Apparatus for monitoring performance of air filter and air filter assembly

Abstract

The present disclosure provides an apparatus for monitoring a performance of an air filter. The air filter includes a perimeter frame and a filter media. The filter media is configured to be disposed in an airflow such that at least a portion of the airflow passes through the filter media. The apparatus is configured to be coupled to the perimeter frame or the filter media. The apparatus includes a sensor board extending between a first board end and a second board end and at least one flap configured to receive the airflow from the filter media. The at least one flap is coupled to the sensor board. The at least one flap is movable relative to the sensor board between, at least one initial position in absence of the airflow and at least one indicating position in presence of the airflow.

Description

TECHNICAL FIELD

[0001] The present disclosure relates generally to an air filter assembly, and more particularly, to an apparatus for monitoring a performance of an air filter.BACKGROUND

[0002] Heating, ventilation, and / or air conditioning (HVAC) systems are commonly used to regulate comfort level within buildings or other structures. These HVAC systems require air filters having a filter media to remove dust, dirt, contaminants, and other undesired particles that can adversely affect air quality. Conventional air filters designed to filter air flowing through the HVAC system are well known in the art. Such air filters are most effective when they are clean and correctly positioned within the ducts. As the filter media captures particles and becomes clogged, the air flow is correspondingly reduced, requiring increased energy to maintain designed operating parameters. Moreover, prolonged operation of the air filter in a clogged condition of the filter unit may lead to a low air-filtering efficiency and is detrimental to the HVAC system.

[0003] To this end, a timely cleaning or replacement of the air filters is required and failure to clean or replace the air filter imposes high risk in the HVAC system. Typically, a calendar-based maintenance schedule is recommended for timely cleaning and replacement of the air filters. However, pollutants levels vary based on local environmental conditions and do not follow a consistent pattern. As a result, the time-based replacement of the air filters may lead to premature disposal of effective filters or reduced performance from clogged filters.

[0004] Therefore, there is a need for an apparatus that monitors a real-time monitoring of a performance of an air filter to ensure efficient and reliable operation of HVAC system.SUMMARY

[0005] In a first aspect, the present disclosure provides an apparatus for monitoring a performance of an air filter. The air filter includes a perimeter frame and a filter media placed within the perimeter frame. The filter media is configured to be disposed in an airflow such that at least a portion of the airflow passes through the filter media. The filter media includes an upstream side and a downstream side. The apparatus is configured to be coupled to the perimeter frame or the filter media. The apparatus includes a sensor board extending between a first board end and a second board end. The apparatus further includes at least one flap configured to receive the airflow associated with the filter media and extending between a first flap end and a second flap end. The at least one flap is coupled to the sensor board. The first flap end is coupled to the sensor board and the second flap end is a free end. The at least one flap is movable relative to the sensor board, between at least one initial position in the absence of the airflow through the apparatus, and at least one indicating position in the presence of the airflow through the apparatus. The apparatus further includes at least one sensor disposed on the sensor board and configured to detect the movement of the at least one flap relative to the sensor board. Furthermore, the apparatus includes a processor configured to receive and process data relating to the movement of the at least one flap relative to the sensor board.

[0006] In a second aspect, the present disclosure provides an air filter assembly. The air filter assembly includes an air filter including a perimeter frame and a filter media placed within the perimeter frame. The filter media is configured to be disposed in an airflow such that at least a portion of the airflow passes through the filter media. The filter media includes an upstream side and a downstream side. The air filter assembly further includes the apparatus of the first aspect for monitoring a performance of the air filter. The apparatus is configured to be coupled to the perimeter frame or the filter media.

[0007] The details of one or more examples of the disclosure are set forth in the accompanying drawings and the description below. Other features, objects, and advantages of the disclosure will be apparent from the description and drawings, and from the claims.BRIEF DESCRIPTION OF THE DRAWINGS

[0008] Exemplary embodiments disclosed herein may be more completely understood in consideration of the following detailed description in connection with the following figures. The figures are not necessarily drawn to scale. Like numbers used in the figures refer to like components. However, it will be understood that the use of a number to refer to a component in a given figure is not intended to limit the component in another figure labeled with the same number.

[0009] FIG. 1 is a perspective view of an air filter assembly including an air filter and an apparatus for monitoring a performance of the air filter, according to an embodiment of the present disclosure;

[0010] FIG. 2 is a perspective view of the apparatus of FIG. 1;

[0011] FIG. 3 is a perspective view of an air filter assembly, according to another embodiment of the present disclosure;

[0012] FIG. 4 is a side view of the air filter assembly of FIG. 3;

[0013] FIG. 5 is a perspective view of an air filter assembly, according to yet another embodiment of the present disclosure;

[0014] FIG. 6 is a perspective view of an apparatus of the air filter assembly of FIG. 3 for monitoring a performance of the air filter, with some components not shown, according to an embodiment of the present disclosure;

[0015] FIG. 7A is a side view of the apparatus of FIG. 6, with some components not shown, wherein at least one flap is shown in at least one initial position, according to an embodiment of the present disclosure;

[0016] FIG. 7B is a side view of the apparatus of FIG. 6, with some components not shown, wherein the at least one flap is shown in at least one indicating position;

[0017] FIGS. 8A and 8B are side views of an apparatus for monitoring a performance of the air filter, with some components not shown, according to yet another embodiment of the present disclosure;

[0018] FIG. 9A is a side view of an apparatus for monitoring a performance of the air filter, with some components not shown, wherein at least one flap is shown in at least one initial position, according to yet another embodiment of the present disclosure;

[0019] FIG. 9B is a side view of the apparatus of FIG. 9A wherein the at least one flap is shown in at least one indicating position;

[0020] FIGS. 10A and 10B are side views of an apparatus for monitoring a performance of the air filter, with some components not shown, according to yet another embodiment of the present disclosure;

[0021] FIG. 11 is a perspective view of an apparatus for monitoring a performance of the air filter, with some components not shown, according to yet another embodiment of the present disclosure;

[0022] FIG. 12 is a perspective view of an apparatus for monitoring a performance of the air filter, with some components not shown, according to yet another embodiment of the present disclosure;

[0023] FIGS. 13A, 13B, and 13C are side views of an apparatus for monitoring a performance of the air filter, with some components not shown, according to yet another embodiment of the present disclosure;

[0024] FIGS. 14A and 14B are side views of an apparatus for monitoring a performance of the air filter, with some components not shown, according to yet another embodiment of the present disclosure;

[0025] FIGS. 15A and 15B are side views of an apparatus for monitoring a performance of the air filter, with some components not shown, according to yet another embodiment of the present disclosure; and

[0026] FIGS. 16A and 16B are side views of an apparatus for monitoring a performance of the air filter, with some components not shown, according to yet another embodiment of the present disclosure.DETAILED DESCRIPTION

[0027] In the following description, reference is made to the accompanying figures that form a part thereof and in which various embodiments are shown by way of illustration. It is to be understood that other embodiments are contemplated and may be made without departing from the scope or spirit of the present disclosure. The following detailed description, therefore, is not to be taken in a limiting sense.

[0028] In the following disclosure, the following definitions are adopted.

[0029] As used herein, all numbers should be considered modified by the term “about”. As used herein, “a,”“an,”“the,”“at least one,” and “one or more” are used interchangeably.

[0030] The term “about”, unless otherwise specifically defined, means to a high degree of approximation (e.g., within + / −5% for quantifiable properties) but again without requiring absolute precision or a perfect match.

[0031] As used herein as a modifier to a property or attribute, the term “generally”, unless otherwise specifically defined, means that the property or attribute would be readily recognizable by a person of ordinary skill but without requiring absolute precision or a perfect match (e.g., within + / −20% for quantifiable properties).

[0032] As used herein, “at least one of A and B” should be understood to mean “only A, only B, or both A and B”.

[0033] As used herein, the statement that two or more parts or components are “coupled” shall mean that the parts are joined or operate together either directly or indirectly, i.e., through one or more intermediate parts or components, so long as a link occurs. As used herein, “directly coupled” means that two elements are directly in contact with each other. As used herein, “fixedly coupled” or “fixed” means that two components are coupled so as to move as one while maintaining a constant orientation relative to each other.

[0034] As used herein, the phrase “removably coupled” or “temporarily coupled” means that one component is coupled with another component in an essentially temporary manner. That is, the two components are coupled in such a way that the joining or separation of the components is easy and would not damage the components. For example, two components secured to each other with a limited number of readily accessible fasteners, i.e., fasteners that are not difficult to access, are “removably coupled” whereas two components that are welded together or joined by difficult to access fasteners are not “removably coupled”. A “difficult to access fastener” is one that requires the removal of one or more other components prior to accessing the fastener wherein the “other component” is not an access device such as, but not limited to, a door.

[0035] As used herein, “substantially” means “for the most part” relevant to the term being modified as would be understood by one of ordinary skill in the art.

[0036] As used herein, “corresponding” indicates that two structural components are sized and shaped similar to each other and can be coupled with a minimum amount of friction. Thus, an opening “corresponding” to a member is sized slightly larger than the member so that the member can pass through the opening with a minimum amount of friction. This definition is changed when the two components are said to “snugly” fit together or “just correspond”. In that situation, the difference between the sizes of those components is even smaller, thereby increasing the amount of friction.

[0037] The present disclosure provides an apparatus for monitoring a performance of an air filter. The air filter includes a perimeter frame and a filter media placed within the perimeter frame. The filter media is configured to be disposed in an airflow such that at least a portion of the airflow passes through the filter media. The filter media includes an upstream side and a downstream side. The apparatus is configured to be coupled to the perimeter frame or the filter media. The apparatus includes a sensor board extending between a first board end and a second board end. The apparatus further includes at least one flap configured to receive the airflow associated with the filter media and extending between a first flap end and a second flap end. The at least one flap is coupled to the sensor board. The first flap end is coupled to the sensor board and the second flap end is a free end. The at least one flap is movable relative to the sensor board, between at least one initial position in the absence of the airflow through the apparatus, and at least one indicating position in the presence of the airflow through the apparatus. The apparatus further includes at least one sensor disposed on the sensor board and configured to detect the movement of the at least one flap relative to the sensor board. Furthermore, the apparatus includes a processor configured to receive and process data relating to the movement of the at least one flap relative to the sensor board.

