CN106794412B - 可均匀扩张的空气过滤器 - Google Patents

可均匀扩张的空气过滤器 Download PDF

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CN106794412B
CN106794412B CN201580045917.6A CN201580045917A CN106794412B CN 106794412 B CN106794412 B CN 106794412B CN 201580045917 A CN201580045917 A CN 201580045917A CN 106794412 B CN106794412 B CN 106794412B
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CN106794412A (zh
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A·R·福克斯
G·O·格雷格森
B·L·格哈特
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3M Innovative Properties Co
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    • B01D46/52—Particle separators, e.g. dust precipitators, using filters embodying folded corrugated or wound sheet material
    • B01D46/521—Particle separators, e.g. dust precipitators, using filters embodying folded corrugated or wound sheet material using folded, pleated material
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    • E—FIXED CONSTRUCTIONS
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    • F24F8/15—Treatment, e.g. purification, of air supplied to human living or working spaces otherwise than by heating, cooling, humidifying or drying by separation, e.g. by filtering by chemical means
    • F24F8/158—Treatment, e.g. purification, of air supplied to human living or working spaces otherwise than by heating, cooling, humidifying or drying by separation, e.g. by filtering by chemical means using active carbon
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    • E06B7/02—Special arrangements or measures in connection with doors or windows for providing ventilation, e.g. through double windows; Arrangement of ventilation roses
