Collapsible extended surface filter and air cleaner system using collapsible extended surface filter

Abstract

A collapsible air cleaner filter is provided. The filter includes a pleated media filter having a first end, a second end, and a filter media extending between the first and second ends, wherein the filter media includes a first plurality of flexible end portions and a second plurality of flexible end portions, the first and second plurality of flexible end portions are separated by a plurality of pleats, and the filter media extends a first length between the first and second plurality of flexible end portions, and an end member coupled to the first end of the pleated media filter, the end member extending a second length parallel to the first length, the first length being greater than the second length.

What is claimed is: 
     
         1 . A collapsible air cleaner filter comprising:
 a pleated media filter having a first end, a second end, and a filter media extending between the first and second ends, wherein the filter media includes a plurality of pleats having a first plurality of flexible width portions and a second plurality of flexible width portions, the filter media having a width extending between and including the first and second plurality of flexible width portions;   a first end member coupled to and extending along the first end of the pleated media filter, the first end member having a structural body with a cross sectional shape generally defining at least one outwardly extending first end foot member, the at least one first end foot member at least partially defining at least one first end retaining channel; and   a second end member coupled to and extending along the second end of the pleated media filter, the second end member having a structural body with a cross sectional shape generally defining at least one outwardly extending second end foot member, the at least one second end foot member defining at least one second end retaining channel.   
     
     
         2 . The collapsible filter of  claim 1 , further comprising at least one first rib extending angularly from the first end member away from the pleated media filter, and at least one second rib extending angularly from the second end member away from the pleated media filter. 
     
     
         3 . The collapsible filter of  claim 2 , wherein a portion of the at least one first rib is generally perpendicular to the first end member, and a portion of the at least one second rib is generally perpendicular to the second end member. 
     
     
         4 . The collapsible filter of  claim 2 , wherein the at least one first rib extends generally parallel to the at least one first end foot member, and the at least one second rib extends generally parallel to the at least one second end foot member. 
     
     
         5 . The collapsible filter of  claim 1 , wherein:
 the at least one first end foot member includes a first portion provided generally perpendicular to the first end member and a second arcuate portion connected to the first portion, the first portion, second portion, and first end member defining the at least one first end retaining channel; and   the at least one second end foot member includes a third portion provided generally perpendicular to the second end member and a fourth arcuate portion connected to the third portion, the third portion, fourth portion, and second end member defining the at least one second end retaining channel.   
     
     
         6 . The collapsible filter of  claim 1 , further comprising:
 a rail assembly for retaining the collapsible filter within an air duct, the rail assembly including a first rail guide coupled to a first wall of the air duct and a second rail guide coupled to a second wall of the air duct, the first rail guide including a first rail edge, and the second rail guide including a second rail edge, wherein:   the collapsible filter is retained by the rail assembly such that the first rail edge is received by the at least one first end retaining channel, and the second rail edge is received by the at least one second end retaining channel.   
     
     
         7 . The collapsible air cleaner filter of  claim 1 , further comprising a rail system having a first rail guide spatially opposing a second rail guide, the first rail guide having a first rail edge and the second rail guide having a second rail edge, wherein the first rail edge is removably received by the first end body channel of the first end foot member and the second rail edge is removably received by the second end body channel of the second end foot member such that the pleated media filter is retained in an extended position between the first and second rail guides. 
     
     
         8 . The collapsible air cleaner filter of  claim 7 , further comprising an air duct having a first wall, a second wall, an air inlet surface, and an air outlet surface, the first rail guide being coupled to the first wall and provided between the air inlet surface and the air outlet surface, the second rail guide being coupled to the second wall and provided between the air inlet surface and the air outlet surface, wherein the pleated media filter is provided across the air duct between the air inlet surface and the air outlet surface, forming an effective seal between the first end member and the first wall, and an effective seal between the second end member and the second wall. 
     
     
         9 . The collapsible air cleaner filter of  claim 8 , further comprising:
 a first rib coupled to the first wall and projecting toward the second wall;   a first channel provided on the first rail guide;   a second rib coupled to the second wall and projecting toward the first wall; and   a second channel provided on the second rail guide;   wherein the first channel receives the first rib, forming an effective seal by a tortuous path between the first rail guide and the first wall, and second channel receives the second rib, forming an effective seal by a tortuous path between the second rail guide and the second wall.   
     
     
         10 . The collapsible air cleaner filter of  claim 8 , wherein the effective seal between the first end member and the first wall of the air duct is formed by a tortuous path between engaged portions of the first end member and the first rail guide, and the effective seal between the second end member and the second wall of the air duct is formed by a tortuous path between engaged portions of the second end member and the second rail guide. 
     
     
         11 . The collapsible air cleaner filter of  claim 1 , wherein the first and second end structural members are substantially shape retaining. 
     
