Filter-Fan Unit

[0001] The invention relates to a filter-fan unit comprising a housing in which at least one fan is arranged and which comprises at least one filter.

[0002] Filter-fan units have a housing made from sheet metal or plastic material in which the fan, optionally a soundproofing device and/or at least one suspended particle filter are installed fixedly. The filter-fan units are rigid and are transported in their assembled state and size, mounted on a filter or mounted, including the filter, in a ceiling grid. For mounting a unit that has a square contour from the cleanroom side, the ceiling has profiled section with insertion strips because the unit when it has a certain height can no longer be pushed diagonally through the opening of the ceiling grid. Storing and transporting such filter-fan units is complex and expensive because of the large size. In particular, the space required for storage and transport is significant.

[0003] It is an object of the present invention to configure a filter-fan unit of the aforementioned kind such that it can be easily stored and/or transported and/or mounted.

[0004] In accordance with the present invention, this is achieved in that the housing can be transferred from a transport/storage position having a small size into a position of used having a large size.

[0005] In the filter-fan unit according to the invention, the housing can have a small size during transport and/or when stored. At the site where the filter-fan unit is to be mounted, the housing is transferred from the transport/storage position into a position of use. In the position of use the housing has its final predetermined size. The housing of the filter-fan unit is thus no rigid component but has a foldable or collapsible construction that can be comprised of different materials, for example, sheet metal, plastic material, fabric and the like. Since the housing can be transferred into a small size for transport and/storage, the filter-fan unit requires only a small space. Once delivered to the site where it is to be installed, the housing is transferred into the large final size. Accordingly, the housing can be unfolded, for example, once it is located in the cleanroom or the supply air plenum, the open edges can be connected and the filter-fan unit formed in this way can be placed onto the filter. Likewise, mounting of the fan can also be realized in the cleanroom or the supply air plenum.

[0006] The filter-fan unit can have the soundproofing elements that obtain their full size and efficiency only upon unfolding of the housing. Such sound-proofing elements can be, for example, open-pore foam material, micro-porous films and the like.

[0007] In a first embodiment, the filter, the housing, and the fan each are an independent component whose housing can be, for example, folded or collapsed. However, it is also possible that the filter and the housing together form a module and that the fan is a separate component. It is also possible that the housing and the fan together form a module and that the filter is a separate component. Finally, the filter, the housing, and the fan can formed a module.

[0008] Since the housing can be folded or collapsed to a small size (to a size or height much smaller or significantly smaller than the housing in its position of use—theoretically it can be reduced to a height that corresponds to the thickness of the sidewalls and the housing frame or the lid), a very small transport/storage size results. When filter and housing form a module, during transport and/or storage the size of the module is not larger than that of the filter or only insignificantly larger. Advantageously, the housing can be folded to be flat. The housing can be combined with filters of different manufacturers.

[0009] In contrast to known filter-fan units, an inventive filter-fan unit having a square contour can be mounted from the cleanroom side without requiring insertion strips. This is so because the housing when in the flat, folded or collapsed state can be pushed diagonally through the opening in the ceiling grid.

[0010] Each component of the filter-fan unit, i.e., the filter, the housing, and the fan can be delivered separately to the construction site. Intermediate transports, for example, transporting the fan to the manufacturer of the housing, are not required. Also, the required space during installation in the cleanroom at the customer site is significantly reduced because of the configuration in accordance with the invention. Also, the installation, in particular, in cleanrooms with high ceilings is significantly simplified because of the reduced size of the collapsed housing.

[0011] The housing can be produced from any suitable material, for example, sheet metal, plastic material or fabric in particular flame resistant canvas material.

[0012] When the housing walls are supported in a pivotable way, it is possible to employ weakened portions in the material as predetermined bending locations, hinges or strap hinges as a pivotable connection. When the housing is made from fabric, it is possible to connect the tailored sections of the fabric by means of a zipper or a hook-and-loop fastener.

[0013] The connection of the fan or the fan unit and the housing can be realized in any suitable way, for example, by placing the fan unit onto an angled portion of the housing wall, by gluing with a double-sided adhesive tape or, for example, by connecting with snap-fit closures.

[0014] FIG. 1 is a schematic side view illustration of a folded housing of a filter-fan unit according to the invention.

[0015] FIG. 2 is a schematic illustration of a suspended particle filter of the filter-fan unit according to the invention.

