WO2013134048A1

WO2013134048A1 - Replacement cartridge filter with pleated filter media and method of adhering a filter material for same

Info

Publication number: WO2013134048A1
Application number: PCT/US2013/028474
Authority: WO
Inventors: Challen Sullivan
Original assignee: Individual
Current assignee: Individual
Priority date: 2012-02-29
Filing date: 2013-02-28
Publication date: 2013-09-12
Anticipated expiration: 2014-08-29

Description

REPLACEMENT CARTRIDGE FILTER WITH PLEATED FILTER

MEDIA AND METHOD OF ADHERING A FILTER MATERIAL FOR

SAME

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. provisional application 61/604,523 filed February 29, 2012 and U.S. patent application 13/524,928 filed June 15, 2012, which are incorporated herein by reference.

BACKGROUND OF THE INVENTION

The invention is directed to a gas or liquid agent filter, in an exemplary embodiment having a cartridge replaceable media. The housing can have a standard width for such filters so as to be a replacement for existing standard filters and future filters or as a pre-filter or may be OEM specified. The housing can contain a movement member, a motor, a power source, a controller and a filter media cartridge in a non-limiting example. The exemplary product strives to be both directly replaceable with a filter and disposable with minimum modification to existing equipment and minimum environmental impact. The replacement filter exemplary embodiment being further located within a flow channel in the filter unit wherein the agents being filtered are passed within the flow channel and passed through the filter media. The replacement filter having a compacted or stored portion of the filter media that is removed as an at least one filter media stack out to replace the initial and subsequent sections of filter media being exposed by the invention to agent within the filter unit. This stack or set of stacks being replaceable in and of themselves as a pre-folded, pre pleated, filter media cartridge system. Additional aspects of the invention include remote monitoring and communication with the filtration unit, enabling monitoring and alert for replacement of the filter. Additionally, the filtration unit may be enabled to monitor and communicate flow qualities, including for instance contaminants, and to take further actions in response to alerts sent through a network.

Additionally the invention is also directed to a method of adhering a pleated filtration media so that the media has a specified pleat spacing and can be selectively deployed from a folded, stored state and placed in an operational state. In an exemplary embodiment this media is formed into a cartridge for use in filters, like those described herein and in related patents owned by the applicant. The invention is further directed to an exemplary embodiment as article of manufacture being a filtration media stack having adhered pleats at a specific spacing such that the filter media in the stack may be selectively removed from the stack and deployed in as part of a filtration operation.

Background of the Invention

An important component in almost all filtration units in general is a filtration mechanism with filter media for removal of particulates and contaminants from the flow of the agent. In Heating Ventilation and Air Conditioning systems (HVAC), for instance, this is preferably before or sometimes after or even both before and after coming into contact with heat exchanging elements. The removal of the contaminants helps prevent reduction in heat transfer associated with accumulation of the contaminants on the heat exchanger elements. Additionally, the removal of these contaminants also improves the quality of the air circulated by the HVAC air handling system. Similarly, in computers, filtration of air used for cooling the electronic elements requires filtration before coming into contact with the electronic elements. Similarly, in pools, the water in the pools requires filtration before being returned to the pool by a circulating system. In some pool systems further filtration is required before chlorination of the pool water. In a host of other industrial and commercial applications, effective media filtration is necessary. The timing for replacing or renewing these filtration mechanisms is therefore important in both improving efficiency and reducing wear and tear in the filtration units and host components in most filtration applications.

In most systems a filter is used through which the media is passed. Dirty filter media result in lower flow rates of the agent in the system which translates to lower efficiency in filtration, especially in HVAC systems where it equates to less heat exchange in the HVAC equipment. The equipment must run longer to accomplish the intended goals, for example contaminant filtration and/or temperature control. In HVAC for instance, air conditioning equipment may freeze up due to such inefficiencies. Additionally, the motors and other components must run longer and harder resulting in increased wear on the entire system, reducing its useful life. Thus, the filtration systems require constant attention and maintenance. In commercial and industrial applications, it is often the case that the air handling functions are monitored by a control center and maintained based on performance measurements. For example, when utilizing multiple refrigeration units in chemical processing the timing and performance of the cooling units is often integral to the manufacturing process. Sometimes, upon determination by the controller or by a set schedule, the filters on such systems are replaced.

