Filter for air conditioning system and method for installing such filter
The rectangular filter body, made of flexible and breathable material, utilizes fracture-resistant cubic components and laser-cut design to solve the problems of inventory management and installation complexity of air conditioning filters, achieving a high-efficiency and low-cost air conditioning filtration solution.
Patent Information
- Authority / Receiving Office
- CN · China
- Patent Type
- Applications(China)
- Current Assignee / Owner
- Filing Date
- 2024-05-22
- Publication Date
- 2026-03-27
AI Technical Summary
Existing air conditioning filters suffer from problems such as difficulty in inventory management, size mismatch leading to reduced efficiency, complex installation requiring tools, and conventional filters are prone to clogging during use, failing to effectively remove airborne molecular pollutants and volatile organic compounds.
The rectangular filter body is made of breathable material and is connected by multiple breakable cubic components. It is formed by laser cutting, which allows for easy manual adjustment of the size to fit different air conditioning filter containers. No tools are required for installation, and the use of flexible materials ensures the filtration effect.
It enables the use of filter containers of various sizes, simplifies the installation process, reduces inventory requirements, improves filtration efficiency, maintains high MERV values, reduces resistance to air conditioning systems, and lowers costs.
Smart Images

Figure CN121752458A_ABST
Abstract
Description
BACKGROUND
[0001] The present invention relates to filters for air conditioning systems. More particularly, the present invention relates to filters that reduce or remove dust, pollen, harmful pollutants and also serve to filter existing cabin air by filtration through a recirculation mode in order to allow removal of in-vehicle odors such as cigarette smoke, food odors and pet odors. More particularly, the present invention relates to such air filters that are installed in a box-like container of an air conditioning system.
[0002] In view of the increasing air pollution, especially in metropolitan areas, it is necessary and desirable to purify the air supplied from the outside to the interior of a motor vehicle in connection with the use of modern air conditioning devices. This purification of the air is performed by a suitable air filter. For example, a particle filter or a deodorizing filter or a combination thereof is suitable for this purpose. The filter should remove or absorb as many as possible of the suspended solids, particles and odors contained in the ambient air. Various embodiments and variants are generally known for such filters for filtering air for the interior of a motor vehicle.
[0003] Air filters for vehicle cabins are typically pleated paper filters that are placed in the outside air intake of the passenger compartment of a vehicle. Cabin air filters typically have a unique shape to fit the available space within the ventilation system of the vehicle. Cabin air filters can greatly affect the effectiveness and heating performance of the air conditioning of a vehicle. A clogged or dirty cabin air filter can significantly reduce airflow through the ventilation system of a vehicle and allow allergens and pollutants to enter the passenger compartment of the vehicle. A drawback of conventional cabin air filters is that, although many people believe that cabin air filters are generally highly efficient, conventional cabin air filters typically have a relatively low Minimum Efficiency Reporting Value (MERV) and thus can allow airborne molecular pollutants and volatile organic compounds (VOCs) to enter the vehicle passenger compartment.
[0004] FIG. 1 shows a typical cabin air filter 10 in the prior art. This typical cabin air filter is formed of a paper material 12 that is folded into pleats and is received within a frame 14. The size of the pleats and the distance between adjacent pleats are configured to maximize the filtration capacity and airflow characteristics of the air filter 10. The frame 14 will have a particular size to fit the filter receiving container of the vehicle. Currently, filters of vehicles have a wide variety of sizes of receiving containers. It is important that the size of the frame 14 and the contained pleated air filter 12 fit properly within the container in order to avoid air leakage around it. Therefore, the air filter 10 must be provided in a wide range of sizes.
[0005] FIG. 2 shows the air filter 10 received within the filter receiving container 16 of the vehicle 18. Typically, there is a small door to the forward facing surface 20 of the filter 10 that locks the filter 10 in place within the filter receiving container 16. At this point, the filter 10 is in the correct position so as to filter the air passing through the air conditioning system of the vehicle. After a period of time, the door of the air conditioning container 16 is opened in the direction of arrow 22 and the filter 10 is slid out of the filter receiving container 16 for removal and / or cleaning.
