Collapsable v-bank filter

Abstract

A V-bank filter having a plurality of filter panels having a first side end opposed to a second side end, the plurality of filter panels arranged into one or more V-configurations, and a first flexible side panel joined to the first side ends and a second flexible side panel joined to the second side ends. The V-bank filter having an operating position having a distance, O, between individual filter panels measured at an open end of the one or more V-configurations when in the operating position and a collapsed position having a distance, C, between individual filter panels measured at the open end when in the collapsed position. The distance C is less than the distance O when the V-bank filter is placed into the collapsed position and the plurality of filters panels can be moved between the collapsed position and the operating position while maintaining a substantially air tight connection between the plurality of filter panels and the first flexible side panel and while maintaining a substantially air tight connection between the plurality of filter panels and the second flexible side panel.

What is claimed is: 
     
         1 . A V-bank filter comprising:
 a plurality of individual filter panels having a first side end opposed to a second side end, the plurality of individual filter panels arranged into one or more V-configurations,   a first side panel joined to the first side ends by a thermoplastic weld, and a second side panel joined to the second side ends by a thermoplastic weld forming the V-bank filter.   
     
     
         2 . The V-bank filter of  claim 1  wherein adjacent filters panels in the plurality of individual filter panels are joined to each other by endcaps thermoplastically welded to the individual filter panels. 
     
     
         3 . The V-bank filter of  claim 1  wherein the first side panel, the second side panel, and the endcaps comprise polypropylene, polyethylene, polyester, polyvinylchloride, chlorinated polyvinylchloride or polyvinylidenefluoride. 
     
     
         4 . The V-bank filter of  claim 1  wherein the first side panel, the second side panel, or the endcaps comprise an inner layer of a thermoplastic material and an outer layer of a nonwoven material thermoplastically welded to the inner layer. 
     
     
         5 . The V-bank filter of  claim 4  wherein the thermoplastic material comprises polyethylene film. 
     
     
         6 . The V-bank filter of  claim 5  wherein the wherein the polyethylene film is between 5 to 30 mils thick. 
     
     
         7 . The V-bank filter of  claim 4  wherein the nonwoven material comprises polyester. 
     
     
         8 . The V-bank filter of  claim 7  wherein the nonwoven material comprises 3-10 mil polyester. 
     
     
         9 . The V-bank filter of  claim 4  wherein the thermoplastic material comprises 5-30 mil polyethylene and the nonwoven material comprises 3-10 mil polyester. 
     
     
         10 . The V-bank filter of  claim 1  wherein the first flexible side panel and the second flexible side panel extend past an upper surface of the plurality of individual filter panels forming a flexible flange. 
     
     
         11 . The V-bank filter of  claim 10  wherein a first end cap applied to a first outer filter panel and a second end cap applied to a second outer filter panel both extend from each filter panel forming a flexible flange. 
     
     
         12 . The V-bank filter of  claim 11  wherein the flexible flanges are disposed into a groove in a frame and held within the groove by an elastomeric member. 
     
     
         13 . The V-bank filter of  claim 12  wherein the elastomeric member extends further than a depth of the groove thereby forming a sealing surface extending from the frame for sealing the V-bank filter to an air intake housing. 
     
     
         14 . The V-bank filter of  claim 13  wherein the elastomeric member has a circular cross section prior to installation in the groove and an hourglass cross section after installation in the groove. 
     
     
         15 . The V-bank filter of  claim 1  wherein the first flexible side panel or the second flexible side panel comprise a structural weakening element. 
     
     
         16 . The V-bank filter element of  claim 15  wherein the structural weakening element comprises a slit, a cutout, an aperture, a perforation, a score line, a fold line, or pleats. 
     
     
         17 . A method of making the V-bank filter of  claim 1  comprising:
 placing the plurality of individual filter panels in a fixture to hold them in the one or more V-shaped configurations; 
 placing the first side panel into the fixture adjacent the first side edges of the plurality of individual filter panels, and placing the second side panel into the fixture adjacent the second side edges of the plurality of individual filter panels; 
 clamping the first side panel and the second side panel between opposing heated platens; 
 heating the first side panel and the second side panel to join them to the first and second side edges of the plurality of individual filter elements; 
 removing the opposing heated platens; and 
 removing the V-bank filter from the fixture.