Similarly, in residential settings, many HVAC companies sell maintenance contracts to residential clients, typically annual or bi-annual in nature, to address routine maintenance. Similarly pool companies regularly inspect and change water filters in chlorination systems and even in home residential water units in the case of hard water softeners for instance. However the removable, replaceable filters that are typically in these units require more frequent replacement by these clients.

Filters for most residential and commercial air filtration and air handling equipment are typically removable, replaceable, rigid, framed units. Rigid framed filters can be time consuming to replace or clean and often require frequent replacement, typically monthly in the case of residential applications. This also requires an added amount of attention by an industrial or commercial maintenance staff in a commercial setting. For instance, in a commercial restaurant setting the restaurant owner or similar commercial customer must provide an even greater amount of attention to cleaning and/or replacing these types of filters. Often such maintenance is mandated by the municipality or state. Even with these requirements, the filters often go unchanged as users forget to change the filter regularly resulting in fines and sanctions. This shortfall has been well known and several attempts have been made in the past to provide long lasting filters. Several attempts have been made to provide a reel system, see for example US Patent Application No. 2006/0102006, Japanese Patent No. JP06233945, German Patent No. DE19654844 Al, US Patent Nos. 6168646, 4470833, 6152998, 4221576.

Though these have extended lengths of service, in each instance, the resulting device requires modification of the filtration unit or uses less efficient media shapes and sizes. This makes these existing devices impractical for easy use, installation and maintenance by a typical end user. For example, as seen in US Patent Nos. 6,152,998, 6,632,269, 6,491,735, 6,402,822, and 6,743,282 and the commercially available OPTIMAIR system, often the reels are located outside the unit and are located in a reel storage area that does not easily fit within the confines of the existing filter system and is not easily scalable. This also prevents replacement of the existing filter with these types of units as the footprints are completely different and these systems are not replacements for the existing filter or an effective filter or pre-filter with pleated, replaceable media...

Other commercial applications use sheets that are stretched between rolls on either side of an air duct, see for example U.S. Patent 6,632,269 to Najm, 4,331,576 to Phillips Jr., or U.S. Patent 6,152,998 to Taylor. In each embodiment, significant modifications to the HVAC or cooling system would need to be made to install the devices or they use a nonstandard footprint. The systems do not provide retrofitting the filter structure to existing HVAC equipment and moreover, they require significant installation steps as outlined above with respect to residential units that operate in a similar manner.

Additional attempts have been made to address the issue in a commercial HVAC application, for instance U.S. Patent 7,186,290 to Sheehan. In U.S. Patent 7,186,290, a stack of filters is cycled through the device. This system requires a large amount of modification to incorporate into existing devices, as with other existing designs. Additionally, the stacks of stored filters require a significant amount of space in or around the HVAC unit. Thus, to fit existing systems requires either significant additional modifications or additional space to operate and provide extended use filter systems. Moreover, no economical method of providing a self-renewing or extended use filter within the standard footprint of the existing filter housings has been provided.

An exemplary replacement filter would be one that fits into existing filter footprints as defined by the OEM or incorporated in an OEM design. A uniform and industry standard width is provided in almost all residential and most commercial filters. Similarly, industrial applications, though often purpose built, have specific filter footprints after completion and replacement of these custom sizes is also contemplated. The filters shown in all of the above noted patents and publications require extensive modifications to fit in the place of the existing filters in these air handler and HVAC systems and lack the specified media stack. In addition, those systems do not provide for a media cartridge that provides for efficient removal and optionally sealing of the exposed media stack. The provision of a compacted, pleated, folded media stack as a cartridge provides for the most efficient shape for most applications. In addition the existing media solutions cannot be used to provide side sealing in conjunction with the filter nor do the cartridges fully isolate and seal once spent. Further the installation of the systems would require additional wiring and would likely require professional installation. Additionally, little or no communications are provided at the source of filtration; therefore, these systems cannot effectively communicate the status of the air being handled or enable the further communication with machinery, networks, or other devices.

