REUSABLE EXOSKELETON FRAME WITH U-SHAPED LOCKING MEMBERS AND ECOLOGICAL AIR FILTER ELEMENT

Abstract

A replaceable air filter element has a multi-layered filter media panel configured to be mounted on a reusable exoskeleton support frame. The exoskeleton support frame can be installed over a flow face of the filter media panel and is provided with U-shaped locking members configured to detachably engage and mount the filter media panel. The exoskeleton support frame is designed for reuse so that only the filter media panel is replaced, thereby reducing environmental waste and creating an environmentally friendly "green" air filter element.

Description

REUSABLE EXOSKELETON FRAME WITH LOCKING MEMBERS UY SHAPE ECO-FRIENDLY AIR FILTER ELEMENT bCbfrnn / rznz / E / YiAi Field of Invention The invention relates to the field of air filtration, and in particular to a replaceable filter element having a reusable exoskeleton support frame. The exoskeleton support frame is arranged on the exterior of the filter medium and includes U-shaped mounting members designed to detachably attach and support the filter medium. The filter element's exoskeleton support frame is configured for reuse, so only the filter medium needs to be replaced, thereby reducing waste and making it an environmentally friendly air filter element. Background of the Invention Air filters are commonly used to remove particles from heating, ventilation, and air conditioning (HVAC) systems in buildings. This includes systems for heating, cooling, and circulating fresh air, such as those found in office buildings, factories, retail establishments, and residential structures. An HVAC system, as used here, can have at least one or more air filters. Ref. 345211 with the following capabilities: air heating, air cooling, humidity control, and air circulation. For larger buildings, such as office buildings and retail stores, one or more HVAC systems, due to the size of the building and the size of the HVAC system, may be installed in relatively inaccessible locations, such as on the roof of the building. Indoor air, as well as outdoor air, can frequently become laden with unwanted or harmful particles, chemicals, odors, microbes, germs, or other airborne contaminants. Removing such contaminants is highly desirable. To remove particles and, preferably, other contaminants, circulated air can be passed through one or more air filter elements located in the air ducts or HVAC system. For larger structures such as factories, office buildings, and retail stores, the filter can be placed in relatively inaccessible locations, such as, for example, on the roof of a building. Prior art air filter elements available for such HVAC and air circulation systems are generally designed to be installed in the ductwork or a filter receptacle in the HVAC system. The air filter has a finite service life. The air filter is used for a finite period of time until the filter becomes clogged or dirty, at which point the filter is removed and discarded. The filter medium, which is typically a cellulose fiber or woven or non-woven material, is itself quite flexible and lacks structural rigidity. Therefore, to provide a structurally stable filter element, the filter medium is permanently enclosed in or surrounded by a support frame. The support frame typically encloses or surrounds the filter medium and is permanently secured to it.In the prior art, the filter element includes a frame that is discarded along with the filter medium whenever a new replacement filter element is installed. The discarded filter element typically ends up in a landfill or garbage dump. Additionally, prior art air filter elements each require additional materials to produce the frame, additional storage space for shipping and handling (due to the space occupied by the frame), and then generate additional waste material when the filter element is removed and replaced at the end of its life. The filter element of the prior art, for cost reasons, frequently has a cardboard or cellulose frame. Such frame members can become structurally compromised, losing rigidity, when the frame becomes damp due to humidity or the presence of water. Such frame members can collapse, and the filter element loses structural integrity and shape, preventing it from sealing in the filter receptacle or housing and allowing unfiltered air to bypass the filter element. Additionally, a damp frame can provide a medium for the growth of mold and unhealthy spores and introduce them into the circulated airflow. Summary of the Invention Therefore, there is a need for a reusable support frame and an improved green, eco-friendly air filter element designed to replace prior art air filter elements in HVAC and air circulation systems. This allows the filter media to be replaced over the existing filter frame. Such a configuration reduces waste generated by filter elements at the end of their life and provides a more environmentally friendly air filtration product that requires less material to manufacture and less storage and packaging space. According to the invention, the air filter element includes a filter media panel having a more Cdp d S air filtration laminate of bCbfrnn / rznz / E / YiAi filter media overlapped and stacked to form the multi-layer air filter media. The filter media panel includes one or more layers of stacked filter media, the filter media preferably being a synthetic polyester material. The filter media panel has a plurality of correlated locking grooves provided on the side edge surfaces.The multi-layer air filter media panel is preferably elastically compressible so that it can be compressed or deformed to be inserted under a U-shaped block member or members provided on the support frame of its exoskeleton, at least until the U-shaped block member engages in the correlated locking recesses, thereby locking the exoskeleton support frame over the air filter media panel to support the multi-layer air filter media panel. The filter media panel may be surrounded by a seal, to