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Abstract

本公开涉及空气过滤器。更具体地，本公开涉及包括可均匀地扩张和收缩的褶状过滤介质的空气过滤器。在一些实施方案中，所述空气过滤器为尺寸可调节的空气过滤器系统。在一些实施方案中，所述空气过滤器可用于窗户开口。

Description

可均匀扩张的空气过滤器
技术领域
本公开涉及空气过滤器。更具体地，本公开涉及包括可均匀地扩张和收缩的褶状过滤介质的空气过滤器。在一些实施方案中，空气过滤器为尺寸可调节的空气过滤器系统。在一些实施方案中，空气过滤器可用于窗户开口。
背景技术
空气污染通常涉及将物质、生物分子和/或其它有害材料引入到地球大气环境中。空气污染的全球化程度正在增大。人类对空气污染的敏感性也在增加。根据2014年的世界卫生组织报告，2012年空气污染在全世界导致大约7百万人死亡。“7Million PrematureDeaths Annually Linked to Air Pollution”(每年7百万的过早死亡与空气污染有关)，世界卫生组织2014年3月25日(参见http://www.who.int/mediacentre/news/releases/2014/air-pollution/en/)。减少空气污染每年能够拯救数百万人的生命。
建筑物的居住者通常会打开其窗户，以让新鲜空气进入住宅、工作场所或其它封闭空间的内部。然而，在许多地方诸如中国或印度人口高度密集的地区，室外空气包括高水平的空气污染物。需要新型过滤解决方案，以在空气进入室内之前从空气中除去污染或污染物。例如，室外污染物可能包括大微粒诸如花粉、粉尘和霉菌孢子，以及例如，较小的微粒诸如PM2.5、细菌和病毒。例如，在一些地方气体室外污染物诸如气味、NOx、SO2、臭氧以及其它物质可能也令人担忧。
加热炉空气过滤中的一些进展涉及制备可扩张以适配各种空气管道尺寸的空气过滤装置。描述此类空气过滤装置的一个示例性专利为美国专利7,037,354。
发明内容
本公开的发明人认识到，可扩张以适配各种空气加热炉管道的加热炉空气过滤器的一个缺点在于它们不均匀扩张。例如，在褶绉折叠和连接的位置，连接通常受到非弹性折叠支撑材料诸如金属网或塑料网的影响。因此，过滤介质上相邻褶绉之间和/或不同区域上的扩张量差异显著。除此之外或另选地，上述的可扩张加热炉过滤介质不均匀地折叠。过滤介质收缩时，介质变平。不均匀的过滤介质和变平的过滤介质可导致性能降低。性能降低的一些示例性类型包括例如空气流减小、空气压力增大和/或空气过滤/污染物捕集能力降低。
考虑到上述缺点，本公开的发明人还认识到对可均匀扩张的空气过滤器的需求。
本发明人还认识到对用于窗户空气过滤器或暖通空调过滤器的可均匀扩张的空气过滤器的需求。
本公开的至少一些空气过滤器：帮助使用者免受室外空气质量污染物的影响，可轻松且均匀地扩张，使新鲜空气通过窗户进入住宅或办公室，可由使用者轻松安装和使用，为适配大多数窗户尺寸的通用型，和/或对光线和可见度具有最小影响。本公开的发明人发明和发现了可实现这些目标中至少一些的装置和方法。本公开的发明人发明了各种空气过滤器的实施方案、制备空气过滤器的方法，以及使用空气过滤器的方法。
本公开的一些实施方案涉及空气过滤器，包括：过滤介质组件，该过滤介质组件能够从塌缩状态扩张到扩张状态并且该过滤介质组件包括具有多个褶绉的褶状过滤介质；和可扩张元件，所述可扩张元件连接多个褶绉中至少一些褶绉；其中过滤介质组件基本上均匀地从塌缩状态扩张到扩张状态。
在一些实施方案中，空气过滤器包括多个可扩张元件。在一些实施方案中，可扩张元件为以下中的至少一者：弹性线、弹性长丝、弹性条、挤出的弹性长丝和/或弹性网。在一些实施方案中，可扩张元件连接至以下中的至少一者：过滤介质的所有褶绉顶端、过滤介质的大部分褶绉顶端、过滤介质的一些褶绉顶端、相邻褶绉顶端、交替褶绉顶端。在一些实施方案中，多于一个可扩张元件连接至单个褶绉顶端。在一些实施方案中，可扩张元件附接至以下中的至少一者：底部褶绉顶端、顶部褶绉顶端、和/或顶部和底部褶绉顶端。