[0006] Unfortunately, this configuration of air filter 10 has a number of disadvantages. For suppliers of this type of air filter, a variety of sizes of this air filter must be kept in inventory. This creates a significant inventory problem for the supplier. The wide range of different sizes of filter receiving containers necessitates a number of different sizes of air filters to be kept in inventory. Many times, the vehicle owner will be provided with an air filter that is not the correct size. The air filter that is not the correct size either does not fit into the container or is not properly fitted into the container, thereby allowing air flow to pass around it and remain unfiltered. The ability of this air filter 10 to filter air is typically dependent on the length of time that the air filter remains in the container. Over time, the pores in the pleated paper material 12 become clogged, thereby reducing the air conditioning filter efficiency. Often, it can become so clogged that the filter is unable to effectively remove contaminants or operate efficiently. Thus, there has been a need to provide this type of air conditioning air filter that accommodates a wide variety of air conditioning filter container sizes and shapes.
[0007] There are other types of replacement filters currently on the market. However, these filters require the use of tools to measure and cut in order to replicate the existing filter. This technique is very time consuming. Moreover, there is an inherent risk of injury with this method.
[0008] In the past, various patents and patent application publications have been issued relating to this type of air conditioning filter. For example, an earlier patent is U.S. Patent No. 5,192,346, which issued to T. Kowalczyk on March 9, 1993. This patent teaches an air cleaner pleated filter that protects the occupants of a motor vehicle from pollutants. This pleated filter is installed in the plenum cavity of the air scoop of the heating-cooling system of the vehicle. The filter is equipped with a sensor switch that notifies the driver whenever the filter becomes dirty and needs to be replaced. The filter contains a hot fluid heater, such as a hot water heater, that protects the filter from freezing and keeps the filter dry, which prevents bacteria from breeding and prevents odor from developing.
[0009] U.S. Patent No. 6,019,676 issued February 1, 2000 to S. Kim provides an air filtration method and apparatus that more effectively cleans ambient air being fed into the passenger compartment of a motor vehicle via an existing OEM heating / ventilation / air conditioning system. The air is treated immediately as it is discharged into the passenger compartment and the filter is compatible with the existing OEM air filtration process provided at the vent hood inlet or located midstream within the ductwork.
[0010] U.S. Patent No. 7,083,514 issued August 1, 2006 to Stamey, Jr. et al. provides an air filtration system provided for use in a vehicle to deliver air to a helmet worn by an operator of the vehicle. The air filtration system includes an air inlet in the form of a window scoop for drawing in outside air, an air duct assembly for delivering air from the air inlet to the helmet, and an air filter assembly disposed in-line between the air inlet and the helmet with the air duct assembly. The air filter assembly includes a catalyst member for converting carbon monoxide to carbon dioxide and a particulate filter member.
[0011] U.S. Patent No. 8,075,658 issued December 13, 2011 to Volkmer et al. provides a filter element having a sawtooth folded pleat pack. At least one terminal element is folded parallel to the folds of the pleat pack. The terminal element has a first leg, a second leg, and a third leg. The first leg is arranged substantially perpendicular to a flow direction of a medium flowing through the filter element. The first leg, the second leg, and the third leg are determined by folds in the terminal element. The first leg and the second leg are positioned substantially at right angles with respect to each other. The third leg protrudes laterally away from the filter element to form a perimeter seal.
[0012] U.S. Patent No. 8,940,069 issued January 27, 2015 to D. Haider shows an in-vehicle air filter for a motor vehicle having a pleat pack with a first side. A strip of material having a first leg and a second leg is disposed on the first side. The first leg is attached to the first side and the second leg has a width greater than a height of the pleat pack. The strip of material at least partially forms a headband or a sideband of the pleat pack. A filter container for the in-vehicle air filter has a sloped wall and a mounting and removal opening through which the in-vehicle air filter is inserted or removed. The sloped wall extends at an angle corresponding to an angle defined by a contact surface of the filter container and the second leg of the strip of material of the in-vehicle air filter.
[0013] U.S. Patent No. 9,687,769 issued to Mardall et al. on June 27, 2017 provides an air filtration system for a passenger cabin of a vehicle, the system including a HEPA filter for filtering air from an air intake into filtered air. The HEPA filter includes a fine particulate filter and a gas filter. An air channel is formed in the vehicle and is configured to transport air from the air intake to the HEPA filter and to transport the filtered air from the HEPA filter to the passenger cabin.
[0014] U.S. Patent No. 9,964,078 issued to Pham et al. on May 8, 2018 teaches a filter assembly for a motor vehicle air cleaner, the assembly including a primary filter, a secondary filter disposed separately from the primary filter, and a filter support secured to and supporting the primary filter and the secondary filter. The filter support is loadable into and removable from a housing of the air cleaner. The filter support includes a sealing element passing between the primary filter and the secondary filter.
