 50% by weight acti
matrices;
said cells in said ?rst honeycomb matrix being offset
from said cells in said second honeycomb matrix
whereby air passing over carbon particles settled in
a cell in one of said honeycomb matrices will pass
through the carbon in an adjacent but offset cell in
the other of said honeycomb matrices.
65
6. The air treatment system of claim 1 in which said
carbon ?lter means comprises two separate ?lters, the
?rst comprising a honeycomb support matrix including
vated carbon and 50% by weight activated carbon im
pregnated with a material attractive to aldehydes;
said second type of activated carbon comprising a
blend of approximately 60% by weight activated
carbon and 40% by weight activated carbon im
pregnated with a material attractive to aldehydes;
said third type of activated carbon comprising a blend
of approximately 20% by weight activated carbon,
40% by weight activated carbon impregnated with
a base attractant material and 40% by weight acti
11
4,737,173
vated carbon impregnated with an acid attractant
material.
12. The air treatment system of claim 11 in which said
12
pre?lter can be readily attached to and removed from
said air treatment system by engaging or disengaging
said loops and loop engaging projections.
honeycomb matrix of said second ?lter whereby air
19. The air treatment system of claim 16 in which said
mating connection means on said pre?lter and said ?rst
ledge comprise a fabric securing strip on one of said
passing over carbon particles settled in a cell in one of
ledge and pre?lter having a plurality of projecting loops
cells in said ?rst honeycomb support matrix of said
second ?lter are offset from said cells in said second
and a fabric securing strip on the other thereof having a
said matrices will pass through the carbon in an adja
plurality of loop engaging projections whereby said
cent but offset cell in the other of said honeycomb ma
10 pre?lter can be readily attached to and removed from
trices.
said air treatment system by engaging or disengaging
13. The air treatment system of claim 1 in which said
said loops and loop engaging projections.
carbon ?lter means comprises at least two separate
20. The air treatment system of claim 1 in which said
carbon ?lters, one containing a ?rst type of carbon and
carbon ?lter means comprises ?rst and second adjacent
the other containing a different type of carbon whereby
honeycomb support matrices, each comprising a plural
different types of contaminants are differentially at
ity of cells containing carbon particles;
tracted to said different types of carbon.
said cells in said ?rst honeycomb matrix being offset
14. The air treatment system of claim 13 in which said
from said cells in said second honeycomb matrix
air inlet of said air treatment system is framed by at least
whereby air passing over carbon particles settled in
two stepped, recessed ledges, recessed inwardly away
a cell in one of said honeycomb matrices will pass
from the exterior of said cabinet, the ?rst of said ledges
through the carbon in an adjacent but offset cell in
being recessed a distance approximately equal to the
the other of said honeycomb matrices.
thickness of said ?rst carbon ?lter, said ?rst carbon
21. The air treatment system of claim 1 in which said
?lter being seated against said ?rst ledge;
carbon ?lter means is seated within said air inlet in said
said second recessed ledge being recessed from said
air treatment system and said pre?lter means is seated
?rst ledge a distance approximately equal to the
over said air inlet, said pre?lter means including con
thickness of said second carbon ?lter and being
necting means cooperating with connecting means on
stepped inwardly to narrow said inlet opening rela
said cabinet whereby said pre?lter can be removably
tive to said ?rst ledge, said second carbon ?lter
mounted on said cabinet, said pre?lter holding said
being smaller in perimeter dimensions than said
carbon ?lter means in position within said inlet opening
?rst carbon ?lter and being seated on said second
when said pre?lter is secured to said cabinet.
ledge.