To date, no commercially successful system has been produced for use in conventional filtration systems without modification or extending beyond the footprint provided for the replaceable filter. Moreover, no economical exemplary method of providing a self-renewing or extended use filter within the standard footprint of the existing filter housings and providing a compacted, pleated, folded filter media that can be expanded and then compacted again has been provided particularly with a side sealing solution. Additionally, no filter to date with such extended use and standard footprints exists that can both store and communicate fluid qualities through a sensor to a communications network and, based on that communication, prompt an alert to a user or control center.

Filtration as a field is also broadening daily. The need for effective filtration in everything from the air we breathe to the water we drink to the electronics we use daily, all these systems require filtration of a gas or liquid. Dirty filters result in lower flow rates which translate to lower efficiency in air filtration. It is often the case that the used filters require cleaning and/or replacement. A lack of maintenance of such filters means the equipment must run longer to accomplish the intended goals, resulting in increased energy usage. The timing for replacing or renewing these filtration mechanisms is therefore important in both improving efficiency and maintaining operational output in most filtration applications. Longer operational life is an important design parameter.

In addition, another important component in almost all filtration operations is balancing flow through the filter and effective removal of contaminants. To increase surface area while maintaining flow, many filters and filter media have adapted a pleated design to filter the flow. This maximizes the surface area for a given dimension. In providing an effective pleated filter media for a filtration operation, it is often the case that a specific density of pleats or pleat spacing or pleats per inch is desired. In existing filter designs, for instance in, but certainly not limited to, the Heating, Ventilation and Air Conditioning (HVAC) product space, a filter media is typically laid out and then hot glued to a static frame to fix the spacing. The static media remains adhered in the presence of the inflowing air and filters the particulates. Once the filter becomes sufficiently clogged with contaminants, it is replaced. In other non-limiting HVAC examples, methods exist to adhere media, especially high loft media which does not retain a "memory" to allow for easy pleating, in static application in a manner similar to the non-high loft media. The high loft material uses a wire mesh, plastic lattice or similar structure across the entirety of the material, giving it the ability to be shaped or formed. Similarly in other non-limiting examples, in water filtration for instance, a majority of pool filters have highly compact pleat spacing media for filtering contaminants and often have irregular filter shapes. These are often statically adhered to rubberized frames using non-reactive glues. The static designs are convenient, but the static media his results in shorter operational lifespans.

Examples of such static devices include a number of filters from major manufacturers like 3M, CLARCOR and similar producers. For example, 3M and CLARCOR produce a number of residential and commercial filters with pleated filter media. Such as 3M's FILTRETE or CLARCOR' s FRESH AIR SUPER AND EXTREME AIR PLUS filters. In most, in these filtration operations these filters are and remain static in nature. Extended lengths of operation for filters, which would reduce maintenance visits and thereby improve efficiency in the deployed filter, can be provided through non-static operation, e.g. movement of the filter media.

There does exist some non-static filters and designs, however these have been extremely limited and typically do not allow for the use of pleated media. Some examples of this types of non-static filters and filter operations include for example US Patent Nos. 7,186,290, 6,152,998, 6,632,269, 6,491,735, 6,402,822, 6,743,282, 6,632,269, 4,331,576, and. Patent 6,152,998. However, these typically do not utilize a pleated filter media, since movement of the media is difficult to accomplish in a consistent manner. Those that do are larger and more specialized, requiring machinery to complete changes and/or special installations which require additional costs and or maintenance and typically change an entire filter in frame. For instance, in U.S. Patent 7,186,290, a stack of filters is cycled through the device. While potentially convenient, the space taken up by this operation is prohibitive in most instances of filtration processes. A need exists for a more effective system of extending the life of a filter media and using the more efficient pleated filter media.

As noted, most existing filtration applications use a static pleated filter media due to difficulties in handling and moving the media, especially in moving the pleated media and maintaining pleat spacing and side sealing and/or pleat adhesion. When forming a non-static media or when a method of manufacture might benefit from compaction of the pleated filter media, special problems arise in the maintenance of the desired spacing. Additionally, due to the movement of non-static media in a filtration operation it is often also desirable to be able to afford some sealing of the sides of the filtration media to prevent leakage of the flow of gas or liquid being filtered that moves with the media. Further, any solution for securing a specific spacing while providing a means of sealing must also allow for the required selective engagement and movement from a stored to a deployed state in a non-static filtration operation.