[0016] FIG. 3 is a plan view onto the folded housing according to FIG. 1.

[0017] FIG. 4 is a schematic illustration of a fan insert of the filter-fan unit according to the invention.

[0018] FIG. 5 shows the housing according to FIG. 1 in the unfolded state.

[0019] FIG. 6 shows the suspended particle filter according to FIG. 2.

[0020] FIG. 7 is a plan view of the unfolded housing according to FIG. 5.

[0021] FIG. 8 shows a side view of the mounted filter-fan un it with unfolded housing, the suspended particle filter, and the inserted fan insert.

[0022] FIG. 9 shows the filter-fan unit according to FIG. 8 in a plan view.

[0023] FIG. 10 is a side view showing schematically a second embodiment of a suspended particle filter of the filter-fan unit according to the invention.

[0024] FIG. 11 is a plan view of a second embodiment of a filter-fan unit according to the invention showing the folded housing in which the filter insert is mounted.

[0025] FIG. 12 is a side view of the folded housing with fan insert according to FIG. 11.

[0026] FIG. 13 shows the unfolded housing with fan insert.

[0027] FIG. 14 is a plan view onto the unfolded housing according to FIG. 13.

[0028] FIG. 15 is a side view of the finish-mounted filter-fan unit with attached suspended particle filter.

[0029] FIG. 16 is a plan view onto the filter-fan unit according to FIG. 15.

[0030] FIG. 17 is a side view of a fan insert of a further embodiment of a filter-fan unit according to the invention.

[0031] FIG. 18 is a schematic side view illustration of a further embodiment of the filter-fan unit according to the invention showing a folded housing that is provided on a suspended particle filter.

[0032] FIG. 19 is a plan view onto the folded housing according to FIG. 18.

[0033] FIG. 20 shows the unfolded housing of FIG. 18.

[0034] FIG. 21 shows a plan view onto the unfolded housing according to FIG. 20.

[0035] FIG. 22 is a schematic side view illustration of another embodiment of the filter-fan unit according to the invention showing an unfolded housing that is provided on a suspended particle filter

[0036] FIG. 23 shows the filter-fan unit according to FIG. 22 in a plan view.

[0037] FIG. 24 is a plan view onto a further embodiment of a folded housing of a filter-fan unit according to the invention.

[0038] FIG. 25 is a side view of the folded housing according to FIG. 24.

[0039] FIG. 26 is an end view of the folded housing according to FIG. 24.

[0040] FIG. 27 shows the folded housing according to FIG. 24 in which the folded sidewalls are folded down.

[0041] FIG. 28 shows the housing according to FIG. 24 in which the folded-down sidewalls are unfolded.

[0042] FIG. 29 is a representation in accordance with FIG. 28 showing a further step of unfolding the sidewalls of the housing.

[0043] FIG. 30 shows the completely unfolded sidewalls of the housing.

[0044] FIG. 31 shows the insertion of a connector for connecting the unfolded sidewalls of the housing.

[0045] FIG. 32 shows the housing according to FIG. 31 with the lid in the closed position.

[0046] FIG. 33 is a schematic side view illustration of the folded state of the housing of another embodiment of the filter-fan unit according to the invention.

[0047] FIG. 34 shows a reinforcement element of the housing according to FIG. 33.

[0048] FIG. 35 is a plan view onto the housing according to FIG. 33.

[0049] FIG. 36 shows the unfolded housing according to FIG. 33 in a side view.

[0050] FIG. 37 shows a section along the section line XXXVII-XXXII of FIG. 36.

[0051] FIG. 38 is a plan view onto the housing according to FIG. 36.

[0052] FIG. 39 show a first pivot connection between neighboring housing sidewalls.

[0053] FIG. 40 shows a second pivot connection between neighboring housing sidewalls.

[0054] FIG. 41 shows a third pivot connection between neighboring housing sidewalls.

[0055] FIG. 42 shows a fourth pivot connection between neighboring housing sidewalls.