在一些实施方案中，过滤介质为以下中的至少一种：耐湿的、防湿的、带静电的、驻极体非织造幅材和/或不带静电的。在一些实施方案中，过滤介质包括以下中的至少一者：碳、活性炭、非织造织物、热塑性塑料、热固性材料、多孔泡沫、玻璃纤维、纸材、高蓬松纺粘幅材、低蓬松纺粘幅材、熔喷幅材和/或双模态纤维直径熔喷介质。在一些实施方案中，过滤介质为自支承和非自支承中的至少一者。在一些实施方案中，空气过滤器为窗户空气过滤器或暖通空调过滤器中的至少一者。
附图说明
图1A为本文一般所述类型的示例性褶状过滤介质组件在处于扩张状态时的透视图。
图1B为沿线1B-1B截取图4A的褶状过滤介质组件所得的剖视图。
图1C为图1A的褶状过滤介质组件的一部分在处于塌缩状态时的侧视图。
图2A-图2C为本文一般所述类型的褶状过滤介质或组件的各种实施方案的剖视图。
图3A-图3B为本文一般所述类型的用于竖直开启窗户的示例性空气过滤器的透视图。
图4A-图4B为本文一般所述类型的安装于水平开启窗户的示例性空气过滤器的透视图。
具体实施方式
将详细描述各种实施方案和具体实施。这些实施方案不应理解为以任何方式限制本专利申请的范围，并且在不脱离实施方案和具体实施的实质和范围的条件下可做出改变和修改。例如，通过具体参照窗户空气过滤器论述了许多实施方案、具体实施和示例，但这些不应理解为将申请范围限制于这一个示例性的具体实施。此外，本文仅论述了一些最终用途，但本文未具体描述的最终用途包括在本申请范围内。因此，本专利申请的范围应按权利要求书确定。
过滤介质组件30的一个实施方案示于图1A至图1C中。过滤介质组件30的过滤介质32呈褶状并且包括多个褶绉70，每个褶绉包括用于限定褶绉顶端74的折叠线72和一对相邻板76。如本文所用，术语“褶状”是指过滤介质，该过滤介质的至少一部分已被折叠而形成包含多行大致平行，相反取向的折叠部的构型。每个折叠部被称为褶绉。可使用本领域中熟知的各种方法和部件在过滤介质32(或在褶状过滤介质组件30中)中形成褶绉(例如，授予Kubokawa等人的美国专利6,740,137、授予Sundet等人的美国专利7,622,063、以及美国专利申请62/073067所述的那些，这些专利中每一个的全部教导内容均以引用方式并入本文中)。本公开的褶状过滤介质可具有任何期望的褶绉间距、尺寸、图案或结构。
褶状过滤介质组件30还包括一个或多个可扩张元件80，该可扩张元件80例如连接、附接、粘合、粘附至褶绉70的至少一些顶端74。可扩张元件80可为例如弹性线、弹性长丝(例如聚氨酯弹性纤维)、挤出的弹性长丝和/或弹性网(诸如购自Conwed的那些)、弹性条和/或挤出的弹性条。可扩张元件80可连接至所有褶绉、一些褶绉、相邻褶绉、交替褶绉等。一个或多个可扩张元件可附接至单个褶绉。在一些实施方案中，可扩张元件附接至褶绉顶端。在一些实施方案中，可扩张元件附接至底部褶绉顶端、顶部褶绉顶端、和/或顶部和底部褶绉顶端。一个或多个可扩张元件80使过滤介质组件30能够从塌缩状态均匀地扩张到扩张状态。如本文所用，相对于过滤介质组件30或过滤介质32的扩张，术语“均匀地”是指过滤介质32或过滤介质组件32在褶状过滤介质或过滤介质组件的长度或宽度上，在附近或相邻的褶绉顶端之间维持基本上恒定的距离比率。
为了明确起见，如本文所用的塌缩状态不要求褶绉为最大限度压缩的构型，更恰当地说，塌缩状态表示小于完全扩张状态的褶绉间距。因此，完全塌缩状态为褶绉被最大限度地压缩的情况。处于完全塌缩状态时，可扩张元件可能为松弛的，并且初始过滤介质或过滤介质组件扩张可能为不均匀的直至可扩张元件不再松弛。此类实例是指落入如本文所用的相对于过滤介质扩张的术语“均匀”或“均匀地”的范围内。