[0038] The apparatus of the present disclosure may be used with any suitable powered air-handling system. In some embodiments, such an air-handling system may be a heating-ventilation-air-conditioning (HVAC) system e.g., for a residence (e.g. a single-family home), a commercial or retail building or space, or a manufacturing unit, or an industry, and so on. The term HVAC is used broadly, in various embodiments, an HVAC system may be configured to perform heating, to perform cooling, or to perform either heating or cooling, as desired. In some embodiments, such an HVAC system may be a centralized air-handling system in which air to be handled is collected via multiple air-return inlets (e.g., located in multiple rooms of a building).

[0039] The at least one flap is movable relative to the sensor board due to the presence and absence of the airflow through the apparatus. Based upon an amount of airflow passing through the filter media, the at least one flap moves between the at least one initial position and the at least one indicating position. This movement is detected or measured by the at least one sensor and the data related to such movement is received by the processor. The processor receives such data and may perform necessary calculations in order to determine a loading condition of the filter media. Therefore, the apparatus may provide continuous and real-time monitoring of the loading condition or, in other words, performance of the air filter. This allows timely maintenance and replacement of the air filter based on actual and real-time loading condition of the filter media rather than predetermined schedules. This may further ensure optimal airflow and improved efficiency of the air-handling system.

[0040] Moreover, continuous and real-time monitoring of the air filter may also prevent premature disposal of an effective air filter. This may lead to reduced operational costs. Additionally, timely maintenance and replacement of the air filter may ensure improved air quality and may also prevent risk of overheating and potential system failure.

[0041] Referring now to Figures, FIG. 1 illustrates a perspective view of an air filter assembly 50, according to an embodiment of the present disclosure. The air filter assembly 50 may be provided in a suitable powered air-handling system, such as a heating-ventilation-air-conditioning (HVAC) system for a residence (e.g. a single-family home), a commercial or retail building or space, or a manufacturing unit, or an industry, and so on.

[0042] The air filter assembly 50 includes an air filter 60. In some embodiments, the air filter 60 may be a disposable air filter. The air filter 60 may generally have a rectangular shape or square shape. The air filter 60 includes a perimeter frame 70 and a filter media 80 placed within the perimeter frame 70. The perimeter frame 70 may include sidewalls 72 and may be made of any suitable material(s), e.g., paperboard or cardboard that may be folded to provide the various sidewalls 72. In some embodiments, the perimeter frame 70 may be made of an injection molded plastic material. In some embodiments, the perimeter frame 70 includes support members (not shown) that extend at least partially across the filter media 80 in order to provide additional support.

[0043] Further, the filter media 80 is configured to be disposed in an airflow AF such that at least a portion of the airflow AF passes through the filter media 80. In the illustrated embodiment of FIG. 1, the filter media 80 is shown as pleated so as to exhibit readily identifiable pleats. In other embodiments, the filter media 80 may be unpleated. The filter media 80 includes an upstream side 82 and a downstream side 84. The filter media 80 is made of any material that is capable of filtering moving air. Accordingly, air passes from the upstream side 82 through the filter media 80 to the downstream side 84.

[0044] The air filter assembly 50 further includes an apparatus 100 for monitoring a performance of the air filter 60. The apparatus 100 is configured to be coupled to the perimeter frame 70 or the filter media 80. In some embodiments, the apparatus 100 is disposed at the downstream side 84 of the filter media 80. In some embodiments, the apparatus 100 may be coupled to the support member (not shown) of the perimeter frame 70. In other embodiments, the apparatus 100 may be coupled to the sidewalls 72 of the perimeter frame 70. It should be noted in the figures, various components of the air filter assembly 50 and the apparatus 100 will be shown schematically.

[0045] FIG. 2 illustrates a perspective view of the apparatus 100, according to an embodiment of the present disclosure. Referring to FIGS. 1 and 2, the apparatus 100 includes a sensor board 102 extending between a first board end 106 and a second board end 108. The apparatus 100 further includes at least one flap 110 configured to receive the airflow AF associated with the filter media 80 and extending between a first flap end 112 and a second flap end 114. In some embodiments, where the apparatus 100 is disposed at the downstream side 84 of the filter media 80, the at least one flap 110 is configured to receive the airflow AF from the filter media 80. In the illustrated embodiment of FIGS. 1 and 2, the at least one flap 110 includes a single flap 110. However, the number of flaps in the apparatus 100 may vary based upon application requirements.

[0046] The at least one flap 110 is coupled to the sensor board 102. As shown, the first flap end 112 is coupled to the sensor board 102 and the second flap end 114 is a free end. In some embodiments, the first flap end 112 is coupled to the sensor board 102 proximate to the first board end 106. The at least one flap 110 is movable relative to the sensor board 102. In some embodiments, the at least one flap 110 is pivotally coupled to the sensor board 102, such that in response to the airflow AF through the apparatus 100, the at least one flap 110 is pivotally movable between two or more positions (described later in description). In some embodiments, in response to the airflow AF through the apparatus 100, the at least one flap 110 flexes or bends between two or more positions relative to the sensor board 102.

[0047] The apparatus 100 further includes at least one sensor 118 disposed on the sensor board 102 and configured to detect the movement of the at least one flap 110 relative to the sensor board 102. In some embodiments, the at least one sensor 118 is a capacitive sensor. The at least one sensor 118 is configured to detect a change in capacitance of the at least one flap 110 due to the movement of the at least one flap 110 between two or more positions relative to the sensor board 102. As shown in FIGS. 1 and 2, the at least one sensor 118 includes a single sensor 118.

[0048] The apparatus 100 further includes a processor 120 configured to receive and process data relating to the movement of the at least one flap 110 relative to the sensor board 102. The processor 120 is communicably coupled to the at least one sensor 118. Upon processing of the data received from the at least one sensor 118, the processor 120 may provide an output 124 indicative of a loading condition of the filter media 80. In some embodiments, the apparatus 100 further includes an output unit 122 communicably coupled to the processor 120 and configured to provide the output 124 indicative of the loading condition of the filter media 80. The processor 120 may be a programmable analog and / or digital device that can store, retrieve, and process data. In an application, the processor 120 may be a controller, a control circuit, a computer, a workstation, a microprocessor, a microcomputer, a central processing unit, a server, or any suitable device or apparatus.

[0049] To facilitate the communication between the processor 120 and the at least one sensor 118, the apparatus 100 further includes a communication module 136 configured to transmit the data wirelessly or through a wired connection from the at least one sensor 118 to the processor 120. In some embodiments, the communication module 136 includes a radio unit. In some embodiments, the apparatus 100 further includes a power source 138 configured to power the at least one sensor 118. In some embodiments, the power source 138 may include one or more batteries.

[0050] FIG. 3 illustrates a perspective view of an air filter assembly 50′, according to another embodiment of the present disclosure. FIG. 4 illustrates a side view of the air filter assembly 50′. Referring to FIGS. 1 to 4, the air filter assembly 50′ is substantially similar to the air filter assembly 50 of FIG. 1, with common components being referred to by the same reference numerals. However, the air filter assembly 50′ includes an apparatus 100′ (instead of the apparatus 100 shown in FIGS. 1 and 2).

[0051] The apparatus 100′ further includes a sensor housing 130 configured to be removably coupled to the perimeter frame 70 or the filter media 80 and disposed at the downstream side 84 of the filter media 80. The sensor housing 130 encloses the sensor board 102, the at least one flap 110, and the at least one sensor 118. In some embodiments, the sensor housing 130 has a triangular cross section or a polygonal cross section. As shown in FIG. 4, the sensor housing 130 has the triangular cross section. Also, as illustrated in FIGS. 3 and 4, the processor 120 is located or arranged remotely from the sensor housing 130.

[0052] Furthermore, the sensor housing 130 includes at least one entry opening 132 and at least one exit opening 134. At least a portion of the airflow AF passing through the filter media 80 enters into the sensor housing 130 via the at least one entry opening 132 and exits from the sensor housing 130 via the at least one exit opening 134. Specifically, each of the sensor board 102 and the at least one flap 110 is disposed in the sensor housing 130 between the at least one entry opening 132 and the at least one exit opening 134.

[0053] In some embodiments, the at least one entry opening 132 includes a single entry opening 132 and the at least one exit opening 134 includes a single exit opening 134. In another embodiment, the at least one entry opening 132 includes two or more entry openings 132 (not shown) and the at least one exit opening 134 includes two or more exit openings 134 (not shown). In the illustrated embodiment of FIG. 4, a size of the at least one entry opening 132 is equal to a size of the at least one exit opening 134. However, in other embodiments, the size of the of the at least one entry opening 132 and the size of the at least one exit opening 134 may be different from each other.

[0054] In the illustrated embodiment of FIG. 3, the at least one entry opening 132 and the at least one exit opening 134 have similar shapes. However, in other embodiments, the at least one entry opening 132 and the at least one exit opening 134 have different shapes. In some embodiments, the at least one entry opening 132 is a U-shaped opening, a circular opening, a polygonal opening, an elliptical opening, an oval opening, a T-shaped opening, or a water drop shaped opening. In the illustrated embodiment of FIG. 3, the at least one entry opening 132 is a circular opening. In some embodiments, the at least one exit opening 134 is a U-shaped opening, a circular opening, a polygonal opening, an elliptical opening, an oval opening, a T-shaped opening, or a water drop shaped opening. In the illustrated embodiment of FIG. 3, the at least one exit opening 134 is a circular opening.

[0055] In some embodiments, the sensor board 102 defines an aperture 140 (shown in FIG. 3) therethrough such that at least a portion of the airflow AF entering the sensor housing 130 via the at least one entry opening 132 passes through the aperture 140 and exits the sensor housing 130 via the at least one exit opening 134. In such case, when there is airflow AF through the sensor housing 130, a portion of the airflow AF passes through the aperture 140 and impinges on the at least one flap 110 to move the at least one flap 110 between two or more positions (described later in description) relative to the sensor board 102.

[0056] Moreover, the aperture 140 may also have similar shape as that of the at least one entry opening 132 and the at least one exit opening 134. However, the aperture 140 may also have a different shape than that of the at least one entry opening 132 and the at least one exit opening 134. In some embodiments, the aperture 140 of the sensor board 102 is a U-shaped aperture, a circular aperture, a polygonal aperture, an elliptical aperture, an oval aperture, a T-shaped aperture, or a water drop shaped aperture. In the illustrated embodiment of FIG. 3, the aperture 140 is a circular aperture.