[0056] Filter-fan units are used advantageously in clean rooms in the ceiling area. The filter-fan units are comprised essentially of three components, i.e., at least one fan 1, at least one suspended particle filter 2, and a housing 3. The suspended particle filter 2 is preferably a HEPA filter (High Efficiency Particulate Air) but can also be any other suitable filter in accordance with the specific requirements of the application. The filter-fan units according to FIGS. 1 through 9 are characterized in that the housing 3 can be folded (FIGS. 1 and 3). The housing 3 therefore requires little space during transport. The housing 3 is unfolded once at the site where it is to be installed. Thereafter, the fan 1 and the suspended particle filter 2 are mounted on the unfolded housing 3. Since the housing 3 is foldable or collapsible, it requires only very little space during transport.

[0057] In the embodiment according to FIGS. 1 through 9, the housing 3 has four sidewalls 4 to 7 that are positioned at a right angle to one another. The housing sidewalls 4, 5, 6, 7 each are trapezoidal in shape and have the same size. As shown in FIG. 1, the sidewalls 4, 5, 6, 7 are provided at their inner side or face with a soundproofing layer 8 that is advantageously comprised of an open-pore foam material.

[0058] The sidewalls 4 through 7 are connected to a narrow circumferential rim 9 having a height that corresponds approximately to the thickness of the soundproofing layer 8. The circumferential rim 9 projects at a right angle from the bottom housing frame 10 that has a square contour, for example.

[0059] As shown in FIG. 3, the sidewalls 4 through 7 taper in a direction away from the rim 9 so that in the folded state the free edges 11 through 14 are spaced from one another. In order to complete the filter-fan unit, first the housing 3 is unfolded such that the sidewalls 4 to 7 are positioned with their slanted lateral edges against one another (FIG. 7). The adjoining lateral edges of the sidewalls 4 to 7 are connected in a suitable way fixedly and tightly to one another. The sidewalls 4 to 7 are positioned at an acute angle relative to the rim 9 of the housing 3 and converge starting at the rim 9. Because the soundproofing layers 8 are attached to the inner side of the sidewalls 4 through 7, the soundproofing layers 8 are moved into their final mounted position when folding upwardly the sidewalls 4 to 7. The housing 3 in the unfolded state has the shape of a square pyramid. The free edges 11 through 14 of the sidewalls 4 through 7 delimit in the illustrated embodiment a square mounting opening 15 into which the fan 1 can be inserted. The fan 1 is part of a fan insert 16 that has a baseplate 17 on which the fan 1 is mounted in a way known in the art. The baseplate 17 is connected by means of vertical supports 18 to a mounting plate 19 that is connected to the free edges 11 to 14 of the sidewalls 4 to 7 with its edge 20, as shown in FIG. 8. The mounting plate 19 has a central opening 21 through which the fan 1 sucks in air. The mounting plate 19 is advantageously connected with its edge 20 air-tightly to the housing 3 so that the clean air which is sucked in by the fan 1 can flow out only through the filter 2.

[0060] At the bottom side of the unfolded housing 3 the suspended particle filter 2 is mounted. The filter 2 has a circumferential filter frame 22 that projects upwardly past the suspended particle filter 2 and is connected with this projecting part to the rim 9 of the housing 3.

[0061] The collapsible housing 3 can be comprised of sheet metal or a suitable plastic material. The plastic material can be polyamide, polyethylene, polypropylene, or polyvinyl chloride as a thermoplastic material. It is also possible to employ a thermosetting material, for example, polyester or polyurethane. Finally, it is also possible to produce the housing, for example, from epoxy resin, polyester resin, Styrofoam® (polystyrene), Macrolon® (polycarbonate), acrylic glass, and the like. The housing 3 has in any case a sufficient stability and strength in order to support the fan insert 16 and the suspended particle filter 2.

[0062] The pivot connection between the sidewalls 4 to 7 and the rim 9 can be designed in different ways. Examples of different configurations will be explained in more detail in connection with FIGS. 39 to 42.

[0063] FIGS. 10 through 16 show a fan unit in which the foldable housing 3 is attached already to the mounting plate 19 of the fan insert 16. After folding out the sidewalls 4 to 7 of the housing 3, it is no longer necessary to connect the fan insert 16 in a separate working step to the housing 3. The sidewalls 4 to 7, in contrast to the preceding embodiment, are rectangular in shape (FIG. 11) and extend between the oppositely positioned parallel extending circumferential edges 23, 24, 25, 26 of a housing lid 27 (compare FIGS. 11 and 14). The lid 27 is of a plane configuration and has in the illustrated embodiment approximately a square contour. It is centrally provided with a mounting opening 28 for the fan insert 16. The mounting plate 19 of the fan insert 16 is attached to the edge of the mounting opening 28 in a way known in the art.