在一些实施方案中，可将非弹性元件附接至与可扩张元件相对的面。当过滤介质或过滤介质组件扩张时或处于扩张位置时，非弹性元件可在最大扩张位置处提供“完全停止”。
可通过任何已知或期望的方法来将一个或多个可扩张元件80连接、附接、粘附、粘合至褶绉顶端80。一些示例性附接方法包括，例如，直接或间接地将一个或多个可扩张元件挤出到褶绉顶端，通过热粘合、化学粘合、超声波粘合、压力粘合、使用粘合剂(包括例如热熔粘合剂)等来附接预形成的可扩张材料。可在多种条件下附接一个或多个可扩张元件，该多种条件包括如下条件：可扩张或弹性元件经受零拉伸或非常小的拉伸至可扩张或弹性元件在经受相当大的拉伸的情况下附接至褶绉顶端。
在一些实施方案中，在低拉伸或零拉伸条件下应用一个或多个可扩张元件。在一些实施方案中，当过滤组件或过滤介质处于10％的最大扩张或更小时应用一个或多个可扩张元件。在一些实施方案中，在高拉伸或相当大的拉伸条件下应用一个或多个可扩张元件。在一些实施方案中，当过滤组件或过滤介质处于30％的最大扩张或更大时应用一个或多个可扩张元件。
本公开的褶状过滤介质组件可具有任何期望形状，包括例如示出的四边形或矩形形状(术语“矩形”具体包括正方形)，从而限定相对的侧部34a和侧部34b以及相对的端部35a和端部35b。
在一些实施方案中，过滤介质组件30可在不破坏过滤介质组件30的结构完整性的情况下，至少从塌缩状态转换为扩张状态。在一些实施方案中，过滤介质组件30可在不破坏过滤介质组件30的结构完整性的情况下，在塌缩状态和扩张状态之间重复转换。
本公开的褶状介质组件可由过滤介质或幅材32单独构成，或可包括一个或多个应用或装配到过滤介质32的附加部件或结构。
组件30的褶状过滤介质32可为自支承的或非自支承的。如本文所用，术语“自支承过滤介质或幅材”可描述以下条件中的至少一者：(1)在过滤介质幅材中不需要加强层、粘合剂或其它增强的情况下抗变形的过滤介质或幅材；或(2)当经受气流时基本上维持其形状的过滤介质，在例如在授予Kubokawa的美国专利7,169,202中对此有所描述，该专利的全部教导内容以引用方式并入本文；或(3)具有足够抱合力和强度以便不需要大力撕裂或破裂即可悬垂和处理的幅材或介质。如本文所用，术语“非自支承的”描述空气过滤介质，该空气过滤介质不存在支撑框架和/或支撑格栅时，不能承受由于通常的气流而遇到的力。
在一些实施方案中，在褶状过滤介质组件30由褶状过滤介质32单独构成的情况下，褶状过滤介质或幅材32可为自支承的或非自支承的。在一些实施方案中，在褶状过滤介质组件30由褶状过滤介质或幅材32和支撑结构构成的情况下，褶状过滤介质32可为非自支承的但具有附加的支撑结构，该附加的支撑结构使得褶状过滤介质组件30作为整体为自支承的。在一些实施方案中，褶状过滤介质32是背面有线的。
图2A-图2C示出了可与可调节空气过滤器20使用的褶状过滤介质的各种示例。在一些实施方案中，褶状过滤介质是可均匀扩张的。在一些实施方案中，褶状过滤介质在至少一个对应于主轴的方向上是可均匀扩张的。图2A示出了示例性实施方案，其中可扩张元件80附接至相邻的“底部”褶绉顶端。图2B示出了示例性实施方案，其中可扩张元件80附接至相邻的“顶部”褶绉顶端。图2C示出了示例性实施方案，其中可扩张元件80附接至相邻的“顶部”和“底部”褶绉顶端。
在一些实施方案中，附接至褶绉顶端的一个或多个可扩张元件可在两个主轴方向上具有不同特性。例如，股线、长丝或条将仅在一个方向上提供弹性特性。网可在一个或多个轴向上提供弹性。在一些实施方案中，网的特性在两个轴向方向上可能有差别，并且横向可能为非弹性的而主轴可能为弹性的。
为过滤介质组件30选择的具体过滤介质32可为特别适合的，具有已知的或本文所述的任何特别期望的特性。在一些实施方案中，过滤介质组件30由耐潮材料构造而成。在一些实施方案中，过滤介质可包括附加的层或特征结构，以具体阻止或挡住水，诸如雨。