[0015] U.S. Patent No. 10,328,377 issued to I. Ferreira on June 25, 2019 shows a filter having a relatively rigid support frame with top and bottom frame members and side frame members. A filter element is disposed within and supported by the frame for filtering a medium passing through the filter element. A pair of opposing members of the frame are bendable into an arc shape, thereby allowing the filter to be gradually inserted into a filter housing along an arcuate path. The filter is a cabin air filter for a vehicle. Opposing sides of the frame are provided with V-shaped notches to facilitate bending the filter into an arc shape for insertion.
[0016] U.S. Patent Application Publication No. 2016 / 0280046 published to Williams et al. on September 29, 2016 shows a cabin air filter including a support frame configured to properly orient the cabin air filter within an air filtration system of a vehicle. The support frame includes a shape and size suitable for supporting the cabin air filter within the ventilation system. A filter medium is also held within the support frame and is configured to remove airborne molecular contaminants and volatile organic compounds from air flowing through the ventilation system. The filter medium electrostatically attracts and aggregates contaminants within air flowing through the air filter.
[0017] U.S. Patent Application Publication No. 2017 / 0001135, published by R. Paramore on January 5, 2017, describes a cabin air filter constructed from washable and reusable materials. This cabin air filter can be positioned within a vehicle's air conditioning and heating systems and can be cleaned while essentially maintaining its original shape.
[0018] U.S. Patent Application Publication No. 2017 / 0368490, published by JJWall on December 28, 2017, teaches a composite air filter provided for isolating airborne contaminants from air flowing through the filter. The air filter includes a support frame 1 having a shape and dimensions adapted to house the air filter within an air filtration system. The composite air filter is held within the support frame. A first media layer of the composite filter media is folded into pleats and configured to exhibit relatively high filtration efficiency even at low cross-media air pressure drops. A second media layer of filter media is coupled to the first media layer and configured to maintain a uniform distribution of pleats within the first media layer.
[0019] The purpose of this invention is to provide a low-cost filter for air conditioners.
[0020] Another object of the present invention is to provide an easy-to-install filter for air conditioning.
[0021] Another object of the present invention is to provide a filter for air conditioning that requires a lower inventory of filter components.
[0022] Another object of the present invention is to provide a filter for air conditioning that filters air very effectively.
[0023] Another object of the present invention is to provide a filter for air conditioning that is suitable for filter containers of various sizes.
[0024] Another object of the present invention is to provide a flame-retardant filter for air conditioning.
[0025] Another object of the present invention is to provide a filter for air conditioning that provides excellent filtration performance.
[0026] Another object of the present invention is to provide a filter for air conditioners that does not require installation tools.
[0027] Another object of the present invention is to provide a filter for air conditioning that can be installed very quickly and easily into a filter receiving container.
[0028] These and other objects and advantages of the present invention will become apparent from reading the appended description and claims. Summary of the Invention
[0029] This invention relates to a filter for air conditioning. The filter has a body of breathable material. The body has a generally rectangular configuration. The body has a top, bottom, front, rear, and a pair of sides. The body has multiple slits extending through its thickness. The multiple slits define multiple cubic members that are breakably connected together.
[0030] Multiple cubic components are connected together by a strand or piece of breathable material. In a preferred embodiment of the invention, this "breathable" material is an open-cell foam material, such as expanded polyurethane, expanded polyether, or expanded polyester (mesh and non-mesh).
[0031] The top of the main body is flat and parallel to the bottom plane. The pair of side surfaces are also flat and parallel to each other. The front is also flat and parallel to the rear.
[0032] Each of the plurality of cubic components is separable from the remainder of the body by hand. In a preferred embodiment, each of the plurality of cubic components has a side surface area of approximately one square inch. In a preferred embodiment of the invention for vehicle applications, the body will have a length of twelve inches and a width of twelve inches. As used herein, the term “vehicle” includes all modes of transportation that include “cabin air” type applications. These vehicles include, but are not limited to, heavy equipment vehicles, agricultural machinery, ships, aircraft equipment, motorhomes, recreational vehicles, and all other kinds of mobile transportation vehicles that include air conditioning systems. Furthermore, the invention can also be applied to stationary air conditioning applications, such as window unit air conditioning units, portable air purifiers, and other systems that require air filters. The body in the air conditioning applications of the invention (such as for window unit air conditioning systems) will have a length of twenty-four inches and a width of twenty-four inches. The body may have a thickness of one inch. The body has no frame around its perimeter. Multiple cuts are laser-cut through the entire thickness of the body. The body is flexible and compressible.