[0064] In the folded state, the sidewalls 4 to 7 rests against the housing lid 27 and are pivotably connected to the edge 26 of the lid 27.

[0065] FIG. 13 shows the situation when the sidewalls 4 to 7 are folded down. The bottom edges of the sidewalls 4 to 7 are connected to the projecting edge of the filter frame 22. As shown in FIG. 15, the upwardly projecting edge of the filter frame 22 extends past the bottom edges of the sidewalls 4 to 7. It is also possible that the bottom edges of the sidewalls 4 to 7 are positioned outwardly relative to the upwardly projecting edge of the filter frame 22. The filter frame 22 and the sidewalls 4 to 7 can be connected to one another in a suitable way so as to be airtight.

[0066] Advantageously, in the area between the sidewalls 4 to 7 and the lid 27 a micro-porous film 29 is provided as a sound-proofing element. Upon folding out the housing 3, the film 29 is moved into a stretched position as illustrated in FIG. 15.

[0067] The filter-fan unit according to FIG. 17 to 23 is similar to the embodiment according to FIGS. 1 through 9. The difference is that the sidewalls 4 to 7 are connected to the projecting edge of the filter frame 22. The folded housing 3 and the suspended particle filter 2 thus form a module. The sidewalls 4 to 7 are folded onto the suspended particle filter 2 (FIG. 18) so that this module comprised of housing 3 and suspended particle filter 2 requires only minimal space during transport. For completing the filter-fan units, the sidewalls 4 to 7 are folded upwardly and are connected fixedly to one another at their edges. The free edges 11 to 14 of the trapezoidal sidewalls 4 to 7 define the mounting opening 15 (FIG. 21) for the fan insert 16 (FIG. 17). The fan insert 16 is connected with its mounting plate 19 in the way described in connection with FIGS. 1 through 9 to the unfolded housing 3. In this embodiment, the suspended particle filter 2 must not be mounted separately so that the installation of the filter-fan unit is possible in a simple and quick way. Since the sidewalls 4 to 7 of the housing 3 are folded onto the suspended particle filter 2, the module of suspended particle filter 2 and folded housing 3 requires only minimal space.

[0068] With the aid of FIGS. 24 to 32 a housing 3 is described whose sidewalls 4 to 7 have a rectangular cross-section (FIG. 30). The housing 3 has a lid 30 that has a rectangular contour. At the longitudinal bottom edge of the lid 31 illustrated in FIG. 24 the sidewalls 4 to 7 are pivotably connected and, in turn, are pivotably connected to one another and are placed on top one another. The height of the sidewalls 4 to 7 is smaller than the width of the lid 30.

[0069] In order to build the housing 3, the folded sidewalls 4 to 7 are first folded about the longitudinal edge 31 of the lid 30 (compare FIG. 24 and FIG. 27). Subsequently, the sidewalls 4 and 5 resting against one another are folded outwardly (FIG. 28). The sidewall 4 is connected with one narrow side 32 to the narrow side 33 of the sidewalls 7 that is hidden from view in FIG. 28. To the other narrow side 34 of the sidewall 4, the narrow side 35 of the sidewall 5 is connected in a pivotable way (compare FIG. 28 and FIG. 29). This sidewall 5, as illustrated in FIG. 29, is then folded about the lateral edges 34, 35. The sidewall 6 is connected with its narrow side 36 to the narrow side 37 of the sidewall 7 in a pivotable way. The sidewall 6 is unfolded finally about pivot axis 36, 37 (FIG. 30). By means of a connecting member 38 (FIG. 38) that is embodied as an angle member, the neighboring narrow sides 39, 40 of the sidewalls 5, 6 are tightly connected to one another.