22. The air treatment system of claim 21 in which said
15. The air treatment system of claim 14 in which
mating connecting means on said cabinet and said pre?l
. each of said ?rst and second carbon ?lters includes a
ter comprise:
' foam gasket perimeter seal which seats against its re
a fabric securing strip on one of said cabinet and
35
- spective one of said ?rst and second ledges.
pre?lter having a plurality of projecting loops and
16. The air treatment system of claim 13 in which said
a fabric securing strip on the other thereof having
inlet opening is de?ned by ?rst, second and third
stepped, recessed ledges, each being recessed further
‘towards the inside of said cabinet and each being
.zsstepped inwardly to successively narrow the dimen
sions of said inlet opening as one proceeds from said
a plurality of loop engaging projections whereby
said pre?lter can be readily attached to and re
moved from said cabinet by engaging or disengag
ing said loops and loop engaging projections.
x?rst ledge to said third ledge;
said ?rst ledge being recessed a distance approxi
mately equal to the thickness of said pre?lter, said
23. The air treatment system of claim 1 in which said
blower means is secured to a plurality of vibration ab
sorbing mounts, which in turn are secured to said cabi
pre?lter including at least top and bottom connec 45 net and which maintain a separation between said cabi
net and said blower means whereby transmission of
tion means engaging mating connection means on
vibrations from said blower means to said cabinet is
said ?rst ledge;
minimized.
said second ledge being recessed from said ?rst ledge
24. The air treatment system of claim 1 in which said
a distance approximately equal to the thickness of
said ?rst carbon ?lter, said ?rst carbon ?lter being 50 cabinet is divided into a front compartment and a rear
compartment, said air inlet opening into said rear com
seated on said second ledge;
said third ledge being recessed from said second
ledge a distance approximately equal to the thick
partment and said air outlet opening out of said front
ness of said second carbon ?lter, said second car
said pre?lter, said carbon ?lter means and said blower
means being mounted in said rear compartment,
said blower means located generally at the bottom
of said rear compartment;
bon ?lter being smaller in lateral and longitudinal
dimensions than said ?rst carbon ?lter whereby it
seats on said third ledge.
17. The air treatment system of claim 16 in which said
?rst and second carbon ?lters include foam gasket seals
engaging and seating on said second and third ledges 60
respectively to minimize air bypassing said ?rst and
second carbon ?lters.
18. The air treatment system of claim 17 in which said
mating connection means on said pre?lter and said ?rst
ledge comprise a fabric securing strip on one of said 65
ledge and pre?lter having a plurality of projecting loops
and a fabric securing strip on the other thereof having a
plurality of loop engaging projections whereby said
compartment;
said blower means opening into and communicating
with a plenum located in the bottom of said front
compartment;
said ?ne ?lter means being positioned above said
plenum and above the level of said blower means
opening into said plenum whereby air exiting said
blower means is forced to turn upwardly in said
plenum before entering said ?ne particle ?lter.
25. The air treatment system of claim 24 in which said
carbon ?lter means comprises at least two separate
carbon ?lters, one containing a ?rst type of carbon and
4,737,173
13
14
the other containing a different type of carbon whereby
and a fabric securing strip on the other thereof having a
different types of contaminants are differentially at
tracted to said different types of carbon.
26. The air treatment system of claim 25 in which said
air inlet of said air treatment system is framed by at least
plurality of . loop engaging projections whereby said
pre?lter can be readily attached to and removed from
said air treatment system by engaging or disengaging
said loops and loop engaging projections.
two stepped, recessed ledges, recessed inwardly away
from the exterior of said cabinet, the ?rst of said ledges
being recessed a distance approximately equal to the
thickness of said ?rst carbon ?lter, said ?rst carbon
?lter being seated against said ?rst ledge;
32. The air treatment system of claim 28 in which said
blower means is secured to a plurality of vibration ab
sorbing mounts, which in turn are secured to said cabi
net and which maintain a separation between said cabi
10. net and said blower means whereby transmission of
said second recessed ledge being recessed from said
?rst ledge a distance approximately equal to the
thickness of said second carbon ?lter and being
stepped inwardly to narrow said inlet opening rela
vibrations from said blower means to said cabinet is
minimized.