seal the perimeter of the filter element to a housing in which the filter element is to be installed. The filter media panel can be treated with EPA-approved treatments to control and reduce microbial growth within the filter element. The U-shaped locking members of the bCbfrnn / eznz / E / YiAi reusable exoskeleton support frame are aligned and positioned to receive and engage layers of the filter media panel via correlated locking slots. The reusable exoskeleton support frame forms a rigid outer exoskeleton support frame for the filter media panel. Preferably, one or more support ribs or wire rods are fixed onto the outer support frame and extend through an interior flow space into the interior of the exoskeleton support frame; in some cases, the support ribs or wire rods may preferably form a support network. At least one of the filtration layers of the filter media panels may include a gas-phase treatment medium that has a granular packing configured to trap and remove gas-phase contaminants, such as irritating and nuisance odors and chemical contaminants. The granular packing may include, for example, granular activated carbon, a mixture of carbon and impregnated alumina, or a mixture of zeolite, carbon, and impregnated aluminum. The granular packing is arranged between two cover sheets, preferably polyester filter media sheets. Preferably, the granular packing is adhesively bonded to at least one of the cover sheets to retain the granular packing in position on the cover sheet and maintain a uniform distribution in the gas-phase treatment medium. In some aspects of the invention, the at least one filtration layers of the filter media panel may advantageously include at least one biofunctional carrier layer. As used herein, we define the term biofunctional material to include any of: antimicrobial materials, which may include antiviral materials, antibacterial materials, and antiallergic materials, which are disposed on, arranged in, or coated on or incorporated in the at least one biofunctional carrier layer. As used herein, we define at least one biofunctional carrier layer to make one or a plurality of adjacent biofunctional carrier layers, each of which may include at least one of the biofunctional materials. Advantageously, the antimicrobial material also serves to prevent the metabolism or breakdown of the anti-allergenic material, particularly by fungi. This is especially relevant for anti-allergenic materials in the form of polyphenols. Zinc pyrithione, in particular, can be used as an antimicrobial material. Alternatively or additionally, octylisothiazolinone can be used as an antimicrobial material. The at least one biofunctional carrier layer may contain dimethyltetradecyl [3-(trimethoxysilyl)propyl ammonium chloride, also known as a quaternary ammonium compound. The at least one biofunctional carrier layer may further comprise antimicrobial or antiviral materials based on silver nanoparticles.The at least one biofunctional carrier layer may also contain antimicrobial or antiviral metals and metallic compounds, in particular silver, copper, and aluminum compounds, and / or 2-bromo-2-nitropropane-1,3-diol, additional isothiazolinone compounds, benzoic acid and its derivatives, benzalkonium halides, water-soluble coenzymes, oil-soluble coenzymes, plant extracts, antibiotics, biocidal metals, aliphatic and / or aromatic fatty acids, and / or quaternary surfactants as antimicrobial materials. The application of a biocidal substance to air filtration applications is registered in accordance with EU BPR528 / 2012 and US PR 2000-1. Polyphenols such as catechins, tannins, or flavonoids are conceivable as anti-allergenic materials. Specifically, caffeic acid, gallic acid, ellagic acid, tannic acid, cyanidin, procyanidin, proanthocyanidin, rutin, quercetin, and resveratrol may be used. Additionally, tannins or tannic acid, particularly those derived from wood (e.g., tree bark), apple extracts, or citrus fruit extracts are also conceivable. This material preferably binds to allergenic substances so that the allergenic effect can be reduced or removed from the filtered air. Allergens are denatured by polyphenols, for example. The anti-allergenic material may also include anti-allergenic enzymes. To reduce waste, the filter media panel is detachably supported on the exoskeleton support frame. The exoskeleton support frame is reusable, so when the air filter element is replaced, the filter media panel also needs to be replaced. The exoskeleton support frame is designed for reuse, and the new filter media panel is then installed and securely attached to the frame. The exoskeleton support frame is preferably made of substantially rigid wire or metal rods, preferably corrosion-treated steel, chrome-plated steel, or aluminum or galvanized steel. The exoskeleton support frame acts to retain the shape of the filter media panel in a desired form or configuration for reception and, preferably at its periphery, seals against a filter receptacle in an air duct or HVAC system. The exoskeleton support frame may have one or more support ribs or rods, preferably made of corrosion-treated steel, chrome-plated steel, aluminum, or galvanized steel, arranged to support the filter medium against forces created by airflow through it. The one or more support ribs or rods are preferably located on the clean side or outlet flow side of the filter medium. Preferably, the exoskeleton support frame material is rigid and moisture-proof, and preferably a single piece. Preferably, the support frame with one or more support ribs or rods is a single, rigid, welded construction. In several aspects of the invention, filter element replacement is achieved by replacing the used filter media panel with a new filter media panel installed on the reusable exoskeleton support frame. The exoskeleton support frame is configured and adapted for reuse, thereby reducing environmental waste and lowering filter element replacement costs. An air filter media element according to the present inventive