[0033] The present invention is also a method for installing a filter into a filter receiving container of an air conditioner. The method includes the following steps: (1) removing an existing filter from the filter receiving container; (2) forming a body of breathable material having a plurality of cubic members that are broken together; (3) separating some of the cubic members from the remainder of the body until the size of the body is not smaller than the size of the existing filter; and (4) inserting the body into the filter receiving container.
[0034] Specifically, in the method of the present invention, the installation step includes compressing the body until it is assembled into the filter receiving container. The separation step includes disconnecting some cubic members from adjacent cubic members until the body has dimensions close to those of the existing filter. Specifically, this can be achieved by laying the body on the removed existing filter. The cubic members are removed from the body until the length and width of the body are close to the length and width of the removed existing filter.
[0035] In a preferred embodiment of the method of the present invention, the breathable material is preferably formed of an open-cell polyurethane foam material. The body may also be formed of polyether and / or polyester foam (mesh and non-mesh). The body has no frame surrounding its periphery. The thickness of the body is equal to the thickness of the existing filter that has been removed.
[0036] The steps of forming the body include laser-cutting slits through the body, allowing multiple cubic components to be brokenably joined together. The laser cutting step is performed across the length and width directions of the body to form the multiple cubic components. In a preferred embodiment, the cubic components have a side length of one inch. The multiple cubic components can be pulled by hand from the body.
[0037] The foregoing section is intended to specifically describe preferred embodiments of the invention. It should be understood that modifications can be made to these preferred embodiments within the scope of these claims. Therefore, this section should not be construed in any way as limiting the broad scope of the invention. The invention should be limited only by the following claims and their legal equivalents. Attached Figure Description
[0038] Figure 1 is a top perspective view of a prior art pleated air filter.
[0039] Figure 2 is a bottom perspective view showing the installation of a prior art pleated air filter into the filter receiver container of a vehicle.
[0040] Figure 3 This is a perspective view of the air filter of the present invention.
[0041] Figure 4 It is a plan view showing the separation of the cubic component of the air filter of the present invention, the purpose of which is to make the size of the air filter match the air filter receiving container of the vehicle. Detailed Implementation
[0042] refer to Figure 3A filter 40 according to a preferred embodiment of the invention is shown. The filter 40 can have a variety of shapes and sizes. Specifically, the air filter 40 includes a body 42 formed of a breathable material. In a preferred embodiment of the invention, this breathable material is an open-cell foam material. This open-cell foam material can be selected from the group consisting of foamed polyurethane, foamed polyether, or foamed polyester (mesh and non-mesh). The body has a generally rectangular configuration. Specifically, the body has a top 44, a bottom 46, a pair of sides 48 and 50, a front portion 52, and a rear portion 54. The body has a plurality of cutouts 56 extending through its thickness. The thickness is defined between the top 44 and the bottom 46. The plurality of cutouts 56 define a plurality of cubic members 58, which are breakably connected together.
[0043] Multiple cubic components 58 are connectable to each other by a section or piece of breathable foam material 60. Thus, the main body 42 is held together by multiple sections or pieces of breathable foam material 60 in a generally rectangular configuration.
[0044] The top 44 and bottom 46 are in a parallel plane relationship. The pair of side surfaces 48 and 50 are in a parallel plane relationship with each other. The front 52 and rear 54 are in a parallel plane relationship.
