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A collapsible HVAC filter that includes a pleated filter media pack with ends that attach to ends of a planar filter frame member. The structure collapses by folding the filter frame member along score lines and compressing the pleated filter media while the media and frame member are attached. The

A collapsible HVAC filter that includes a pleated filter media pack with ends that attach to ends of a planar filter frame member. The structure collapses by folding the filter frame member along score lines and compressing the pleated filter media while the media and frame member are attached. The collapsed components occupy little space relative to the expanded filter, and can be expanded to form a completed filter with little effort required by the end user. Most of the filter media is collapsed in a generally U-shaped channel formed from the folded filter frame member.

대표청구항 ▼

1. A collapsible air filter comprising: (a) an air filter media assembly comprising a plurality of generally rectangular panels interconnected together in a pleated configuration with each panel connecting to at least one adjacent panel at longitudinal panel edges, wherein one of the plurality of ge

1. A collapsible air filter comprising: (a) an air filter media assembly comprising a plurality of generally rectangular panels interconnected together in a pleated configuration with each panel connecting to at least one adjacent panel at longitudinal panel edges, wherein one of the plurality of generally rectangular panels is a first filter media end panel located at a first end of the filter media and another of the plurality of generally rectangular panels is a second filter media end panel located at a second end of the filter media, wherein the first end of the filter media is opposite from the second end of the filter media;(b) a filter frame member comprising first and second side walls and first and second end walls, each first and second side wall being connected to each first and second end wall to form a generally rectangular structure with a central area formed in the center of the generally rectangular structure, wherein the central area comprises at least one opening formed therein(c) wherein the filter media is attached to the filter frame member thereby forming the collapsible air filter, wherein the attachment of the filter frame member with the filter media comprises the first filter media end panel being mounted to the first end wall while the second filter media end panel is mounted to the second end wall, wherein the filter media is not adhered to the central area of the filter frame member and wherein the filter media is not adhered to the first and second side panels; and(d) the collapsible air filter comprises a collapsed condition and an expanded condition, wherein when the collapsible air filter is in the expanded condition the first sidewall, the second sidewall, the first end wall and the second end wall are foldable to positions angled to the central area and wherein when the collapsible air filter is in the collapsed condition the filter frame member and the air filter media are foldable in a generally pleated configuration. 2. The air filter in accordance with claim 1, further comprising a plurality of score lines extending laterally across the filter frame member to define hinge points for the filter frame member to fold along when the filter frame member is folded along with the pleated air filter media to the collapsed condition. 3. The air filter in accordance with claim 2, wherein, when the filter frame member is folded to the collapsed condition, a U-shaped channel is formed in which a majority of the panels of the pleated air filter media assembly are retained. 4. The air filter in accordance with claim 3, further comprising a second filter frame member configured to mount to the filter frame member, wherein the second filter frame member comprises first and second side portions and first and second end portions, wherein each of the first and second side portions is connected to each of the first and second end portions to form a generally rectangular portion with a central portion formed in the center of the generally rectangular portion, wherein the central portion comprises at least one open area formed therein, and wherein the first end portion, the second end portion, the first side portion and the second side portion are foldable to positions angled to the central portion, and wherein the second filter frame member being foldable to a collapsed condition. 5. The air filter in accordance with claim 3, wherein the filter frame member further comprises a plurality of frame panels wherein the frame panels extend from the first and second end walls and the first and second side walls, the frame panels being foldable over lateral and longitudinal edges of the pleated air filter media assembly when the collapsible air filter is in the expanded condition. 6. The air filter in accordance with claim 4, further comprising a guide mounted to one of the side portions to engage a filter mounting system. 7. A collapsed air filter comprising: (a) an filter media assembly comprising a plurality of generally rectangular panels interconnected together in a pleated configuration with each panel connecting to at least one adjacent panel at longitudinal panel edges, wherein one of the plurality of generally rectangular panels is a first filter media end panel located at a first end of the filter media and another of the plurality of generally rectangular panels is a second filter media end panel located at a second end of the filter media, wherein the first end of the filter media is opposite from the second end of the filter media;(b) a filter frame member comprising first and second side walls and first and second end walls, each first and second side wall being connected to each first and second end wall with a central area formed therebetween, wherein the central area comprises at least one opening formed therein, the filter frame member having a plurality of substantially parallel score lines extending laterally across the filter frame member to define hinge points for the filter frame member to fold along; and(c) wherein the filter media is attached to the filter frame member thereby forming the collapsible air filter, wherein the attachment of the filter frame member to the filter media comprises the first filter media end panel being mounted to the first end wall while the second filter media end panel is mounted to the second end wall, wherein the filter media is not adhered to the central area of the filter frame member and wherein the filter media is not adhered to the first and second side panels;(d) the collapsed air filter comprises a collapsed condition, wherein when the collapsed air filter is in the collapsed condition, the filter frame member is folded along the hinge points such that the filter frame member and the air filter media are foldable in a generally pleated configuration and wherein when the collapsed air filter is in the collapsed position, a U-shaped channel is formed in the filter frame member such that a maioritv of the panels are retained in the U-shaped channel. 