description includes a multi-layer filter media panel comprising a plurality of overlapping and stacked air filtration laminate layers of filter media to form the multi-layer air filter media panel bcizfrnn / eznz / E / YiAi. At least some of the air filtration laminate layers may comprise a synthetic woven fabric material. The multi-layer air filter media panel has an inflow face where air to be filtered enters the multi-layer air filter media panel; and an outflow face where filtered air exits the multi-layer air filter media panel.The air filtration laminate layers of the stacked multi-layer air filter media panel are bonded to immediately adjacent sheets of the stacked multi-layer air filter media panel, which retains the air filtration laminate layers of the filter media as a multi-layer air filter media panel. The layers may be bonded together by radio frequency welding. The multi-layer air filter media panel has a plurality of outer side edge surfaces that together circumferentially surround the multi-layer air filter media panel, the plurality of outer side edge surfaces extending from the incoming flow face to the outgoing flow face. The multi-layer air filter media panel includes at least one pair of correlated locking grooves.Each groove of an individual of at least one pair of correlated blocking grooves is formed on a respective of the plurality of side edge surfaces and extends laterally from the outer side edge surface inward into the overlapping filter medium, extending completely through the multi-layer air filter medium panel from the incoming flow face to the outgoing flow face. A first correlated blocking groove of the pair of correlated blocking grooves extends on the incoming flow face and the outgoing flow face in an inward direction γ, spaced from and not reaching a second correlated blocking groove of the pair of correlated blocking grooves.The first correlated locking slot of the pair of correlated locking slots is formed on a different plurality of outer lateral edge surfaces relative to the second correlated locking slot of the pair of correlated locking slots. Each of the correlated locking slots is configured to receive and mount in a mountable manner U-shaped locking member(s) of the exoskeleton support frame. In some aspects of the invention, the multi-layer air filter media pad has outer side edge surfaces comprising a first outer side edge surface and a second outer side edge surface. The first and second outer side edge surfaces may be directly adjacent or positioned opposite each other across the multi-layer air filter media panel. In some cases, the first outer side edge surface joins the adjacent second outer side edge surface, forming a corner between them. This elastically deformable corner is advantageously shaped to compress in size to fit under and engage the legs of the U-shaped mounting member of the exoskeleton support frame. In all aspects of the invention, the multi-layer air filter media panel is preferably elastically compressible, allowing the panel to fit under a U-shaped locking member of an exoskeleton support frame and be elastically compressed to receive the legs of the U-shaped locking member in the correlated locking slots. In aspects of the invention, the exoskeleton support frame has a circumferentially enclosed outer peripheral frame that forms an outer boundary of the exoskeleton support frame and surrounds and defines an opening after internal flow of the exoskeleton support frame. The circumferentially enclosed frame is dimensioned to have outer peripheral edges or peripheral edge corners of the circumferentially enclosed frame disposed against which it supports the media panel of the bCbfrnn / eznz / E / YiAi multi-layer air filter, preferably on the outgoing flow face. In aspects of the invention, the exoskeleton support frame comprises at least one U-shaped locking member, the U-shaped locking member having two legs uniquely spaced by the mounting member, the two legs having an outer end secured to the exoskeleton support frame, the at least one U-shaped locking member projecting outward away from a plane of the exoskeleton support frame. The mounting member of the mounting member is arranged on and extends from the first correlated locking slot to the second correlated locking slot of the pair of correlated locking slots. In some aspects of the invention, the exoskeleton support frame includes one or more support ribs or support rods extending through the circumferentially enclosed frame and through the internal flow space opening of the exoskeleton support frame, opposite ends of the one or more support ribs or support rods being securely fastened to the exoskeleton support frame. The one or more support ribs or support rods may be spaced across the internal flow space opening of the exoskeleton support frame. The one or more support ribs or support rods extend across the outgoing flow space of the filter media panel, supporting the filter media panel against flow forces induced by airflow through the filter media panel. In some aspects of the invention, the exoskeleton frame is formed from wire or metal rod material that creates a structurally rigid exoskeleton support frame. Preferably, the wire or metal rod material of the exoskeleton frame is corrosion-treated steel, chrome-plated steel, aluminum, or galvanized steel. In some aspects of the invention, one or more support ribs or support rods intersect in the inner flow space opening of the exoskeleton support frame, forming a support network to support the outward flow face of the filter media panel against flow forces. In some aspects of the filter media panel, the one or more air filtration laminate layers include at least one gas-phase treatment media laminate layer having a granular fill configured to trap and remove gas-phase contaminants, chemical contaminants, and irritating and nuisance odors. This at least one gas-phase treatment media laminate layer has at least one cover sheet. Preferably, the granular fill is adhesively bonded