[0057] FIG. 5 is a perspective view of an air filter assembly 50″, according to another embodiment of the present disclosure. The air filter assembly 50″ is substantially similar to the air filter assembly 50′ of FIGS. 3 and 4, with common components being referred to by the same reference numerals. However, the air filter assembly 50″ includes an apparatus 100″ (instead of the apparatus 100, shown in FIGS. 3 and 4). The apparatus 100″ is substantially similar to the apparatus 100′ shown in FIG. 3, with common components being referred to by the same numerals.

[0058] However, in the apparatus 100″, the sensor board 102 includes two sensors 118. In other words, in the apparatus 100″, the at least one sensor 118 includes two sensors 118 (instead of only a single sensor 118) in total. In other embodiments, the at least one sensor 118 may include three or more sensors 118 in total, or the sensor board 102 may include three or more sensors 118 in total. Additionally, in the apparatus 100″, the processor 120 is located onboard the sensor housing 130. In such a case, the processor 120 may be connected to the at least one sensor 118 by the wired connection.

[0059] FIG. 6 is a perspective view of the apparatus 100′ (also shown in FIGS. 3 and 4). FIG. 7A is a side view of the apparatus 100′, wherein the at least one flap 110 is shown in an at least one initial position P1, according to an embodiment of the present disclosure. FIG. 7B is another perspective side view of the apparatus 100′, wherein the at least one flap 110 is shown in an at least one indicating position P2, according to an embodiment of the present disclosure. Some components, such as the processor 120, are not shown in FIGS. 6 to 7B for illustrative purposes. In the illustrated embodiment of FIGS. 7A and 7B, the at least one flap 110 has a linear profile. However, in other embodiments, the at least one flap 110 may have a non-linear profile or curved profile. Further, in some embodiments, the at least one flap 110 has a uniform thickness. In some embodiments, the at least one flap 110 has a variable thickness.

[0060] Referring to FIGS. 3, 4, 6 to 7B, the at least one flap 110 is movable relative to the sensor board 102, between the at least one initial position P1 in the absence of the airflow AF through the apparatus 100′, and at least one indicating position P2 in the presence of the airflow AF through the apparatus 100. It should be noted that the sensor board 102 may be disposed upstream of the at least one flap 110 or downstream of the at least one flap 110 depending on application requirements. Further, the sensor board 102 and the at least one flap 110 may be disposed in line with the direction of the airflow AF.

[0061] In the illustrated embodiment of FIGS. 7A and 7B, the sensor board 102 is disposed downstream of the at least one flap 110. As illustrated in FIG. 7A, in the absence of the airflow AF through the apparatus 100′, the sensor board 102 and the at least one flap 110 are inclined to each other, such that the at least one flap 110 is in the at least one initial position P1. When the at least one flap 110 is in the at least one initial position P1, the sensor board 102 and the at least one flap 110 may be inclined to each other at an angle ranging from about 20 degrees to about 90 degrees.

[0062] As illustrated in FIG. 7B, in the presence of the airflow AF through the apparatus 100′, the at least one flap 110 moves from the at least one initial position P1 to the at least one indicating position P2 in a direction at least generally aligned with the direction of the airflow AF through the apparatus 100′, such that the second flap end 114 moves towards the sensor board 102. In the at least one indicating position P2 of the at least one flap 110, the at least one flap 110 and the sensor board 102 are arranged substantially parallel and adjacent to each other. Although, in FIG. 7B, the at least one flap 110 is shown to be arranged parallel and adjacent to the sensor board 102, however, it should be noted that, in the at least one indicating position P2, the at least one flap 110 may be inclined to the sensor board 102 at a small angle (ranging from about 5 degrees to about 10 degrees).

[0063] It can be stated that in response to the airflow AF through the apparatus 100′, the at least one flap 110 is pivotally movable between the at least one initial position P1 and the at least one indicating position P2 relative to the sensor board 102. In some embodiments, in response to the airflow AF through the apparatus 100′, the at least one flap 110 flexes or bends between the at least one initial position P1 and the at least one indicating position P2 relative to the sensor board 102. It may be appreciated that in such case, the at least one flap 110 may have a variable thickness to facilitate easy flexing of the at least one flap 110. However, in some cases, the at least one flap 110 having constant thickness along its length may also flex or bend between the at least one initial position P1 and the at least one indicating position P2 relative to the sensor board 102.

[0064] The at least one sensor 118 is configured to detect the change in capacitance of the at least one flap 110 due to the movement of the at least one flap 110 between the at least one initial position P1 and the at least one indicating position P2 relative to the sensor board 102. The at least one sensor 118 detects the movement of the at least one flap 110 between the at least one initial position P1 and the at least one indicating position P2 and collects data related to such movement of the at least one flap 110 relative to the sensor board 102.

[0065] When the at least one sensor 118 detects the movement of the at least one flap 110 from the at least one initial position P1 to the at least one indicating position P2 relative to the sensor board 102, the processor 120 (shown in FIG. 3) processes data relating to such movement, and the output unit 122 (shown in FIG. 3) provides the output 124 indicative of a clear state of the filter media 80. When the at least one sensor 118 detects the movement of the at least one flap 110 from the at least one indicating position P2 to the at least one initial position P1 relative to the sensor board 102, the processor 120 processes data relating to such movement, and the output unit 122 provides the output 124 indicative of a clogged state of the filter media 80.

[0066] Therefore, the apparatus 100′ determines the loading condition of the filter media 80 based on the movement of the at least one flap 110 between two or more positions (i.e., the at least one initial position P1 and the at least one indicating position P2) relative to the sensor board 102. The apparatus 100′ may provide continuous and real-time monitoring of the loading condition or, in other words, performance of the air filter 60. This allows timely maintenance and replacement of the air filter 60 based on actual and real-time loading condition of the filter media 80 rather than predetermined schedules. This may ensure optimal airflow and improved efficiency of an air-handling system, such as a Heating, ventilation, and / or air conditioning (HVAC) system.

[0067] Moreover, continuous and real-time monitoring of the air filter 60 may also prevent premature disposal of the effective air filter. This may lead to reduced operational costs. Additionally, timely maintenance and replacement of the air filter 60 may ensure improved air quality and may also prevent risk of overheating and potential system failure.

[0068] With continued reference to FIGS. 7A and 7B, in the at least one indicating position P2 of the at least one flap 110, the second flap end 114 is proximal to the at least one entry opening 132 and distal to the at least one exit opening 134. In some embodiments, the first board end 106 is proximal to and the second board end 108 is distal to the at least one entry opening 132.

[0069] FIG. 8A is a side view of an apparatus 100′″, with some components not shown, according to another embodiment of the present disclosure. The apparatus 100′″ is substantially similar to the apparatus 100′ of FIGS. 7A and 7B, with common components being referred to by the same numerals. In FIG. 8A, the at least one flap 110 is shown in the at least one initial position P1.

[0070] However, in the apparatus 100′″, the size of the at least one entry opening 132 is different than the size of the at least one exit opening 134. Specifically, the size of the at least one entry opening 132 is greater than the size of the at least one exit opening 134. Additionally, in the apparatus 100′″, the sensor housing 130 has a polygonal cross section. In the illustrated embodiment of FIG. 8A, the second board end 108 is proximal to and the first board end 106 is distal to the at least one exit opening 134.

[0071] FIG. 8B is another side view of the apparatus 100′″, wherein the coupling point of the sensor board 102 and the at least one flap 110 is different than that of the apparatus 100′″ shown in FIG. 8A. In FIG. 8B, the at least one flap 110 is shown in the at least one initial position P1. In the at least one initial position of the at least one flap 110, the second flap end 114 is proximal to the at least one exit opening 134 and distal to the at least one entry opening 132.

[0072] FIG. 9A is a side view of an apparatus 200, with some components not shown, according to another embodiment of the present disclosure. The apparatus 200 is substantially similar to the apparatus 100′ of FIG. 7A, with common components being referred to by the same numerals. However, in the apparatus 200, the sensor board 102 is disposed upstream (instead of downstream) of the at least one flap 110. In FIG. 9A, the at least one flap 110 is shown in the at least one initial position P1. FIG. 9B is another side view of the apparatus 200, wherein the at least one flap 110 is shown in the at least one indicating position P2.

[0073] As illustrated in FIG. 9A, in the absence of the airflow AF through the apparatus 200, the sensor board 102 and the at least one flap 110 are arranged substantially parallel and adjacent to each other, such that the at least one flap 110 is in the at least one initial position P1. Although, in FIG. 9A, the at least one flap 110 is shown to be arranged parallel and adjacent to the sensor board 102, however, it should be noted that, in the at least one initial position P1, the at least one flap 110 may be inclined to the sensor board 102 at a small angle (ranging from about 5 degrees to about 10 degrees).

[0074] As illustrated in FIG. 9B, in the presence of the airflow AF through the apparatus 200, the at least one flap 110 moves from the at least one initial position P1 to the at least one indicating position P2 in a direction at least generally aligned with the direction of the airflow AF through the apparatus 100′, such that the second flap end 114 moves away from the sensor board 102. In the at least one indicating position P2 of the at least one flap 110, the at least one flap 110 and the sensor board 102 are inclined to each other. When the at least one flap 110 is in the at least one indicating position P2, the sensor board 102 and the at least one flap 110 may be inclined to each other at an angle ranging from about 20 degrees to about 90 degrees. Moreover, as shown, in the at least one indicating position P2 of the at least one flap 110, the second flap end 114 is proximal to the at least one exit opening 134 and distal to the at least one entry opening 132.

[0075] Referring to FIGS. 3, 9A, and 9B, when there is airflow AF through the sensor housing 130, a portion of the airflow AF passes through the aperture 140 and impinges on the at least one flap 110 to move the at least one flap 110 from the at least one initial position P1 to the at least one indicating position P2 relative to the sensor board 102.

[0076] FIG. 10A is a side view of an apparatus 200′, with some components not shown, according to another embodiment of the present disclosure. The apparatus 200′ is substantially similar to the apparatus 200 of FIGS. 9A and 9B, with common components being referred to by the same numerals. In FIG. 10A, the at least one flap 110 is shown in the at least one indicating position P2.