[0045] In the air filter 40 of the present invention, each of the plurality of cubic members 58 is separable by hand from the remainder of the body 42. Preferably, each of the plurality of cubic members 58 has a side surface area of one square inch. These one-inch sides of the cubic members will allow the user to easily determine the appropriate size of the filter 40 to be inserted into the filter receiving container of the vehicle for the purpose of fitting into the air conditioning container of the vehicle. For example, if the OEM filter is seven inches by nine inches in size, each cubic member 58 can be removed until it reaches the appropriate size. In a preferred embodiment, the body 42 will have a twelve-inch by twelve-inch size for vehicle applications, or a twenty-four-inch by twenty-four-inch size for window unit air conditioning systems. As used herein, the term “vehicle” includes all modes of transportation that include “cabin air” type applications. These include, but are not limited to, heavy equipment vehicles, agricultural machinery, ships, aircraft equipment, motorhomes, recreational vehicles, and all other kinds of mobile transportation vehicles that include air conditioning systems. Furthermore, the present invention can also be applied to stationary air conditioning applications, such as window unit air conditioning units, portable air purifiers, and other systems that require air filters. Thus, the body 42 can be properly shaped by removing the cubic members 58 until the desired size is achieved. Because the body 42 is very large, many vehicle filters can be formed from a single body 42. In terms of storage, using relatively large bodies 42 allows the bodies to be stacked on top of each other in the storage area. When a specific size air filter is needed, the body 42 can be removed and the cubic member 48 removed until the desired size is achieved. The remainder of the body 42 can be returned to the storage area for future forming. Because the body 42 does not have a frame around its perimeter, it can be formed quickly and easily by separating the cubic member 58 from adjacent cubic members.
[0046] Multiple cuts 56 are achieved by laser cutting through the thickness of the body 42. Specifically, there is a series of equally spaced cuts extending along the length of the body and a series of equally spaced cuts extending along the width of the body 42. During this laser cutting process, a small section of material 60 is retained, allowing the cubic member 58 to be brokenably fixed together. Therefore, the cubic member 58 can be separated from the rest of the body 42 by applying very little force by hand.
[0047] Figure 4 This operation is illustrated. Specifically, in Figure 4As can be seen, the user's hand 64 grasps the main body 42. The user's hand 64 bends the main body 42, causing the cubic component 66 to separate from the cubic component 68. This continues, causing the cubic components along line 70 to continue separating from each other, thereby forming an installable filter 72. The installable filter 72 has a shape and size suitable for fitting into the filter receiving container of a vehicle's air conditioning system. The remaining portion 74 can be returned to the storage area for future use or discarded. The polymer foam material used to manufacture the main body 42 is flexible and compressible. Ultimately, the installable filter 72 should have dimensions no smaller than those of the OEM filter. If it is slightly larger than the OEM filter, it can be easily compressed to fit into the filter receiving container of the vehicle. This compressibility allows the filter of the present invention to be properly held without a frame and to establish a reliable assembly within the filter receiving container.
[0048] Experiments using the polyurethane foam material of the body 42 of the filter 40 of the present invention have demonstrated excellent particulate retention capabilities. Particulate matter is removed from the airflow, while the airflow through the air conditioning system is not significantly impeded. Therefore, the present invention has a suitable Minimum Reported Efficiency Value (MERV). The configuration of the molded filter achieved by the present invention prevents airborne molecular contaminants and volatile organic compounds from entering the vehicle passenger compartment. In tests using the filter 40 of the present invention, a MERV value of 11 was found. For reference, the American Society of Heating, Refrigerating and Air-Conditioning Engineers (ASHEAE) has established MERV values to measure air filter performance. Under MERV, air filters are classified into grades 1 to 16 (with grades 17 to 20 reserved for true HEPA filters). The higher the grade, the stronger the air filter's ability to capture airborne particulate matter as small as 0.3 µm. For example, MERV values of 1 to 4 will capture most types of dust, pollen, and dust mites. MERV values of 5 to 8 will capture most mold spores and pet dander. MERV values of 9 to 12 will capture vehicle exhaust particles and Legionella bacteria. A MERV value of 13 to 16 will capture all bacteria, most smoke, dust, and paint. According to the U.S. Environmental Protection Agency, filters with a MERV value of 7 to 12 are just as effective as true HEPA filters in removing most airborne particulate matter.
[0049] It's important to remember that a higher MERV rating doesn't automatically mean better performance. As the MERV value increases, the pore size within the air filter decreases. This creates more resistance to airflow. This can cause HVAC systems not designed for that specific filter to operate more laboredly. This can not only potentially damage the HVAC system but also reduce indoor air quality due to the reduced airflow through the filter. Therefore, the National Air Filtration Association recommends filters with MERV ratings of 9 to 12 for residential and vehicle systems. In this solution, a MERV value of 11 is achieved by the polyurethane foam material of the filter body 42, providing optimal particulate retention while reducing the burden and resistance on the vehicle's HVAC system.