to the at least one cover sheet to fix the granular fill in position on the cover sheet and maintain a uniform distribution within the gas-phase treatment media laminate layer. In some aspects of the invention, the granular filler is selected from a set consisting of: granular activated carbon, a mixture of carbon and impregnated alumina, or a mixture of zeolite, carbon, and impregnated alumina. In some aspects of the invention, the synthetic woven fabric material of the filtration medium laminate layers includes a synthetic polyester material. In some aspects of the invention, a radially outer circumferential portion of the filter media panel includes an elastic, compressible seal configured to form a seal between the filter media panel and a housing configured to receive the filter media panel. In preferred aspects of the invention, the filter media panel has a filtration efficiency rating of MERV 6 to MERV 13. Brief Description of the Figures The attached figures, in which similar reference numbers refer to identical or functionally similar elements across separate views and which together with the detailed description below are incorporated into and form part of the description, serve to further illustrate various embodiments and to explain various principles and advantages all in accordance with the present invention. Features of the present invention, which are believed to be novel, are set forth in the figures and more particularly in the appended claims. The invention, together with its objectives and additional advantages, can be better understood with reference to the following description, taken in conjunction with the appended figures. The figures show a currently preferred embodiment of the invention; however, the invention is not limited to the precise arrangement shown in the figures. Figure 1 illustrates a perspective view of an air filter element having an air filter panel with one or more stacked filtration layers and a locking slit cut through the peripheral edges of the air filter panel, consistent with the present inventive description; Figure 2 illustrates a schematic plan view of an exoskeleton frame having U-shaped locking members configured to mount and support the air filter panel for Figure 1, consistent with the present inventive description; Figure 2B illustrates a schematic partial perspective view of a corner region 2A of Figure 2A, showing the U-shaped locking member; Figure 3A illustrates a schematic perspective view of the air filter panel of Figure 2 mounted to the exoskeleton frame of Figure 2A by the U-shaped locking members of the exoskeleton frame, consistent with the present inventive description; Figure 3B illustrates a partial perspective view of one corner of the air filter panel of the Figure 1, consistent with the present inventive description; Figure 3C illustrates a partial perspective view of Figure 3B, wherein corners or sides of the air filter panel of Figure 3B and Figure 1 are received under and engaged in a U-shaped locking member of the exoskeleton frame, consistent with the present inventive description; Figure 4 illustrates a plan view of the incoming flow side air filter element, illustrating the air filter panel that rests against the exoskeleton frame of Figure 2A and is locked to the frame by the U-shaped locking members of the exoskeleton frame, consistent with the present inventive description; and Figure bCbfrnn / cznz / E / YiAi illustrates a perspective view of the air filter panel of Figure 1 having a U-shaped locking member of the exoskeleton frame extending through the air filter panel from a first side surface of the air filter panel to an opposite side surface of the air filter panel, consistent with the present inventive description. Those skilled in the art will appreciate that elements in the figures are illustrated for simplicity and clarity and are not necessarily drawn to scale. For example, the dimensions of some elements in the figures may be exaggerated relative to other elements to aid in understanding embodiments of the present invention. Detailed Description of the Invention Before describing in detail embodiments that conform to the present invention, it should be noted that these embodiments primarily consist of combinations of apparatus components related to a filter apparatus. Accordingly, the apparatus components have been represented where appropriate by conventional symbols in the figures, which show only those specific details pertinent to understanding the embodiments of the present invention so as not to obscure the detailed description, which will be readily apparent to those skilled in the art who benefit from the description herein. In this document, relational terms such as first and second, superior and inferior, and the like may be used only to distinguish one entity or action from another without necessarily requiring or implying any actual relationship or order between such entities or actions. The terms comprise, which includes, or any variation thereof, are intended to cover a non-exclusive inclusion, such as a process, method, article, or apparatus comprising a list of elements that does not include only those elements but may include other elements not expressly listed or inherent in such process, method, article, or apparatus. An element preceded by comprises does not, without further restriction, preclude the existence of additional identical elements in the process, method, article, or apparatus comprising the element. Figure 1 illustrates a perspective view of a replaceable air filter element 10 having an air filter panel with one or more stacked filtration layers 12 and correlated locking slits 36A, 36B cut through the peripheral edges of the air filter panel on the inside of the air filter panel 12. Figure 2A illustrates a schematic plan view of an exoskeleton frame 14 having U-shaped locking members 38 configured to mount and support the air filter panel, for example, as for Figure 1. Figure 2B illustrates a schematic partial perspective view of