[0070] The lid 30 has a prependicularly projecting rim 30a which extends along three sides of the lid 30. Only at the longitudinal side 31 where the sidewall 7 is pivotably attached the rim 30a is not provided. When the housing 3 is in the folded state, the sidewalls 4 to 7 that are folded onto one another are located within the rim 30a. The rim 30a is advantageously only so tall that the folded sidewalls 4 to 7 do not project or project only slightly past the rim 30a. It is advantageous that the rim 30a has approximately the same height as the thickness of the folded sidewalls 4 through 7. When the lid 30 is closed (FIG. 32) the rim 30a projects past the upper longitudinal edge of the sidewalls 4 to 6. As shown in FIG. 32, the longitudinal edge 31 serving as the pivot axis is positioned at the level of the free edge of the lid rim 30a. In the lid 30 there is centrally a mounting opening 28 that has a rectangular contour in the illustrated embodiment but, depending on the configuration of the fan insert 16, can also have different contour shapes. The fan insert 16 is mounted in the mounting opening 28 of the housing 3 according to FIG. 32. Subsequently, the housing 3 that is open in the downward direction is placed onto the suspended particle filter 2 and is fixedly connected thereto. The suspended particle filter 2 closes off the bottom side of the housing 3.

[0071] The housing according to FIGS. 33 to 35 has a shape-stable housing frame 41 with an angled circumferential rim 41a. The housing 3 is attached to the rim 41a. The housing is comprised of a fabric 42 that is flame resistant. As a reinforcement, centrally within the fabric a rectangular reinforcement frame 43 is attached into which the fan insert 16 is inserted.

[0072] In order for the housing 3 that is made from fabric to keep its shape, profiled sections 44 are provided as reinforcement. They are arranged in the corner areas of the housing frame 41 in such a way that the fabric will keep taut the unfolded housing 3. On the inner side of the fabric 42 along the seams 45 (FIG. 38) receptacles 46 for the reinforcing profiled sections 44 are provided. The receptacles 46 can extend across the entire length of the seams 45 but can also be arranged along the seams at a spacing from one another. The reinforcing profiled sections 44 are, for example, round elastically bendable rods that are supported with their first end in receptacles (not illustrated) in the corner area of the housing frame 41 and with their second end in receptacles in the corner area of the reinforcement frame 43. The fabric 42 is tailored such that the rods 44 are bent about their length when they are positioned with their ends in the receptacles of the two frames 41, 43. The fabric 42, as shown in FIG. 36, is curved outwardly and is kept in a stretched position.

[0073] The fabric 42 forming the housing is comprised advantageously of four trapezoidal tailored sections 47 to 50 which are connected to one another at their abutting edges by seams 45. The seams 45 can be formed also by a zipper or by a hook-and-loop fastener.

[0074] FIGS. 39 to 42 finally show possible configurations of the pivot connections as they are provided in all disclosed embodiments.

[0075] FIG. 39 shows that the parts to be pivotably connected to one another are connected by a hinge 51 in a pivotable way. As is known in the art, the hinge fittings 52, 53 are attached to the parts that are pivotable relative to one another. The pivot direction is indicated by arrow 54.

[0076] FIG. 40 shows the possibility of providing the pivot connection 55 by a portion of reduced or weakened material between the parts to be pivoted relative to one another. This portion of reduced material thickness forms a predetermined bending location.

[0077] FIG. 41 shows the possibility of providing on the parts to be pivotable relative to one another shaped pivot elements 56, 57 that are curved approximately like a part of a circle and that engage one another. The shaped pivot elements 56, 57 are attached to the end faces of the corresponding parts that are pivotable relative to one another and can extend about the entire length of these end faces. It is also possible to provide individual pivot elements across the length of the end faces. The pivot elements 56, 57 engage one another in such a way that in the pivot direction they cannot be detached from one another. The two parts that are pivotably connected to one another can be detached from one another only by sliding in the direction of the pivot axis. As is shown in FIG. 41, the pivot elements 56, 57 are curved in such a way that their free ends engage or mesh with one another and their curved areas 58, 59 rest against the respective neighboring part to be pivoted when they are in the parallel position illustrated in FIG. 41.

[0078] FIG. 42 finally shows the possibility of connecting the two parts pivotable relative to one another by a profiled section 60 that has the shape of an H. The two parts to be connected to one another project into the profiled section and are separated from one another by the transverse web 61 of the profiled section 60. The profiled section 60 extends also advantageously across the length of the corresponding edges of the parts to be connected.

[0079] In the described embodiments, the different parts can be connected to one another at their abutting locations in ways known in the art.

[0080] The specification incorporates by reference the entire is closure of German priority document 10 2005 062 523.1 having a filing date of 19 Dec. 2005.

[0081] While specific embodiments of the invention have been shown and described in detail to illustrate the inventive principles, it will be understood that the invention may be embodied otherwise without departing from such principles.