33. The air treatment system of claim 24 in which said
blower means is secured to a plurality of vibration ab
sorbing mounts, which in turn are secured to said cabi
net and which maintain a separation between said cabi
net and said blower means whereby transmission of
vibrations from said blower means to said cabinet is
tive to said ?rst ledge, said second carbon ?lter
being smaller in perimeter dimensions than said
?rst carbon ?lter and being seated on said second
ledge.
27. The air treatment system of claim 26 in which
each of said ?rst and second carbon ?lters includes a 20
foam gasket perimeter seal which seats against its re
spective one of said ?rst and second ledges.
28. The air treatment system of claim 25 in which said
inlet opening is de?ned by ?rst, second and third
stepped, recessed ledges, each being recessed further
'
34. A room air treatment system comprising:
a cabinet;
air ?lter means;
blower means, said blower means being mounted in
said cabinet through vibration absorbing isolation
25
towards the inside of said cabinet and each being
stepped inwardly to successively narrow the dimen
sions of said inlet opening as one proceeds from said
?rst ledge to said third ledge;
said ?rst ledge being recessed a distance approxi
mounts, said blower means being secured to said
mounts and said mounts engaging said cabinet but
holding said blower means spaced from said cabi
net whereby vibration generated by said blower
means tend to be absorbed by said mounts rather
than transmitted to said cabinet;
said cabinet being divided into a front compartment
mately equal to the thickness of said pre?lter, said
pre?lter including at least top and bottom connec
and a rear compartment; said cabinet including an
tion means engaging mating connection means on
said ?rst ledge;
minimized.
air inlet opening into said rear compartment and an
'
said second ledge being recessed from said ?rst ledge 35
a distance approximately equal to the thickness of
said ?rst carbon ?lter, said ?rst carbon ?lter being
air outlet opening out of said front compartment;
said air ?lter means including a large particle pre?l
ter, and carbon flter means, located along. with
said blower means in said rear compartment, said
blower means being located generally at the bot
seated on said second ledge;
said third ledge being recessed from said second
ledge a distance approximately equal to the thick
tom of said rear compartment;
ness of said second carbon ?lter, said second car
bon ?lter being smaller in lateral and longitudinal
dimensions than said ?rst carbon ?lter whereby it
seats on said third ledge.
29. The air treatment system of claim 28 in which said 45
?rst and second carbon ?lters include foam gasket seals
engaging and seating on said second and third ledges
said blower means opening into and communicating
with a plenum located in the bottom of said front
compartment; and
said air ?lter means including a ?ne particle ?lter
means positioned above said plenum whereby air
exiting said blower means is forced to turn up
wardly in said plenum before entering said ?ne
second carbon ?lters.
30. The air treatment system of claim 29 in which said
mating connection means on said pre?lter and said ?rst
ledge comprise a fabric securing strip on one of said
particle ?lter means.
35. A room air treatment system comprising:
a cabinet including an air inlet and an air outlet;
carbon ?lter means seated within said air inlet and
pre?lter means located over said air inlet;
a fabric securing strip on one of said cabinet and
ledge and pre?lter having a plurality of projecting loops
pre?lter having a plurality of projecting loops and
and a fabric securing strip on the other thereof having a
a fabric securing strip on the other thereof having
respectively to minimize air bypassing said ?rst and
plurality of loop engaging projections whereby said
a plurality of loop engaging projections whereby
pre?lter can be readily attached to and removed from
said air treatment system by engaging or disengaging
said pre?lter can be readily attached to and re
moved from said air treatment system by engaging
said loops and loop engaging projections.
or disengaging said loops and loop engaging pro
jections, said pre?lter holding said carbon ?lter
31. The air treatment system of claim 28 in which said
mating connection means on said pre?lter and said ?rst
ledge comprise a fabric securing strip on one of said
means in position within said air inlet when said
pre?lter is secured to said cabinet.
ledge and pre?lter having a plurality of projecting loops
‘It
65
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