a corner region 2Ά of Figure 2Ά, showing the U-shaped locking member 38 projecting upwards out of a plane of the exoskeleton support frame 14. Figure 3A illustrates a schematic perspective view of the air filter panel 12 of Figure 1 mounted to the exoskeleton frame 14 of Figure 2A by the U-shaped locking members 38 of the exoskeleton frame. Figure 3B illustrates a partial perspective view of a corner of the air filter panel of Figure 1, more clearly illustrating the correlated locking slots 36A and 36B that extend completely through the air filter panel 12 from the inflow face 20 to the outflow face 22 of the air filter panel 12. Locking slots 36A, 36B extend only partially through the air filter panel 12 between the locking slots 36A, 36B. Figure 3C illustrates a partial perspective view of Figure 3B, in which corners or sides of the air filter panel 12 of Figure 3B and Figure 1 are received under and engaged in the U-shaped locking member 38 of the exoskeleton support frame 14. The air filter panel 12 is elastically compressed to allow fit under the U-shaped locking member 38. The air filter panel 12 is then elastically expanded back to its original shape so that the legs 40 of the locking member 38 engage in the corresponding locking recesses 36A and 36B, retaining or fixing the filter panel 12 onto the exoskeleton support frame 14. Figure 4 illustrates a plan view of the inflow side 20 of the air filter element 10 and filter media panel 12, showing the air filter panel 12 resting against the exoskeleton frame 14 of Figure 2A and locked to the frame by the U-shaped locking members 38 of the exoskeleton frame 14. The exoskeleton support frame 14 is shown in dashed (hidden) lines as the support frame that is on the opposite inflow face 20 of the filter media panel 12. As shown in Figure 5, and in some cases, one or more of the U-shaped blocking members 38 can be configured to extend completely through the incoming flow face 2C of the filter medium panel 12, and engage in blocking slots 36A or 36B arranged on opposite outer side surfaces 32 of the filter medium panel 12. The replaceable filter media panel 12 has one or more filter media sheets, laminates, or layers having porosities selected for particle removal. The filter media preferably includes a synthetic woven fabric. In the specific example illustrated, a plurality of correlated locking slots 36A, 36B are each formed on a different respective side surface or edge surfaces of the side sides of the air filter media panel 12, and extend inward into or partially through the incoming flow face 20 and the outgoing flow face 22 of the air filter media panel 12. The locking slots 36A and 36B are correlated to receive and mountably engage a U-shaped locking member 38 of an exoskeleton support frame 14. The filter media panel 12 can be provided with and surrounded by a compressible seal 28, to seal the outer circumference of the filter media panel 12 to a filter receptacle (not shown) of an air vent or HVAC system in which the filter element 11 is to be installed. Correlated pairs of locking slots 36A and 36B receive the legs 4 0 of the U-shaped locking members 38 of the corner portions 30 of the reusable exoskeleton support frame 14. The air filter media panel 12 is deformable or compressible to the extent that the air filter media panel 12 can be fitted into the U-shaped locking members. The legs 4 0 of the U-shaped locking member engage in the correlated locking slots 36A, 36B of the air filter media panel 12, thereby retaining the air filter media panel 12 on the exoskeleton support frame 14. The reusable exoskeleton support frame 14 forms a rigid outer frame support for the filter media panel 12, supporting the filter media panel 12 against flow-induced forces caused by airflow through the filter media panel 12. The filtration layers of the 12 filter media panel may include a gas-phase treatment medium that has a granular packing configured to trap and remove gas-phase contaminants, such as irritating and nuisance odors, and chemical contaminants, as discussed previously. To reduce waste, the filter media panel, 12 is supported on a reusable exoskeleton support frame 14, so that when the air filter media panel 12 of the air filter element 10 is replaced, only the filter media panel, 12, needs to be replaced. The exoskeleton support frame 14 frcirfrnn / eznz / E / YiAi is preferably formed of substantially rigid wire or metal rods. The exoskeleton support frame 14 acts to retain the shape of the filter media panel 12 in a desired form to be received in and sealed in a filter receptacle in an air duct or HVAC system. Preferably one or more support ribs, rods or wire rods 16 are fixed over the circumferentially closed frame that forms the outer boundary of the exoskeleton support frame 14 and extends through the inner flow space of the exoskeleton support frame 14. In the preceding description, specific embodiments of the present invention have been described. However, a person skilled in the art will appreciate that several modifications and changes can be made without departing from the scope of the present invention as set forth in the claims below. Accordingly, the description and figures are to be considered in an illustrative rather than a restrictive sense, and all such modifications are intended to be included within the scope of the present invention.The benefits, advantages, solutions to problems, and any of the element(s) that may cause any benefit, advantage, or solution to occur or become more pronounced shall not be construed as critical, required, or essential features or elements of any or all of the claims - The invention is finally defined by the appended claims including any amendments made during the pending status of this application and all equivalents of those claims as issued. It is hereby stated that, as of this date, the best method known to the applicant for putting the aforementioned invention into practice is the one that is clear from the present description of the invention.