在一些实施方案中，任选地将静电荷传递到过滤介质32的一种或多种材料中或一种或多种材料上。在一些实施方案中，可以使用带静电的介质32，其中许多等级是可获得的，并且其中许多提供具有低压降的高效率。通过引入扩张的表面积以及通过覆盖窗户的适度部分，结合使用通过静电充电得到的低压降幅材，可为过滤器实现适当地低压降，这可有助于使适度的空气流通过过滤器。在一些实施方案中，过滤介质32可为驻极体非织造幅材。电荷可以本领域中熟知的多种方式传递到过滤介质32，例如通过水充电、电晕充电等(例如，在美国专利7,947,142中所述，其全文以引用方式并入本文中)。
在一些实施方案中，过滤介质32不带静电。在一些实施方案中，包含活性炭或其它用于净化气相污染物的材料的附加多功能介质等级也可或可选择地结合到过滤结构中。在一些实施方案中，过滤介质32可例如由非织造纤维介质构造而成，该非织造纤维介质由热塑性或热固性材料诸如聚丙烯、线性聚乙烯和聚氯乙烯制成。用于过滤介质的其它合适的非限制性材料包括多孔泡沫、非织造织物、纸材、玻璃纤维等。在一些实施方案中，过滤介质32包括吸引和捕集来自室外空气中粉尘、过敏原(诸如花粉和霉菌孢子)和/或细小微粒污染物的过滤介质。
可与过滤介质32使用的非织造幅材可为高蓬松纺粘网，诸如在授予Fox等人的美国专利8,162,153中所述，该专利的全文并入本文中。在其它实施方案中，过滤介质32可为低蓬松纺粘网，诸如在授予Fox等人的美国专利7,947,142中所述，该专利的全文并入本文中。在另外的其它实施方案中，可与过滤介质32使用的非织造幅材通过其它技术生成和/或具有其它特征，诸如授予Shah等人的美国专利6,858,297中所公开的熔喷非织造幅材，该专利的全文并入本文中。可用非织造幅材形式的其它非限制性示例包括双模态纤维直径熔喷介质，诸如美国专利7,858,163中所述的那些，该专利的全文并入本文中。
在一些实施方案中，过滤介质32为带静电的非织造类型的介质。在一些实施方案中，过滤介质32可为褶状过滤介质，该褶状过滤介质包括已被折叠而形成包含多行大致平行，相反取向的折叠部的构型的至少一部分。在一些实施方案中，可使用本领域中熟知的各种方法和部件在过滤介质32(或在褶状过滤介质组件30中)中形成褶绉，例如以形成用于诸如空气过滤应用的褶状过滤器，例如授予Kubokawa等人的美国专利6,740,137和授予Sundet等人的美国专利7,622,063中所述的那些，这两个专利的全部教导内容均以引用方式并入本文中。
在一些实施方案中，可扩张且可折叠的空气过滤器可用于保护使用者免受空气质量污染物的影响。
图3A-图3C示出安装于滑动型窗户180的示例性可回缩过滤器120的材料和构造的各方面，该滑动型窗户可为单悬窗或双悬窗。滑动窗户主要用于北美和中国。可回缩过滤器120至窗户180的附接可为永久性或半永久性的。在一些实施方案中，因为当过滤介质组件扩张和回缩时，附接点可经受来自内弹簧力的适度力，所以附接机构可安全地将可回缩过滤器120固定至窗户180。一些示例性永久性固定选项包括钉子、螺钉和某些类型的粘合剂。在一些实施方案中，附接是半永久性的，诸如使用高曼TM条(CommandTM strips)、背胶联锁钩、稀土磁体等。当扩张时，过滤介质组件130的侧边缘可通过机械部件或粘附部件附接至窗框/窗台构件。在一些实施方案中，由于收缩力相同，可扩张的过滤器框架还包括用于锁定可扩张框架的装置。
最后，类似于上文图3A-图3C所述的竖直滑动窗户180，图4A和图4B示出了安装于水平滑动窗户280的示例性可折叠且可扩张的空气过滤器220。在一些实施方案中，将可回缩的过滤器220附接在窗户280的一端，将窗户280部分打开，以及将过滤介质组件230扩张以覆盖窗户间隙。两个窗户部分之间可形成小间隙，从而使空气能够在两个窗户部分之间从室外流动，并绕过过滤介质组件230进入室内。在一些实施方案中，可通过使用泡沫材料片、挡风雨条等(未示出)来避免出现此类绕过。