[0077] However, in the apparatus 200′, the size of the at least one entry opening 132 is different than the size of the at least one exit opening 134. Specifically, the size of the at least one entry opening 132 is greater than the size of the at least one exit opening 134. Additionally, in the apparatus 200′, the sensor housing 130 has a polygonal cross section. In the illustrated embodiment of FIG. 10A, the second board end 108 is proximal to and the first board end 106 is distal to the at least one entry opening 132.

[0078] FIG. 10B is another side view of the apparatus 200′, wherein the coupling point of the sensor board 102 and the at least one flap 110 is different than that of the apparatus 200′ shown in FIG. 10A. In FIG. 10B, the at least one flap 110 is shown in the at least one indicating position P2. In the illustrated embodiment of FIG. 10B, the first board end 106 is proximal to and the second board end 108 is distal to the at least one exit opening 134.

[0079] FIG. 11 is a perspective view of an apparatus 300, with some components not shown, according to another embodiment of the present disclosure. The apparatus 300 is substantially similar to the apparatus 100′ of FIG. 6, with common components being referred to by the same numerals. However, in the apparatus 300, the at least one entry opening 132 and the at least one exit opening 134 have different shapes. As shown, in the illustrated embodiment of FIG. 11, the at least one entry opening 132 is a water drop shaped opening, and the at least one exit opening is a circular opening. Further, the aperture 140 also has a different shape from the at least one entry opening 132 and the at least one exit opening 134. As shown, the aperture 140 is a T-shaped aperture.

[0080] Moreover, in the apparatus 300, the at least one flap 110 includes a first flap 110A and a second flap 110B. As shown, the first flap 110A and the second flap 110B are spaced apart from each other. In the illustrated embodiment of FIG. 11, the first flap 110A and the second flap 110B have similar shapes.

[0081] FIG. 12 is a perspective view of an apparatus 300′, with some components not shown, according to another embodiment of the present disclosure. The apparatus 300′ is substantially similar to the apparatus 100′ of FIG. 6, with common components being referred to by the same numerals. However, in the apparatus 300′, the at least one flap 110 includes the first flap 110A and the second flap 110B (also shown in FIG. 11). Moreover, the first flap 110A and the second flap 110B have different shapes. As shown, a length of the first flap 110A is greater than a length of the second flap 110B. Further, a width of the first flap 110A is greater than a width of the second flap 110B.

[0082] FIG. 13A is a side view of an apparatus 400, with some components not shown, according to another embodiment of the present disclosure. The apparatus 400 is substantially similar to the apparatus 100′ of FIG. 6, with common components being referred to by the same numerals. However, in the apparatus 400, the at least one flap 110 has a non-linear profile or curved profile. Moreover, in the apparatus 400, the size of the at least one entry opening 132 is different than the size of the at least one exit opening 134. Specifically, the size of the at least one entry opening 132 is greater than the size of the at least one exit opening 134. Additionally, in the apparatus 400, the sensor housing 130 has a polygonal cross section. As shown, the at least one flap 110 includes a plurality of sections inclined to each other. In FIG. 13A the at least one flap 110 is shown in the at least one initial position P1. The non-linear profile of the at least one flap 110 achieves better space management inside the apparatus 400 and improves sensitivity of the at least one flap 110 to the airflow AF.

[0083] FIG. 13B is a side view of an apparatus 400′, with some components not shown, according to another embodiment of the present disclosure. The apparatus 400′ is substantially similar to the apparatus 400 of FIG. 13A, with common components being referred to by the same numerals. However, in the apparatus 400′, the at least one flap 110 has a single arcuate section 410.

[0084] FIG. 13C is a side view of an apparatus 400″, with some components not shown, according to another embodiment of the present disclosure. The apparatus 400″ is substantially similar to the apparatus 400 of FIG. 13A, with common components being referred to by the same numerals. However, in the apparatus 400′, the at least one flap 110 has a first arcuate section 420 and a second arcuate section 430. The first arcuate section 420 is longer than the second arcuate section 430. The second arcuate section 430 of the at least one flap 110 enables improved air-catching of the at least one flap 110, which may lead to improved sensitivity of the at least one flap 110 to the airflow AF.

[0085] FIG. 14A is a side view of an apparatus 500, with some components not shown, according to another embodiment of the present disclosure. The apparatus 500 is substantially similar to the apparatus 200 of FIG. 9A, with common components being referred to by the same numerals. However, in the apparatus 500, the sensor board 102 is neither disposed downstream (as shown in FIG. 9A) nor upstream (as shown in FIG. 7A) of the at least one flap 110, and instead, the sensor board 102 and the at least one flap 110 are arranged or disposed in line generally with the direction of the airflow AF. Moreover, the first board end 106 is arranged proximal to the at least one exit opening 134 and the second board end 108 is arranged proximal to the at least one entry opening 132.

[0086] In FIG. 14A, the at least one flap 110 is shown in the at least one initial position P1. FIG. 14B is another side view of the apparatus 500, wherein the at least one flap 110 is shown in the at least one indicating position P2. As illustrated in FIG. 14B, in the at least one indicating position P2 of the at least one flap 110 (i.e., in the presence of the airflow AF), the at least one flap 110 and the sensor board 102 are inclined to each other.

[0087] FIG. 15A is a side view of an apparatus 500′, with some components not shown, according to another embodiment of the present disclosure. The apparatus 500′ is substantially similar to the apparatus 500 of FIG. 14A, with common components being referred to by the same numerals. However, in the apparatus 500′, positions of the at least one entry opening 132 and the at least one exit opening 134 are different from that of the positions in the apparatus 500.

[0088] In FIG. 15A, the at least one flap 110 is shown in the at least one initial position P1. FIG. 15B is another side view of the apparatus 500′, wherein the at least one flap 110 is shown in the at least one indicating position P2. As illustrated in FIG. 15B, in the at least one indicating position P2 of the at least one flap 110 (i.e., in the presence of the airflow AF), the at least one flap 110 and the sensor board 102 are inclined to each other. The at least one flap 110 moves from the at least one initial position P1 to the at least one indicating position P2 such that the second flap end 114 moves away the sensor board 102.

[0089] FIG. 16A is a side view of an apparatus 500″, with some components not shown, according to another embodiment of the present disclosure. The apparatus 500″ is substantially similar to the apparatus 500′ of FIG. 15A, with common components being referred to by the same numerals. However, in the apparatus 500″, the first end 106 of sensor board 102 is disposed proximal to the at least one entry opening 132. Moreover, the sensor board 102 and the at least one flap 110 are not disposed fully in line with the direction of the airflow AF.

[0090] Further, In FIG. 16A, the at least one flap 110 is shown in the at least one initial position P1. As shown, in the illustrated embodiment of FIG. 16A, the sensor board 102 and the at least one flap 110 are inclined to each other in the at least one initial position P1. FIG. 16B is another side view of the apparatus 500″, wherein the at least one flap 110 is shown in the at least one indicating position P2. As illustrated in FIG. 16B, in the at least one indicating position P2, the at least one flap 110 and the sensor board 102 are arranged substantially parallel and adjacent to each other. Accordingly, the at least one flap 110 moves from the at least one initial position P1 to the at least one indicating position P2 such that the second flap end 114 moves towards the sensor board 102.

[0091] Unless otherwise indicated, all numbers expressing feature sizes, amounts, and physical properties used in the specification and claims are to be understood as being modified by the term “about”. Accordingly, unless indicated to the contrary, the numerical parameters set forth in the foregoing specification and attached claims are approximations that can vary depending upon the desired properties sought to be obtained by those skilled in the art utilizing the teachings disclosed herein.

[0092] Although specific embodiments have been illustrated and described herein, it will be appreciated by those of ordinary skill in the art that a variety of alternate and / or equivalent implementations can be substituted for the specific embodiments shown and described without departing from the scope of the present disclosure. This application is intended to cover any adaptations or variations of the specific embodiments discussed herein. Therefore, it is intended that this disclosure be limited only by the claims and the equivalents thereof.

Examples

Embodiment Construction

[0027]In the following description, reference is made to the accompanying figures that form a part thereof and in which various embodiments are shown by way of illustration. It is to be understood that other embodiments are contemplated and may be made without departing from the scope or spirit of the present disclosure. The following detailed description, therefore, is not to be taken in a limiting sense.

[0028]In the following disclosure, the following definitions are adopted.

[0029]As used herein, all numbers should be considered modified by the term “about”. As used herein, “a,”“an,”“the,”“at least one,” and “one or more” are used interchangeably.

[0030]The term “about”, unless otherwise specifically defined, means to a high degree of approximation (e.g., within + / −5% for quantifiable properties) but again without requiring absolute precision or a perfect match.

[0031]As used herein as a modifier to a property or attribute, the term “generally”, unless otherwise specifically defined...

TECHNICAL FIELD

[0001] The present disclosure relates generally to an air filter assembly, and more particularly, to an apparatus for monitoring a performance of an air filter.BACKGROUND

[0002] Heating, ventilation, and / or air conditioning (HVAC) systems are commonly used to regulate comfort level within buildings or other structures. These HVAC systems require air filters having a filter media to remove dust, dirt, contaminants, and other undesired particles that can adversely affect air quality. Conventional air filters designed to filter air flowing through the HVAC system are well known in the art. Such air filters are most effective when they are clean and correctly positioned within the ducts. As the filter media captures particles and becomes clogged, the air flow is correspondingly reduced, requiring increased energy to maintain designed operating parameters. Moreover, prolonged operation of the air filter in a clogged condition of the filter unit may lead to a low air-filtering efficiency and is detrimental to the HVAC system.

[0003] To this end, a timely cleaning or replacement of the air filters is required and failure to clean or replace the air filter imposes high risk in the HVAC system. Typically, a calendar-based maintenance schedule is recommended for timely cleaning and replacement of the air filters. However, pollutants levels vary based on local environmental conditions and do not follow a consistent pattern. As a result, the time-based replacement of the air filters may lead to premature disposal of effective filters or reduced performance from clogged filters.