Claims

1. An air filter element, characterized in that it comprises: a multi-layer filter media panel comprising: a plurality of air filtration laminate layers of filter media overlapping and stacked to form the multi-layer air filter media panel; wherein at least some of the air filtration laminate layers comprise a synthetic woven fabric material; wherein the multi-layer air filter media panel has: an inflow face in which air to be filtered enters the multi-layer air filter media panel; and an outflow face in which filtered air exits the multi-layer air filter media panel;wherein layers of air filtration laminate of the multi-layer air filter media panel are fixed to immediately adjacent sheets of stacked multi-layer filter media panel, retaining the air filtration laminate layers of the filter media together as a unitary multi-layer filter media panel; wherein the multi-layer air filter media panel has a plurality of outer side edge surfaces that together circumferentially surround the multi-layer air filter media panel, the plurality of outer side edge surfaces extending from the incoming flow face to the outgoing flow face;at least one pair of correlated locking slots, each locking slot of an individual of the at least one pair of correlated locking slots formed on a respective of the plurality of outer lateral edge surfaces and extending laterally from the outer lateral edge surface inward into the overlaid filter medium, the slots of the at least one pair of correlated locking slots extending across the multi-layer air filter medium panel from the incoming flow face to the outgoing flow face; wherein the first correlated locking slot of the pair of correlated locking slots extends over the incoming flow face and the outgoing flow face in an inwardly spaced direction and does not reach a second correlated locking slot of the pair of correlated locking slots;wherein the first correlated locking groove of the pair of correlated locking grooves is formed on a different plurality of outer lateral edge surfaces relative to the second correlated locking groove of the pair of correlated locking grooves; wherein each of the correlated locking grooves is configured to receive and mountably engage a U-shaped locking member of an exoskeleton support frame for interchangeably mounting the multi-layer air filter media panel onto the exoskeleton support frame.