8. The air filter in accordance with claim 7, further comprising a second filter frame member configured to mount to the filter frame member wherein the second filter frame member comprises first and second side portions and first and second end portions, wherein each of the first and second side portions is connected to each of the first and second end portions with a central portion formed therebetween, wherein the central portion comprises at least one open area formed therein, and wherein the first end portion, the second end portion, the first side portion and the second side portion are foldable to positions angled to the central portion, and wherein the second filter frame member being foldable to a collapsed condition. 9. The air filter in accordance with claim 7, wherein the filter frame member further comprises a plurality of frame panels wherein the frame panels extend from the first and second end walls and the first and second side walls, the frame panels being foldable over lateral and longitudinal edges of the pleated air filter media assembly to positions angled to the central area when the collapsible air filter is in the expanded condition. 10. The air filter in accordance with claim 8, further comprising a guide mounted to one of the side portions to engage a filter mounting system. 11. A method of making an air filter comprising the steps of: (a) providing an air filter media assembly comprising a plurality of generally rectangular panels interconnected together in a pleated configuration with each panel connecting to at least one adjacent panel at longitudinal panel edges, wherein one of the plurality of generally rectangular panels is a first filter media end panel located at a first end of the filter media and another of the plurality of generally rectangular panels is a second filter media end panel located at a second end of the filter media, wherein the first end of the filter media is opposite from the second end of the filter media;(b) attaching the filter media to a filter frame member, the filter frame member comprising first and second side walls and first and second end walls, each first and second side wall being connected to each first and second end wall to form a generally rectangular structure with a central area formed in the center of the generally rectangular structure wherein the central area comprises at least one opening formed therein, wherein the first filter media end panel is mounted to the first end wall and the second filter media end panel is mounted to the second end wall, wherein the filter media is neither adhered to the central area of the filter frame member nor to the first and second side panels;(c) folding the filter frame member, along a plurality of substantially parallel score lines extending laterally across the filter frame member blank to define hinge points, to a collapsed condition in which a U-shaped channel is formed in the filter frame member; and(d) collapsing the filter media and disposing a majority of the panels of the filter media in the U-shaped channel, wherein when the collapsible air filter is in the collapsed condition the filter frame member and the air filter media are folded in a generally pleated configuration. 12. The method in accordance with claim 11, further comprising simultaneously elongating the filter frame member and the filter media while maintaining the first filter media end panel mounted to the first end wall and the second filter media end panel mounted to the second end wall. 13. The method in accordance with claim 12, further comprising folding frame panels, extending from the end walls and the side walls of the filter frame member, over lateral and longitudinal edges of the filter media to positions angled to the central area after the filter frame member and the filter media are elongated. 14. A collapsible air filter comprising: (a) an air filter media assembly comprising a plurality of generally rectangular panels interconnected together in a pleated configuration with each panel connecting to at least one adjacent panel at longitudinal panel edges, wherein one of the plurality of generally rectangular panels is a first filter media end panel located at a first end of the filter media and another of the plurality of generally rectangular panels is a second filter media end panel located at a second end of the filter media, wherein the first end of the filter media is opposite from the second end of the filter media;(b) a filter frame member comprising first and second side walls and first and second end walls, each first and second side wall being connected to each first and second end wall to form a generally rectangular structure with a central area formed in the center of the generally rectangular structure, wherein the central area comprises at least one opening formed therein;(c) wherein the filter media is attached to the filter frame member thereby forming the collapsible air filter, wherein the attachment of the filter frame member with the filter media comprises the first filter media end panel being mounted to the first end wall while the second filter media end panel is mounted to the second end wall, wherein the filter media is not adhered to the central area of the filter frame member and wherein the filter media is not adhered to the first and second side panels; and(d) the collapsible air filter comprises a collapsed condition and an expanded condition, wherein when the collapsible air filter is in the expanded condition the first sidewall, the second sidewall, the first end wall and the second end wall are foldable to positions angled to the central area and wherein when the collapsible air filter is in the collapsed condition the filter frame member and the air filter media are foldable in a generally pleated configuration.