[0004] Therefore, there is a need for an apparatus that monitors a real-time monitoring of a performance of an air filter to ensure efficient and reliable operation of HVAC system.SUMMARY

[0005] In a first aspect, the present disclosure provides an apparatus for monitoring a performance of an air filter. The air filter includes a perimeter frame and a filter media placed within the perimeter frame. The filter media is configured to be disposed in an airflow such that at least a portion of the airflow passes through the filter media. The filter media includes an upstream side and a downstream side. The apparatus is configured to be coupled to the perimeter frame or the filter media. The apparatus includes a sensor board extending between a first board end and a second board end. The apparatus further includes at least one flap configured to receive the airflow associated with the filter media and extending between a first flap end and a second flap end. The at least one flap is coupled to the sensor board. The first flap end is coupled to the sensor board and the second flap end is a free end. The at least one flap is movable relative to the sensor board, between at least one initial position in the absence of the airflow through the apparatus, and at least one indicating position in the presence of the airflow through the apparatus. The apparatus further includes at least one sensor disposed on the sensor board and configured to detect the movement of the at least one flap relative to the sensor board. Furthermore, the apparatus includes a processor configured to receive and process data relating to the movement of the at least one flap relative to the sensor board.

[0006] In a second aspect, the present disclosure provides an air filter assembly. The air filter assembly includes an air filter including a perimeter frame and a filter media placed within the perimeter frame. The filter media is configured to be disposed in an airflow such that at least a portion of the airflow passes through the filter media. The filter media includes an upstream side and a downstream side. The air filter assembly further includes the apparatus of the first aspect for monitoring a performance of the air filter. The apparatus is configured to be coupled to the perimeter frame or the filter media.

[0007] The details of one or more examples of the disclosure are set forth in the accompanying drawings and the description below. Other features, objects, and advantages of the disclosure will be apparent from the description and drawings, and from the claims.BRIEF DESCRIPTION OF THE DRAWINGS

[0008] Exemplary embodiments disclosed herein may be more completely understood in consideration of the following detailed description in connection with the following figures. The figures are not necessarily drawn to scale. Like numbers used in the figures refer to like components. However, it will be understood that the use of a number to refer to a component in a given figure is not intended to limit the component in another figure labeled with the same number.

[0009] FIG. 1 is a perspective view of an air filter assembly including an air filter and an apparatus for monitoring a performance of the air filter, according to an embodiment of the present disclosure;

[0010] FIG. 2 is a perspective view of the apparatus of FIG. 1;

[0011] FIG. 3 is a perspective view of an air filter assembly, according to another embodiment of the present disclosure;

[0012] FIG. 4 is a side view of the air filter assembly of FIG. 3;

[0013] FIG. 5 is a perspective view of an air filter assembly, according to yet another embodiment of the present disclosure;

[0014] FIG. 6 is a perspective view of an apparatus of the air filter assembly of FIG. 3 for monitoring a performance of the air filter, with some components not shown, according to an embodiment of the present disclosure;

[0015] FIG. 7A is a side view of the apparatus of FIG. 6, with some components not shown, wherein at least one flap is shown in at least one initial position, according to an embodiment of the present disclosure;

[0016] FIG. 7B is a side view of the apparatus of FIG. 6, with some components not shown, wherein the at least one flap is shown in at least one indicating position;

[0017] FIGS. 8A and 8B are side views of an apparatus for monitoring a performance of the air filter, with some components not shown, according to yet another embodiment of the present disclosure;

[0018] FIG. 9A is a side view of an apparatus for monitoring a performance of the air filter, with some components not shown, wherein at least one flap is shown in at least one initial position, according to yet another embodiment of the present disclosure;

[0019] FIG. 9B is a side view of the apparatus of FIG. 9A wherein the at least one flap is shown in at least one indicating position;

[0020] FIGS. 10A and 10B are side views of an apparatus for monitoring a performance of the air filter, with some components not shown, according to yet another embodiment of the present disclosure;

[0021] FIG. 11 is a perspective view of an apparatus for monitoring a performance of the air filter, with some components not shown, according to yet another embodiment of the present disclosure;

[0022] FIG. 12 is a perspective view of an apparatus for monitoring a performance of the air filter, with some components not shown, according to yet another embodiment of the present disclosure;

[0023] FIGS. 13A, 13B, and 13C are side views of an apparatus for monitoring a performance of the air filter, with some components not shown, according to yet another embodiment of the present disclosure;

[0024] FIGS. 14A and 14B are side views of an apparatus for monitoring a performance of the air filter, with some components not shown, according to yet another embodiment of the present disclosure;

[0025] FIGS. 15A and 15B are side views of an apparatus for monitoring a performance of the air filter, with some components not shown, according to yet another embodiment of the present disclosure; and

[0026] FIGS. 16A and 16B are side views of an apparatus for monitoring a performance of the air filter, with some components not shown, according to yet another embodiment of the present disclosure.DETAILED DESCRIPTION

[0027] In the following description, reference is made to the accompanying figures that form a part thereof and in which various embodiments are shown by way of illustration. It is to be understood that other embodiments are contemplated and may be made without departing from the scope or spirit of the present disclosure. The following detailed description, therefore, is not to be taken in a limiting sense.

[0028] In the following disclosure, the following definitions are adopted.

[0029] As used herein, all numbers should be considered modified by the term “about”. As used herein, “a,”“an,”“the,”“at least one,” and “one or more” are used interchangeably.

[0030] The term “about”, unless otherwise specifically defined, means to a high degree of approximation (e.g., within + / −5% for quantifiable properties) but again without requiring absolute precision or a perfect match.

[0031] As used herein as a modifier to a property or attribute, the term “generally”, unless otherwise specifically defined, means that the property or attribute would be readily recognizable by a person of ordinary skill but without requiring absolute precision or a perfect match (e.g., within + / −20% for quantifiable properties).

[0032] As used herein, “at least one of A and B” should be understood to mean “only A, only B, or both A and B”.

[0033] As used herein, the statement that two or more parts or components are “coupled” shall mean that the parts are joined or operate together either directly or indirectly, i.e., through one or more intermediate parts or components, so long as a link occurs. As used herein, “directly coupled” means that two elements are directly in contact with each other. As used herein, “fixedly coupled” or “fixed” means that two components are coupled so as to move as one while maintaining a constant orientation relative to each other.

[0034] As used herein, the phrase “removably coupled” or “temporarily coupled” means that one component is coupled with another component in an essentially temporary manner. That is, the two components are coupled in such a way that the joining or separation of the components is easy and would not damage the components. For example, two components secured to each other with a limited number of readily accessible fasteners, i.e., fasteners that are not difficult to access, are “removably coupled” whereas two components that are welded together or joined by difficult to access fasteners are not “removably coupled”. A “difficult to access fastener” is one that requires the removal of one or more other components prior to accessing the fastener wherein the “other component” is not an access device such as, but not limited to, a door.

[0035] As used herein, “substantially” means “for the most part” relevant to the term being modified as would be understood by one of ordinary skill in the art.

[0036] As used herein, “corresponding” indicates that two structural components are sized and shaped similar to each other and can be coupled with a minimum amount of friction. Thus, an opening “corresponding” to a member is sized slightly larger than the member so that the member can pass through the opening with a minimum amount of friction. This definition is changed when the two components are said to “snugly” fit together or “just correspond”. In that situation, the difference between the sizes of those components is even smaller, thereby increasing the amount of friction.

[0037] The present disclosure provides an apparatus for monitoring a performance of an air filter. The air filter includes a perimeter frame and a filter media placed within the perimeter frame. The filter media is configured to be disposed in an airflow such that at least a portion of the airflow passes through the filter media. The filter media includes an upstream side and a downstream side. The apparatus is configured to be coupled to the perimeter frame or the filter media. The apparatus includes a sensor board extending between a first board end and a second board end. The apparatus further includes at least one flap configured to receive the airflow associated with the filter media and extending between a first flap end and a second flap end. The at least one flap is coupled to the sensor board. The first flap end is coupled to the sensor board and the second flap end is a free end. The at least one flap is movable relative to the sensor board, between at least one initial position in the absence of the airflow through the apparatus, and at least one indicating position in the presence of the airflow through the apparatus. The apparatus further includes at least one sensor disposed on the sensor board and configured to detect the movement of the at least one flap relative to the sensor board. Furthermore, the apparatus includes a processor configured to receive and process data relating to the movement of the at least one flap relative to the sensor board.

[0038] The apparatus of the present disclosure may be used with any suitable powered air-handling system. In some embodiments, such an air-handling system may be a heating-ventilation-air-conditioning (HVAC) system e.g., for a residence (e.g. a single-family home), a commercial or retail building or space, or a manufacturing unit, or an industry, and so on. The term HVAC is used broadly, in various embodiments, an HVAC system may be configured to perform heating, to perform cooling, or to perform either heating or cooling, as desired. In some embodiments, such an HVAC system may be a centralized air-handling system in which air to be handled is collected via multiple air-return inlets (e.g., located in multiple rooms of a building).

[0039] The at least one flap is movable relative to the sensor board due to the presence and absence of the airflow through the apparatus. Based upon an amount of airflow passing through the filter media, the at least one flap moves between the at least one initial position and the at least one indicating position. This movement is detected or measured by the at least one sensor and the data related to such movement is received by the processor. The processor receives such data and may perform necessary calculations in order to determine a loading condition of the filter media. Therefore, the apparatus may provide continuous and real-time monitoring of the loading condition or, in other words, performance of the air filter. This allows timely maintenance and replacement of the air filter based on actual and real-time loading condition of the filter media rather than predetermined schedules. This may further ensure optimal airflow and improved efficiency of the air-handling system.

[0040] Moreover, continuous and real-time monitoring of the air filter may also prevent premature disposal of an effective air filter. This may lead to reduced operational costs. Additionally, timely maintenance and replacement of the air filter may ensure improved air quality and may also prevent risk of overheating and potential system failure.

[0041] Referring now to Figures, FIG. 1 illustrates a perspective view of an air filter assembly 50, according to an embodiment of the present disclosure. The air filter assembly 50 may be provided in a suitable powered air-handling system, such as a heating-ventilation-air-conditioning (HVAC) system for a residence (e.g. a single-family home), a commercial or retail building or space, or a manufacturing unit, or an industry, and so on.

[0042] The air filter assembly 50 includes an air filter 60. In some embodiments, the air filter 60 may be a disposable air filter. The air filter 60 may generally have a rectangular shape or square shape. The air filter 60 includes a perimeter frame 70 and a filter media 80 placed within the perimeter frame 70. The perimeter frame 70 may include sidewalls 72 and may be made of any suitable material(s), e.g., paperboard or cardboard that may be folded to provide the various sidewalls 72. In some embodiments, the perimeter frame 70 may be made of an injection molded plastic material. In some embodiments, the perimeter frame 70 includes support members (not shown) that extend at least partially across the filter media 80 in order to provide additional support.