[0050] The filter 40 of this invention greatly enhances the supplier's ability to supply such air filters for a wide variety of vehicles. Suppliers no longer need to stock a large quantity and variety of these air filters in different sizes. Because this invention does not include the frame associated with existing pleated filters, it can be stored and transported in a relatively simple and efficient manner by simply compressing the filter and stacking it. When a specific size is required, the supplier simply removes these cubic components from the main body until the desired size is achieved. This invention provides ease of installation by eliminating the need for tools such as scissors, measuring tools, knives, or other cutting devices. Because the filter of this invention is compressible, small variations in size requirements and supplier-supplied sizes will not significantly affect the ability to supply filters or hinder their ability to perform their intended filtration function. The filter of this invention has a relatively long lifespan compared to prior art pleated paper filters (as shown in Figure 1). The filter of this invention is relatively inexpensive. Due to its extremely simple installation, installation-related costs can be significantly reduced.
[0051] The foregoing disclosure and description of the present invention are illustrative and interpretative. Various changes may be made to the details of the illustrated structures within the scope of the appended claims without departing from the true spirit of the invention. The invention should be limited only by the following claims and their legal equivalents.
Claims
1. A filter for an air conditioner in a vehicle, the filter comprising: The body, formed entirely of a breathable, open-cell polymer material, has a generally rectangular configuration, a top and bottom, a front and a rear, and a pair of sides. The body has multiple cutouts extending from the top to the bottom, completely through the thickness of the body. These cutouts define multiple cubic members that are brokenably joined together, such that each of the multiple cubic members can be separated by hand from the remainder of the body, and that an individual cubic member can be removed along both a portion of the length and a portion of the width of the body.
2. The filter of claim 1, wherein the plurality of cubic components are connected together by a section of breathable, open-pore polymer material.
3. The filter of claim 1, wherein the breathable open-cell polymer material is selected from the group consisting of foamed polyurethane, foamed polyether, and foamed polyester.
4. The filter as described in claim 3, wherein the breathable open-cell polymer material is open-cell foamed polyurethane.
5. The filter as claimed in claim 1, wherein the top is planar and is parallel to the bottom, the pair of side surfaces are planar and are parallel to each other, and the front portion is planar and is parallel to the rear portion.
6. The filter of claim 1, wherein each of the plurality of cubic components has a side surface area of approximately one square inch.
7. The filter of claim 1, wherein the body is flexible and compressible.
8. A filter for an air conditioner in a vehicle, the filter comprising: The body, formed entirely of a breathable material, has a generally rectangular configuration, a top and bottom, a front and a rear, and a pair of sides. The body has multiple cutouts extending from the top to the bottom, passing entirely through the thickness of the body. These cutouts define multiple cubic members that are brokenably joined together. The body has no frame around its perimeter, and there is no supporting surface on the top or bottom of the body. The multiple cutouts extend in both the length and width directions across the body, allowing individual cubic members among the multiple cubic members to be removed along both a portion of the length and a portion of the width of the body.
9. A method of installing a filter into a filter receiving container of an air conditioner in a vehicle, the method comprising: Remove the existing filter from the filter receiving container; A body is formed entirely of a breathable, open-cell polymer material, the body having multiple cubic components that are breakably connected together, the forming steps including: - A slit is cut completely through the body, such that the plurality of cubic components can be broken together, the slit extending in the length direction and the width direction across the body to form the plurality of cubic components; By hand, some of the cube components are separated from the remainder of the body until the size of the body is not smaller than the size of the existing filter, such that individual cube components among the plurality of cube components can be separated along both a portion of the length and a portion of the width of the body; and The main body, which is at least as large as the existing filter, is inserted into the filter receiving container of the air conditioner of the vehicle.
10. The method of claim 9, wherein the installation step comprises: The body, having a size not smaller than that of the existing filter, is compressed until it is assembled into the filter receiving container.
11. The method of claim 9, wherein the separation step comprises: By hand, some of the cubic components are disconnected from adjacent cubic components until the body has a size close to that of the existing filter.
12. The method of claim 9, further comprising: The main body is laid on top of the removed existing filter, and the separation step includes: - Remove some of the cube components from the plurality of cube components until the length and width of the body are close to the length and width of the existing filter that was removed.
13. The method of claim 9, wherein the main body is formed of foamed polyurethane material, foamed polyether material and foamed polyester material.
14. The method of claim 13, wherein the body is formed of an open-cell polyurethane material.
15. The method of claim 9, wherein the body has no frame surrounding it.
16. The method of claim 9, wherein the body has a thickness equal to the thickness of the existing filter being removed.
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