本公开的空气过滤器可置于任何期望的框架或外壳中。一些示例性框架在例如美国专利62/041496和62/041499中有所描述，这两个专利均全文并入本文中。本公开的空气过滤组件可用于电动空气过滤系统诸如，例如美国专利申请62/041501中所述，该专利全文并入本文中。空气过滤介质可为卷筒形式诸如，例如美国专利申请62/041500中所述的，该专利全文并入本文中。
本文所述的空气过滤器可用于任何期望的应用，该应用包括但不限于窗户或暖通空调系统。
说明书和权利要求书中的术语第一、第二、第三等用于区分相似元件，并且不一定用于描述顺序或时间顺序。应当理解，如此使用的术语在适当的情况下是可互换的，并且本文描述的本发明的实施方案能够以不同于本文所述或所示的其它顺序操作。
本文所述的所有参考文献均全文并入本文中。
此外，说明书和权利要求书中的术语顶部、底部、之上、之下等用于描述的目的并且不一定用于描述相对位置。应当理解，如此使用的术语在适当的情况下是可互换的，并且本文描述的本发明的实施方案能够以不同于本文所述或所示的其它取向操作。
对由端值限定的所有数值范围的表述旨在包括归入该范围内的所有数字(即，1至10的范围包括例如1、1.5、3.33、和10)。
本领域中的技术人员将会知道，可在不脱离本公开基本原理的前提下对上述实施方案和具体实施的细节做出许多改变。此外，在不脱离本发明的实质和范围的前提下，本发明的各种修改和更改对本领域技术人员将是显而易见的。因此，本申请的范围应当仅由以下权利要求书以及其等同物所确定。

Claims (10)

1.一种空气过滤器，所述空气过滤器包括：
过滤介质组件，所述过滤介质组件能够从塌缩状态扩张到扩张状态并且所述过滤介质组件包括具有多个褶绉的褶状过滤介质；和
弹性的可扩张元件，所述可扩张元件连接所述多个褶绉中的至少一些褶绉；
其中所述弹性的可扩张元件包括多个弹性的可扩张元件，所述弹性的可扩张元件由一组挤出的弹性长丝组成，所述弹性长丝被挤出到所述褶绉顶端上并热粘合到所述褶绉顶端上，并且
其中所述过滤介质组件基本上均匀地从所述塌缩状态扩张到所述扩张状态。
2.根据权利要求1所述的空气过滤器，包括多个可扩张元件。
3.根据权利要求1所述的空气过滤器，其中所述可扩张元件连接至以下中的至少一者：所述过滤介质的所有褶绉顶端、所述过滤介质的大部分所述褶绉顶端、所述过滤介质的一些所述褶绉顶端、相邻褶绉顶端、交替褶绉顶端。
4.根据权利要求1所述的空气过滤器，其中多于一个可扩张元件连接至单个褶绉顶端。
5.根据权利要求1所述的空气过滤器，其中所述可扩张元件附接至以下中的至少一者：底部褶绉顶端、顶部褶绉顶端、和/或所述顶部和底部褶绉顶端。
6.根据权利要求1所述的空气过滤器，其中所述过滤介质为以下中的至少一种：耐湿的、防湿的、带静电的、驻极体非织造幅材和/或不带静电的。
7.根据权利要求1所述的空气过滤器，其中所述过滤介质包括以下中的至少一者：碳、活性炭、非织造织物、热塑性塑料、热固性材料、多孔泡沫、玻璃纤维、纸材、高蓬松纺粘幅材、低蓬松纺粘幅材、熔喷幅材和/或双模态纤维直径熔喷介质。
8.根据权利要求1所述的空气过滤器，其中所述过滤介质为自支承和非自支承中的至少一种。
9.根据权利要求1所述的空气过滤器，其中所述空气过滤器为窗户空气过滤器或暖通空调过滤器中的至少一者。
10.根据权利要求1所述的空气过滤器，其中所述过滤介质组件是自支承的并且不包括支撑框架。
CN201580045917.6A 2014-08-25 2015-08-24 可均匀扩张的空气过滤器 Active CN106794412B (zh)

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US201562206928P 2015-08-19 2015-08-19
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