[0043] Further, the filter media 80 is configured to be disposed in an airflow AF such that at least a portion of the airflow AF passes through the filter media 80. In the illustrated embodiment of FIG. 1, the filter media 80 is shown as pleated so as to exhibit readily identifiable pleats. In other embodiments, the filter media 80 may be unpleated. The filter media 80 includes an upstream side 82 and a downstream side 84. The filter media 80 is made of any material that is capable of filtering moving air. Accordingly, air passes from the upstream side 82 through the filter media 80 to the downstream side 84.

[0044] The air filter assembly 50 further includes an apparatus 100 for monitoring a performance of the air filter 60. The apparatus 100 is configured to be coupled to the perimeter frame 70 or the filter media 80. In some embodiments, the apparatus 100 is disposed at the downstream side 84 of the filter media 80. In some embodiments, the apparatus 100 may be coupled to the support member (not shown) of the perimeter frame 70. In other embodiments, the apparatus 100 may be coupled to the sidewalls 72 of the perimeter frame 70. It should be noted in the figures, various components of the air filter assembly 50 and the apparatus 100 will be shown schematically.

[0045] FIG. 2 illustrates a perspective view of the apparatus 100, according to an embodiment of the present disclosure. Referring to FIGS. 1 and 2, the apparatus 100 includes a sensor board 102 extending between a first board end 106 and a second board end 108. The apparatus 100 further includes at least one flap 110 configured to receive the airflow AF associated with the filter media 80 and extending between a first flap end 112 and a second flap end 114. In some embodiments, where the apparatus 100 is disposed at the downstream side 84 of the filter media 80, the at least one flap 110 is configured to receive the airflow AF from the filter media 80. In the illustrated embodiment of FIGS. 1 and 2, the at least one flap 110 includes a single flap 110. However, the number of flaps in the apparatus 100 may vary based upon application requirements.

[0046] The at least one flap 110 is coupled to the sensor board 102. As shown, the first flap end 112 is coupled to the sensor board 102 and the second flap end 114 is a free end. In some embodiments, the first flap end 112 is coupled to the sensor board 102 proximate to the first board end 106. The at least one flap 110 is movable relative to the sensor board 102. In some embodiments, the at least one flap 110 is pivotally coupled to the sensor board 102, such that in response to the airflow AF through the apparatus 100, the at least one flap 110 is pivotally movable between two or more positions (described later in description). In some embodiments, in response to the airflow AF through the apparatus 100, the at least one flap 110 flexes or bends between two or more positions relative to the sensor board 102.

[0047] The apparatus 100 further includes at least one sensor 118 disposed on the sensor board 102 and configured to detect the movement of the at least one flap 110 relative to the sensor board 102. In some embodiments, the at least one sensor 118 is a capacitive sensor. The at least one sensor 118 is configured to detect a change in capacitance of the at least one flap 110 due to the movement of the at least one flap 110 between two or more positions relative to the sensor board 102. As shown in FIGS. 1 and 2, the at least one sensor 118 includes a single sensor 118.

[0048] The apparatus 100 further includes a processor 120 configured to receive and process data relating to the movement of the at least one flap 110 relative to the sensor board 102. The processor 120 is communicably coupled to the at least one sensor 118. Upon processing of the data received from the at least one sensor 118, the processor 120 may provide an output 124 indicative of a loading condition of the filter media 80. In some embodiments, the apparatus 100 further includes an output unit 122 communicably coupled to the processor 120 and configured to provide the output 124 indicative of the loading condition of the filter media 80. The processor 120 may be a programmable analog and / or digital device that can store, retrieve, and process data. In an application, the processor 120 may be a controller, a control circuit, a computer, a workstation, a microprocessor, a microcomputer, a central processing unit, a server, or any suitable device or apparatus.

[0049] To facilitate the communication between the processor 120 and the at least one sensor 118, the apparatus 100 further includes a communication module 136 configured to transmit the data wirelessly or through a wired connection from the at least one sensor 118 to the processor 120. In some embodiments, the communication module 136 includes a radio unit. In some embodiments, the apparatus 100 further includes a power source 138 configured to power the at least one sensor 118. In some embodiments, the power source 138 may include one or more batteries.

[0050] FIG. 3 illustrates a perspective view of an air filter assembly 50′, according to another embodiment of the present disclosure. FIG. 4 illustrates a side view of the air filter assembly 50′. Referring to FIGS. 1 to 4, the air filter assembly 50′ is substantially similar to the air filter assembly 50 of FIG. 1, with common components being referred to by the same reference numerals. However, the air filter assembly 50′ includes an apparatus 100′ (instead of the apparatus 100 shown in FIGS. 1 and 2).

[0051] The apparatus 100′ further includes a sensor housing 130 configured to be removably coupled to the perimeter frame 70 or the filter media 80 and disposed at the downstream side 84 of the filter media 80. The sensor housing 130 encloses the sensor board 102, the at least one flap 110, and the at least one sensor 118. In some embodiments, the sensor housing 130 has a triangular cross section or a polygonal cross section. As shown in FIG. 4, the sensor housing 130 has the triangular cross section. Also, as illustrated in FIGS. 3 and 4, the processor 120 is located or arranged remotely from the sensor housing 130.

[0052] Furthermore, the sensor housing 130 includes at least one entry opening 132 and at least one exit opening 134. At least a portion of the airflow AF passing through the filter media 80 enters into the sensor housing 130 via the at least one entry opening 132 and exits from the sensor housing 130 via the at least one exit opening 134. Specifically, each of the sensor board 102 and the at least one flap 110 is disposed in the sensor housing 130 between the at least one entry opening 132 and the at least one exit opening 134.

[0053] In some embodiments, the at least one entry opening 132 includes a single entry opening 132 and the at least one exit opening 134 includes a single exit opening 134. In another embodiment, the at least one entry opening 132 includes two or more entry openings 132 (not shown) and the at least one exit opening 134 includes two or more exit openings 134 (not shown). In the illustrated embodiment of FIG. 4, a size of the at least one entry opening 132 is equal to a size of the at least one exit opening 134. However, in other embodiments, the size of the of the at least one entry opening 132 and the size of the at least one exit opening 134 may be different from each other.

[0054] In the illustrated embodiment of FIG. 3, the at least one entry opening 132 and the at least one exit opening 134 have similar shapes. However, in other embodiments, the at least one entry opening 132 and the at least one exit opening 134 have different shapes. In some embodiments, the at least one entry opening 132 is a U-shaped opening, a circular opening, a polygonal opening, an elliptical opening, an oval opening, a T-shaped opening, or a water drop shaped opening. In the illustrated embodiment of FIG. 3, the at least one entry opening 132 is a circular opening. In some embodiments, the at least one exit opening 134 is a U-shaped opening, a circular opening, a polygonal opening, an elliptical opening, an oval opening, a T-shaped opening, or a water drop shaped opening. In the illustrated embodiment of FIG. 3, the at least one exit opening 134 is a circular opening.

[0055] In some embodiments, the sensor board 102 defines an aperture 140 (shown in FIG. 3) therethrough such that at least a portion of the airflow AF entering the sensor housing 130 via the at least one entry opening 132 passes through the aperture 140 and exits the sensor housing 130 via the at least one exit opening 134. In such case, when there is airflow AF through the sensor housing 130, a portion of the airflow AF passes through the aperture 140 and impinges on the at least one flap 110 to move the at least one flap 110 between two or more positions (described later in description) relative to the sensor board 102.

[0056] Moreover, the aperture 140 may also have similar shape as that of the at least one entry opening 132 and the at least one exit opening 134. However, the aperture 140 may also have a different shape than that of the at least one entry opening 132 and the at least one exit opening 134. In some embodiments, the aperture 140 of the sensor board 102 is a U-shaped aperture, a circular aperture, a polygonal aperture, an elliptical aperture, an oval aperture, a T-shaped aperture, or a water drop shaped aperture. In the illustrated embodiment of FIG. 3, the aperture 140 is a circular aperture.

[0057] FIG. 5 is a perspective view of an air filter assembly 50″, according to another embodiment of the present disclosure. The air filter assembly 50″ is substantially similar to the air filter assembly 50′ of FIGS. 3 and 4, with common components being referred to by the same reference numerals. However, the air filter assembly 50″ includes an apparatus 100″ (instead of the apparatus 100, shown in FIGS. 3 and 4). The apparatus 100″ is substantially similar to the apparatus 100′ shown in FIG. 3, with common components being referred to by the same numerals.

[0058] However, in the apparatus 100″, the sensor board 102 includes two sensors 118. In other words, in the apparatus 100″, the at least one sensor 118 includes two sensors 118 (instead of only a single sensor 118) in total. In other embodiments, the at least one sensor 118 may include three or more sensors 118 in total, or the sensor board 102 may include three or more sensors 118 in total. Additionally, in the apparatus 100″, the processor 120 is located onboard the sensor housing 130. In such a case, the processor 120 may be connected to the at least one sensor 118 by the wired connection.

[0059] FIG. 6 is a perspective view of the apparatus 100′ (also shown in FIGS. 3 and 4). FIG. 7A is a side view of the apparatus 100′, wherein the at least one flap 110 is shown in an at least one initial position P1, according to an embodiment of the present disclosure. FIG. 7B is another perspective side view of the apparatus 100′, wherein the at least one flap 110 is shown in an at least one indicating position P2, according to an embodiment of the present disclosure. Some components, such as the processor 120, are not shown in FIGS. 6 to 7B for illustrative purposes. In the illustrated embodiment of FIGS. 7A and 7B, the at least one flap 110 has a linear profile. However, in other embodiments, the at least one flap 110 may have a non-linear profile or curved profile. Further, in some embodiments, the at least one flap 110 has a uniform thickness. In some embodiments, the at least one flap 110 has a variable thickness.

[0060] Referring to FIGS. 3, 4, 6 to 7B, the at least one flap 110 is movable relative to the sensor board 102, between the at least one initial position P1 in the absence of the airflow AF through the apparatus 100′, and at least one indicating position P2 in the presence of the airflow AF through the apparatus 100. It should be noted that the sensor board 102 may be disposed upstream of the at least one flap 110 or downstream of the at least one flap 110 depending on application requirements. Further, the sensor board 102 and the at least one flap 110 may be disposed in line with the direction of the airflow AF.