2. The air filter element according to claim 1, characterized in that the multi-layer air filter media pad of outer side edge surfaces has: a first outer side edge surface, the multi-layer air filter media panel of outer side edge surfaces; an adjacent second outer side edge surface, the multi-layer air filter media panel of outer side edge surfaces; wherein the first outer side edge surface joins the adjacent second outer side edge surface forming a corner between them; wherein the first correlated locking notch of the pair of correlated locking notches is disposed in the first outer side edge surface;wherein the second correlated locking groove of the pair of correlated locking grooves is disposed on the second adjacent outer lateral edge surface.; 3. The air filter element according to claim 1, characterized in that the multi-layer air filter media panel can be elastically compressed to fit under the U-shaped locking member on the exoskeleton support frame to interchangeably mount the multi-layer air filter media panel on the exoskeleton support frame.

4. The air filter element according to claim 3, characterized in that it further comprises: the exoskeleton support frame, comprising: a circumferentially closed frame forming an outer boundary of the exoskeleton support frame that surrounds an inner flow space opening of the exoskeleton support frame, the circumferentially closed frame dimensioned to have peripheral edges or peripheral edge corners of the circumferentially closed frame disposed against and supporting the multi-layer air filter media panel; at least one U-shaped locking member, the U-shaped locking member having two legs uniquely spaced by the mounting member, the two legs having an outer end clamped onto the exoskeleton support frame, the at least one U-shaped locking member projecting outwards away from a plane to the exoskeleton support frame;and wherein the mounting member of the mounting member is disposed over and extends at least partially through the multi-layer air filter media panel from the first correlated locking slot to the second correlated locking slot of the pair of correlated locking slots.; 5. The air filter element according to claim 4, characterized in that the exoskeleton frame includes: one or more support ribs or support rods extending through the circumferentially closed frame and through the flow space opening of the exoskeleton support frame, opposite ends of the one or more support ribs or support rods being fixedly secured to the exoskeleton support frame, wherein the one or more support ribs or support rods are spaced through flow space openings of the exoskeleton support frame; wherein the one or more support ribs or support rods extend through the projecting flow face of the filter media panel, supporting the filter media panel against flow forces induced by airflow through the filter media panel.

6. The air filter element according to claim 5, characterized in that the exoskeleton frame is formed from wire or metal rod material that forms a structurally rigid exoskeleton support frame. 7.- The air filter element according to claim 6, characterized in that the wire or metal rod material of the exoskeleton frame is corrosion-treated steel, chrome-plated steel, or aluminum.

8. - The air filter element according to claim 5, characterized in that one or more support ribs or support rods intersect in the inner flow space opening of the exoskeleton support frame, forming a support network.

9. The air filter element according to claim 1, characterized in that the one or more air filtration laminate layers of the filter media panel include at least one gas-phase treatment media laminate layer having a granular filler configured to trap and remove gas-phase contaminants, chemical contaminants, and irritating and nuisance odors, the at least one gas-phase treatment media laminate layer having at least one cover sheet; wherein the granular filler is adhesively bonded to the at least one cover sheet to fix the granular filler in position on the at least one cover sheet and maintain a uniform distribution in the gas-phase treatment media laminate layer.

10. The air filter element according to claim 9, characterized in that the granular packing is selected from the assembly consisting of: granular activated carbon, a mixture of carbon and impregnated alumina, or a mixture of zeolite, carbon, and impregnated alumina. bCbfrnn / eznz / E / YiAi 11. The air filter element according to claim 1, characterized in that the multi-layer air filter medium panel further comprises: at least one biofunctional carrier layer comprising biofunctional material; wherein the biofunctional material includes at least one of: antiviral materials, antibacterial materials, and anti-allergenic materials, the biofunctional material disposed on, arranged in, or coated on or incorporated in the at least one biofunctional barrier layer.

12. The air filter element according to claim 1, characterized in that the synthetic woven fabric material comprises a synthetic polyester material.

13. The air filter element according to claim 1, characterized in that a radially outer portion of the filter medium panel is elastic and compressible and configured to form a seal between the filter medium panel and a housing configured to receive the filter medium panel. 14.- The air filter element according to claim 1, characterized in that the filter medium panel has a filtration efficiency rating of MERV 6 to MERV 13.

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