     
         12 . A rail system to support a collapsible air cleaner filter comprising:
 a first rail guide having at least one rail edge and a plurality of support arm receiving apertures;   a second rail guide opposing the first rail guide, the second rail guide having at least one rail edge and a plurality of support arm receiving apertures; and   a plurality of support arms coupled to and extending between the first and second rail guides, each of the plurality of support arms having a first end keyed to engage and be received by one of the plurality of support arm receiving apertures provided on the first rail guide and a second end keyed to engage and be received by one of the plurality of support arm receiving apertures provided on the second rail guide.   
     
     
         13 . The rail system of  claim 12 , wherein the plurality of support arm receiving apertures provided on the first rail guide include four support arm receiving apertures, the plurality of support arm receiving apertures provided on the second rail guide include four support arm receiving apertures, and the plurality of support arms includes four support arms. 
     
     
         14 . The rail system of  claim 12 , further comprising an air duct having a first wall and a second wall, wherein the first rail guide is coupled to the first wall, and the second rail guide is coupled to the second wall. 
     
     
         15 . The rail system of  claim 14 , wherein the first rail guide includes a first rib receiving channel which engageably receives a first rib coupled to and projecting away from the first wall, and the second rail guide includes a second rib receiving channel which engageably receives a second rib coupled to and projecting away from the second wall. 
     
     
         16 . The rail system of  claim 15 , wherein an effective seal is formed between the first rail guide and first wall through a tortuous path between the engaged first rib receiving channel and the first rib, and an effective seal is formed between the second rail guide and second wall through a tortuous path between the engaged second rib receiving channel and the second rib. 
     
     
         17 . The rail system of  claim 14 , further comprising a flexible tab provided on the first rail guide and a flexible tab provided on the second rail guide, wherein the flexible tabs each are bendable toward the respective first wall or second wall of the air duct to assist in retaining the rail system in the air duct. 
     
     
         18 . The rail system of  claim 14 , further comprising a collapsible air cleaner filter removably received by the rail system, the collapsible air cleaner filter including a pleated media filter having a first end, a second end, and a filter media extending between the first and second ends, a first end member coupled to the first end, a second end member coupled to the second end, the first end member having a first rail edge receiving channel, the second end member having a second rail edge receiving channel, wherein the first rail edge receiving channel engageably receives a portion of the at least one rail edge of the first rail guide and the second rail edge receiving channel engageably receives a portion of the at least one rail edge of the second rail guide such that the collapsible air cleaner filter is engaged and retained in an extended position across the air duct. 
     
     
         19 . The rail system of  claim 18 , wherein the filter media includes a first plurality of flexible end portions and a second plurality of flexible end portions, the first and second plurality of flexible end portions being separated by a plurality of pleats, and the filter media extending a first length between the first and second plurality of flexible end portions, the first member extending a second length generally parallel to a plurality of pleat edges interconnecting the plurality of pleats, and the second member extending a third length generally parallel to the plurality of pleat edges, the first length being greater than the second length and the third length. 
     
     
         20 . An air cleaner filter assembly comprising:
 an air duct having a first wall and a second wall;   a first support member coupled to the first wall;   a second support member coupled to the second wall;   an air filter having a first end member opposing a second end member, a media filter extending between the first and second end members, the media filter having at least one first end portion and at least one second end portion, the filter media extending a first length between the first and second end portions, the first end member extending a second length, the second end member extending a third length, the first end member provided generally parallel to the second end member, and the first length being greater than the second length and the third length;   the air filter being removably retained in the air duct, such that the first end member engages the first support member to form an effective seal between the air filter and the first wall, and the second end member engages the second support member to form an effective seal between the air filter and the second wall, such that the media filter is provided in an extended position across the air duct.   
     
     
         21 . The air cleaner filter assembly of  claim 20 , wherein the effective seal between the air filter and the first wall is formed by a tortuous path between the first support member and the first end member, and the effective seal between the air filter and the second wall is formed by a tortuous path between the second support member and the second end member. 
     
     
         22 . The air cleaner filter assembly of  claim 20 , further comprising:
 a third support member coupled to the first wall; and   a fourth support member coupled to the second wall, wherein the first end member engages the third support member to assist in forming an effective seal between the air filter and the first wall, and the second end member engages the fourth support member to assist in forming an effective seal between the air filter and the second wall.   
     
     
         23 . The air cleaner filter assembly of  claim 22 , wherein the first end member includes a first foot extending generally parallel to a second foot, the first foot defines a first channel which receives a portion of the first support member, the second foot defines a second channel which receives a portion of the third support member, and the second end member includes a third foot extending generally parallel to a fourth foot, the third foot defines a third channel which receives a portion of the second support member, the fourth foot defines a fourth channel which receives a portion of the fourth support member. 
     
     
         24 . The air cleaner filter assembly of  claim 23 , wherein the first and third support members are defined by a first rail guide, the first rail guide is removably coupled to the first wall, and the second and fourth support members are defined by a second rail guide, the second rail guide is removably coupled to the second wall.