[0061] In the illustrated embodiment of FIGS. 7A and 7B, the sensor board 102 is disposed downstream of the at least one flap 110. As illustrated in FIG. 7A, in the absence of the airflow AF through the apparatus 100′, the sensor board 102 and the at least one flap 110 are inclined to each other, such that the at least one flap 110 is in the at least one initial position P1. When the at least one flap 110 is in the at least one initial position P1, the sensor board 102 and the at least one flap 110 may be inclined to each other at an angle ranging from about 20 degrees to about 90 degrees.

[0062] As illustrated in FIG. 7B, in the presence of the airflow AF through the apparatus 100′, the at least one flap 110 moves from the at least one initial position P1 to the at least one indicating position P2 in a direction at least generally aligned with the direction of the airflow AF through the apparatus 100′, such that the second flap end 114 moves towards the sensor board 102. In the at least one indicating position P2 of the at least one flap 110, the at least one flap 110 and the sensor board 102 are arranged substantially parallel and adjacent to each other. Although, in FIG. 7B, the at least one flap 110 is shown to be arranged parallel and adjacent to the sensor board 102, however, it should be noted that, in the at least one indicating position P2, the at least one flap 110 may be inclined to the sensor board 102 at a small angle (ranging from about 5 degrees to about 10 degrees).

[0063] It can be stated that in response to the airflow AF through the apparatus 100′, the at least one flap 110 is pivotally movable between the at least one initial position P1 and the at least one indicating position P2 relative to the sensor board 102. In some embodiments, in response to the airflow AF through the apparatus 100′, the at least one flap 110 flexes or bends between the at least one initial position P1 and the at least one indicating position P2 relative to the sensor board 102. It may be appreciated that in such case, the at least one flap 110 may have a variable thickness to facilitate easy flexing of the at least one flap 110. However, in some cases, the at least one flap 110 having constant thickness along its length may also flex or bend between the at least one initial position P1 and the at least one indicating position P2 relative to the sensor board 102.

[0064] The at least one sensor 118 is configured to detect the change in capacitance of the at least one flap 110 due to the movement of the at least one flap 110 between the at least one initial position P1 and the at least one indicating position P2 relative to the sensor board 102. The at least one sensor 118 detects the movement of the at least one flap 110 between the at least one initial position P1 and the at least one indicating position P2 and collects data related to such movement of the at least one flap 110 relative to the sensor board 102.

[0065] When the at least one sensor 118 detects the movement of the at least one flap 110 from the at least one initial position P1 to the at least one indicating position P2 relative to the sensor board 102, the processor 120 (shown in FIG. 3) processes data relating to such movement, and the output unit 122 (shown in FIG. 3) provides the output 124 indicative of a clear state of the filter media 80. When the at least one sensor 118 detects the movement of the at least one flap 110 from the at least one indicating position P2 to the at least one initial position P1 relative to the sensor board 102, the processor 120 processes data relating to such movement, and the output unit 122 provides the output 124 indicative of a clogged state of the filter media 80.

[0066] Therefore, the apparatus 100′ determines the loading condition of the filter media 80 based on the movement of the at least one flap 110 between two or more positions (i.e., the at least one initial position P1 and the at least one indicating position P2) relative to the sensor board 102. The apparatus 100′ may provide continuous and real-time monitoring of the loading condition or, in other words, performance of the air filter 60. This allows timely maintenance and replacement of the air filter 60 based on actual and real-time loading condition of the filter media 80 rather than predetermined schedules. This may ensure optimal airflow and improved efficiency of an air-handling system, such as a Heating, ventilation, and / or air conditioning (HVAC) system.

[0067] Moreover, continuous and real-time monitoring of the air filter 60 may also prevent premature disposal of the effective air filter. This may lead to reduced operational costs. Additionally, timely maintenance and replacement of the air filter 60 may ensure improved air quality and may also prevent risk of overheating and potential system failure.

[0068] With continued reference to FIGS. 7A and 7B, in the at least one indicating position P2 of the at least one flap 110, the second flap end 114 is proximal to the at least one entry opening 132 and distal to the at least one exit opening 134. In some embodiments, the first board end 106 is proximal to and the second board end 108 is distal to the at least one entry opening 132.

[0069] FIG. 8A is a side view of an apparatus 100′″, with some components not shown, according to another embodiment of the present disclosure. The apparatus 100′″ is substantially similar to the apparatus 100′ of FIGS. 7A and 7B, with common components being referred to by the same numerals. In FIG. 8A, the at least one flap 110 is shown in the at least one initial position P1.

[0070] However, in the apparatus 100′″, the size of the at least one entry opening 132 is different than the size of the at least one exit opening 134. Specifically, the size of the at least one entry opening 132 is greater than the size of the at least one exit opening 134. Additionally, in the apparatus 100′″, the sensor housing 130 has a polygonal cross section. In the illustrated embodiment of FIG. 8A, the second board end 108 is proximal to and the first board end 106 is distal to the at least one exit opening 134.

[0071] FIG. 8B is another side view of the apparatus 100′″, wherein the coupling point of the sensor board 102 and the at least one flap 110 is different than that of the apparatus 100′″ shown in FIG. 8A. In FIG. 8B, the at least one flap 110 is shown in the at least one initial position P1. In the at least one initial position of the at least one flap 110, the second flap end 114 is proximal to the at least one exit opening 134 and distal to the at least one entry opening 132.

[0072] FIG. 9A is a side view of an apparatus 200, with some components not shown, according to another embodiment of the present disclosure. The apparatus 200 is substantially similar to the apparatus 100′ of FIG. 7A, with common components being referred to by the same numerals. However, in the apparatus 200, the sensor board 102 is disposed upstream (instead of downstream) of the at least one flap 110. In FIG. 9A, the at least one flap 110 is shown in the at least one initial position P1. FIG. 9B is another side view of the apparatus 200, wherein the at least one flap 110 is shown in the at least one indicating position P2.

[0073] As illustrated in FIG. 9A, in the absence of the airflow AF through the apparatus 200, the sensor board 102 and the at least one flap 110 are arranged substantially parallel and adjacent to each other, such that the at least one flap 110 is in the at least one initial position P1. Although, in FIG. 9A, the at least one flap 110 is shown to be arranged parallel and adjacent to the sensor board 102, however, it should be noted that, in the at least one initial position P1, the at least one flap 110 may be inclined to the sensor board 102 at a small angle (ranging from about 5 degrees to about 10 degrees).

[0074] As illustrated in FIG. 9B, in the presence of the airflow AF through the apparatus 200, the at least one flap 110 moves from the at least one initial position P1 to the at least one indicating position P2 in a direction at least generally aligned with the direction of the airflow AF through the apparatus 100′, such that the second flap end 114 moves away from the sensor board 102. In the at least one indicating position P2 of the at least one flap 110, the at least one flap 110 and the sensor board 102 are inclined to each other. When the at least one flap 110 is in the at least one indicating position P2, the sensor board 102 and the at least one flap 110 may be inclined to each other at an angle ranging from about 20 degrees to about 90 degrees. Moreover, as shown, in the at least one indicating position P2 of the at least one flap 110, the second flap end 114 is proximal to the at least one exit opening 134 and distal to the at least one entry opening 132.

[0075] Referring to FIGS. 3, 9A, and 9B, when there is airflow AF through the sensor housing 130, a portion of the airflow AF passes through the aperture 140 and impinges on the at least one flap 110 to move the at least one flap 110 from the at least one initial position P1 to the at least one indicating position P2 relative to the sensor board 102.

[0076] FIG. 10A is a side view of an apparatus 200′, with some components not shown, according to another embodiment of the present disclosure. The apparatus 200′ is substantially similar to the apparatus 200 of FIGS. 9A and 9B, with common components being referred to by the same numerals. In FIG. 10A, the at least one flap 110 is shown in the at least one indicating position P2.

[0077] However, in the apparatus 200′, the size of the at least one entry opening 132 is different than the size of the at least one exit opening 134. Specifically, the size of the at least one entry opening 132 is greater than the size of the at least one exit opening 134. Additionally, in the apparatus 200′, the sensor housing 130 has a polygonal cross section. In the illustrated embodiment of FIG. 10A, the second board end 108 is proximal to and the first board end 106 is distal to the at least one entry opening 132.

[0078] FIG. 10B is another side view of the apparatus 200′, wherein the coupling point of the sensor board 102 and the at least one flap 110 is different than that of the apparatus 200′ shown in FIG. 10A. In FIG. 10B, the at least one flap 110 is shown in the at least one indicating position P2. In the illustrated embodiment of FIG. 10B, the first board end 106 is proximal to and the second board end 108 is distal to the at least one exit opening 134.

[0079] FIG. 11 is a perspective view of an apparatus 300, with some components not shown, according to another embodiment of the present disclosure. The apparatus 300 is substantially similar to the apparatus 100′ of FIG. 6, with common components being referred to by the same numerals. However, in the apparatus 300, the at least one entry opening 132 and the at least one exit opening 134 have different shapes. As shown, in the illustrated embodiment of FIG. 11, the at least one entry opening 132 is a water drop shaped opening, and the at least one exit opening is a circular opening. Further, the aperture 140 also has a different shape from the at least one entry opening 132 and the at least one exit opening 134. As shown, the aperture 140 is a T-shaped aperture.

[0080] Moreover, in the apparatus 300, the at least one flap 110 includes a first flap 110A and a second flap 110B. As shown, the first flap 110A and the second flap 110B are spaced apart from each other. In the illustrated embodiment of FIG. 11, the first flap 110A and the second flap 110B have similar shapes.

[0081] FIG. 12 is a perspective view of an apparatus 300′, with some components not shown, according to another embodiment of the present disclosure. The apparatus 300′ is substantially similar to the apparatus 100′ of FIG. 6, with common components being referred to by the same numerals. However, in the apparatus 300′, the at least one flap 110 includes the first flap 110A and the second flap 110B (also shown in FIG. 11). Moreover, the first flap 110A and the second flap 110B have different shapes. As shown, a length of the first flap 110A is greater than a length of the second flap 110B. Further, a width of the first flap 110A is greater than a width of the second flap 110B.

[0082] FIG. 13A is a side view of an apparatus 400, with some components not shown, according to another embodiment of the present disclosure. The apparatus 400 is substantially similar to the apparatus 100′ of FIG. 6, with common components being referred to by the same numerals. However, in the apparatus 400, the at least one flap 110 has a non-linear profile or curved profile. Moreover, in the apparatus 400, the size of the at least one entry opening 132 is different than the size of the at least one exit opening 134. Specifically, the size of the at least one entry opening 132 is greater than the size of the at least one exit opening 134. Additionally, in the apparatus 400, the sensor housing 130 has a polygonal cross section. As shown, the at least one flap 110 includes a plurality of sections inclined to each other. In FIG. 13A the at least one flap 110 is shown in the at least one initial position P1. The non-linear profile of the at least one flap 110 achieves better space management inside the apparatus 400 and improves sensitivity of the at least one flap 110 to the airflow AF.

[0083] FIG. 13B is a side view of an apparatus 400′, with some components not shown, according to another embodiment of the present disclosure. The apparatus 400′ is substantially similar to the apparatus 400 of FIG. 13A, with common components being referred to by the same numerals. However, in the apparatus 400′, the at least one flap 110 has a single arcuate section 410.

[0084] FIG. 13C is a side view of an apparatus 400″, with some components not shown, according to another embodiment of the present disclosure. The apparatus 400″ is substantially similar to the apparatus 400 of FIG. 13A, with common components being referred to by the same numerals. However, in the apparatus 400′, the at least one flap 110 has a first arcuate section 420 and a second arcuate section 430. The first arcuate section 420 is longer than the second arcuate section 430. The second arcuate section 430 of the at least one flap 110 enables improved air-catching of the at least one flap 110, which may lead to improved sensitivity of the at least one flap 110 to the airflow AF.

[0085] FIG. 14A is a side view of an apparatus 500, with some components not shown, according to another embodiment of the present disclosure. The apparatus 500 is substantially similar to the apparatus 200 of FIG. 9A, with common components being referred to by the same numerals. However, in the apparatus 500, the sensor board 102 is neither disposed downstream (as shown in FIG. 9A) nor upstream (as shown in FIG. 7A) of the at least one flap 110, and instead, the sensor board 102 and the at least one flap 110 are arranged or disposed in line generally with the direction of the airflow AF. Moreover, the first board end 106 is arranged proximal to the at least one exit opening 134 and the second board end 108 is arranged proximal to the at least one entry opening 132.

[0086] In FIG. 14A, the at least one flap 110 is shown in the at least one initial position P1. FIG. 14B is another side view of the apparatus 500, wherein the at least one flap 110 is shown in the at least one indicating position P2. As illustrated in FIG. 14B, in the at least one indicating position P2 of the at least one flap 110 (i.e., in the presence of the airflow AF), the at least one flap 110 and the sensor board 102 are inclined to each other.

[0087] FIG. 15A is a side view of an apparatus 500′, with some components not shown, according to another embodiment of the present disclosure. The apparatus 500′ is substantially similar to the apparatus 500 of FIG. 14A, with common components being referred to by the same numerals. However, in the apparatus 500′, positions of the at least one entry opening 132 and the at least one exit opening 134 are different from that of the positions in the apparatus 500.

[0088] In FIG. 15A, the at least one flap 110 is shown in the at least one initial position P1. FIG. 15B is another side view of the apparatus 500′, wherein the at least one flap 110 is shown in the at least one indicating position P2. As illustrated in FIG. 15B, in the at least one indicating position P2 of the at least one flap 110 (i.e., in the presence of the airflow AF), the at least one flap 110 and the sensor board 102 are inclined to each other. The at least one flap 110 moves from the at least one initial position P1 to the at least one indicating position P2 such that the second flap end 114 moves away the sensor board 102.

[0089] FIG. 16A is a side view of an apparatus 500″, with some components not shown, according to another embodiment of the present disclosure. The apparatus 500″ is substantially similar to the apparatus 500′ of FIG. 15A, with common components being referred to by the same numerals. However, in the apparatus 500″, the first end 106 of sensor board 102 is disposed proximal to the at least one entry opening 132. Moreover, the sensor board 102 and the at least one flap 110 are not disposed fully in line with the direction of the airflow AF.

[0090] Further, In FIG. 16A, the at least one flap 110 is shown in the at least one initial position P1. As shown, in the illustrated embodiment of FIG. 16A, the sensor board 102 and the at least one flap 110 are inclined to each other in the at least one initial position P1. FIG. 16B is another side view of the apparatus 500″, wherein the at least one flap 110 is shown in the at least one indicating position P2. As illustrated in FIG. 16B, in the at least one indicating position P2, the at least one flap 110 and the sensor board 102 are arranged substantially parallel and adjacent to each other. Accordingly, the at least one flap 110 moves from the at least one initial position P1 to the at least one indicating position P2 such that the second flap end 114 moves towards the sensor board 102.

[0091] Unless otherwise indicated, all numbers expressing feature sizes, amounts, and physical properties used in the specification and claims are to be understood as being modified by the term “about”. Accordingly, unless indicated to the contrary, the numerical parameters set forth in the foregoing specification and attached claims are approximations that can vary depending upon the desired properties sought to be obtained by those skilled in the art utilizing the teachings disclosed herein.

[0092] Although specific embodiments have been illustrated and described herein, it will be appreciated by those of ordinary skill in the art that a variety of alternate and / or equivalent implementations can be substituted for the specific embodiments shown and described without departing from the scope of the present disclosure. This application is intended to cover any adaptations or variations of the specific embodiments discussed herein. Therefore, it is intended that this disclosure be limited only by the claims and the equivalents thereof.

Examples

Embodiment Construction

[0027]In the following description, reference is made to the accompanying figures that form a part thereof and in which various embodiments are shown by way of illustration. It is to be understood that other embodiments are contemplated and may be made without departing from the scope or spirit of the present disclosure. The following detailed description, therefore, is not to be taken in a limiting sense.

[0028]In the following disclosure, the following definitions are adopted.

[0029]As used herein, all numbers should be considered modified by the term “about”. As used herein, “a,”“an,”“the,”“at least one,” and “one or more” are used interchangeably.

[0030]The term “about”, unless otherwise specifically defined, means to a high degree of approximation (e.g., within + / −5% for quantifiable properties) but again without requiring absolute precision or a perfect match.

[0031]As used herein as a modifier to a property or attribute, the term “generally”, unless otherwise specifically defined...

Claims

1. An apparatus for monitoring a performance of an air filter, the air filter comprising a perimeter frame and a filter media placed within the perimeter frame, the filter media being configured to be disposed in an airflow such that at least a portion of the airflow passes through the filter media, the filter media comprising an upstream side and a downstream side, the apparatus configured to be coupled to the perimeter frame or the filter media, the apparatus comprising:a sensor board extending between a first board end and a second board end;at least one flap configured to receive the airflow associated with the filter media and extending between a first flap end and a second flap end, the at least one flap coupled to the sensor board, wherein at least one flap end is coupled to the sensor board, wherein the at least one flap or sensor board is movable relative to the other, between at least one initial position in the absence of the airflow through the apparatus, and at least one indicating position in the presence of the airflow through the apparatus;at least one sensor disposed on the sensor board and configured to detect the movement of the at least one flap relative to the sensor board; anda processor configured to receive and process data relating to the movement of the at least one flap relative to the sensor board.

2. The apparatus of claim 1, further comprising an output unit communicably coupled to the processor and configured to provide an output indicative of a loading condition of the filter media.

3. The apparatus of claim 2, wherein when the at least one sensor detects the movement of the at least one flap from the at least one initial position to the at least one indicating position relative to the sensor board, the processor processes data relating to such movement, and the output unit provides the output indicative of a clear state of the filter media.

4. The apparatus of claim 2, wherein when the at least one sensor detects the movement of the at least one flap from the at least one indicating position to the at least one initial position relative to the sensor board, the processor processes data relating to such movement, and the output unit provides the output indicative of a clogged state of the filter media.

5. The apparatus of claim 1, wherein the sensor board is disposed upstream of the at least one flap.

6. The apparatus of claim 1, wherein the sensor board is disposed downstream of the at least one flap.

7. The apparatus of claim 6, wherein in the at least one indicating position of the at least one flap, the at least one flap and the sensor board are arranged substantially parallel and adjacent to each other.

8. The apparatus of claim 1, further comprising a communication module configured to transmit the data wirelessly or through a wired connection from the at least one sensor to the processor.

9. The apparatus of claim 1, further comprising a power source configured to power the at least one sensor.

10. The apparatus of claim 1, wherein the apparatus is disposed at the downstream side of the filter media.

11. The apparatus of claim 10, further comprising a sensor housing configured to be removably coupled to the perimeter frame or the filter media and disposed at the downstream side of the filter media, wherein the sensor housing encloses the sensor board, the at least one flap, and the at least one sensor.

12. The apparatus of claim 11, wherein the sensor housing comprises at least one opening, wherein at least a portion of the airflow passing through the filter media enters into the sensor housing.

13. The apparatus of claim 1, wherein the at least one sensor is a capacitive sensor.

14. The apparatus of claim 13, wherein the at least one sensor is configured to detect a change in capacitance of the at least one flap due to the movement of the at least one flap between the at least one initial position and the at least one indicating position relative to the sensor board.

15. The apparatus of claim 1, wherein the first flap end is pivotally coupled to the sensor board, such that in response to the airflow through the apparatus, the at least one flap is pivotally movable between the at least one initial position and the at least one indicating position relative to the sensor board.

16. The apparatus of claim 1, wherein in response to the airflow through the apparatus, the at least one flap flexes or bends between the at least one initial position and the at least one indicating position relative to the sensor board.

17. The apparatus of claim 1, wherein the first flap end is coupled to the sensor board proximate to the first board end.

18. An air filter assembly comprising:an air filter comprising a perimeter frame and a filter media placed within the perimeter frame, the filter media being configured to be disposed in an airflow such that at least a portion of the airflow passes through the filter media, the filter media comprising an upstream side and a downstream side; andthe apparatus of claim 1 for monitoring a performance of the air filter, wherein the apparatus is configured to be coupled to the perimeter frame or the filter media.

19. The air filter assembly of claim 18, wherein the apparatus is disposed at the downstream side of the filter media.

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