To date no such pleated, adhered, spaced filter media is available. As such, a need exists for a method of adhering a pleated filter media to secure a desired spacing, provide sealing, and allow, in the cases of non-static applications, for movement of the media in a non-static filtration operation while providing the aforementioned sealing and spacing.

There is, therefore, a need for a method and apparatus for providing for a self-renewing or extended use filter for filtration applications that has a standard footprint that fits within existing commercial and residential apparatus on OEM designed specifications, provides extended useful life to the filter, requires little or no modification to install in existing equipment, facilitates and/or enhances communication of the air quality, communicates with other elements of the filter or a network, provides for replaceable media through a filter media stack cartridge, and has a minimal impact on the environment when discarded. Further, though the exemplary embodiments are shown for replacement air handler filters, in addition to air handlers and HVAC systems, the instant invention is adaptable to other filtration applications, some non-limiting examples being spray booths, computers, room and building air purification, gaming machines, clean rooms, electronics manufacturing, water filtration, pool and spa filtration, chemical and other liquid and gas filtration, and other applications utilizing filtration. A further need also exists for a device and article of manufacture wherein a length of media is adhered in such a fashion as to provide filtration media in a filtration operation that allows for the filter or filter media stack to secure a desired spacing in the pleated filter media, provide for sealing when the pleated filter media is deployed, and allow, in the cases of non-static applications, for movement of the media in a filtration operation.

SUMMARY OF THE INVENTION

An aspect of the invention is to provide an extended life replacement cartridge filter having pleated filter media that is moved and returned in a compact folded, pleated filter media stack.

A further aspect of the invention is provide an even further extended life replacement cartridge filter having a magazine cartridge storage area having several changes of material stored therein.

Yet another aspect of the invention is to provide a sealed replacement filter to minimize re-admission and exposure to the collected contaminants during operation and replacement, the spent filter being contained within the sealed housing unlike many roller systems which require removal or handling of the spent filter material, the instant invention minimizes this contact and the potential for readmission to the flow.

An aspect of the invention is to provide a compact, pleated, folded filter media stack provided in a cartridge and extended into the replacement filter from the compact, pleated, folded state to an extended state and then back to a compact, folded exposed filter media stack.

A further aspect of the invention is to seal the filter cartridge such that the filter media is extended from its compact stored state to a deployed state and back to its compact, folded, pleated state after exposure and sealed in the cartridge.

Yet another aspect of the invention is to provide a filter cartridge with a compact, pleated, folded filter media stack that moves to an expanded state and provides side sealing in the filter media.

A still further aspect of the instant invention is to provide a replacement filter having a pleated, folded filter media stack with a controller, the pleated filter media stack and the controller being in a housing and the pleated media filter being unfolded at its pleats in the flow channel. The controller moving the media within the housing over an extended period of time from a cartridge with the filter media stack, while the housing fits a standard width or footprint for an existing filter.

A still further aspect of the invention is to provide the filter media stack in an at least one replaceable cartridge, the at least one replaceable cartridge deploying the filter media stack so as to unfold the filter media stack, expose the unfolded filter media, and then restack the filter media so as to compact the filter media for removal and insertion of a new cartridge.

Yet another aspect of the invention is to provide measurement and reporting of the status or quality of the air being handled, with enhanced communications directly from the filter through sensors on the unit and provide communications with other devices or a network or both.

An aspect of the invention is to provide a method of applying an adhesive that will selectively adhere a pleated filter media in a folded/compacted state and allow for efficient removal from the folded compacted state while maintaining a desired pleat spacing and devices and articles of manufacture using same.

Yet another aspect of the invention is to provide a method of applying an adhesive that will selectively adhere a pleated high loft filter media in a folded/compacted state and allow for efficient removal from the folded compacted state while maintaining a desired pleat spacing while still adhering at least a portion of each pleat and devices and articles of manufacture using same.

A still further aspect of the instant invention is to provide is to provide a folded, pleated media stack having an adhesive that will selectively adhere the pleated filter media in a folded/compacted state and allow for efficient removal from the folded compacted state while maintaining a desired pleat spacing and adhering at least a portion of each pleat in the stack to prevent leakage of a media being filtered through the edges of the folded, pleated media stack when selectively removed and put in an operational position or state.

Yet another aspect of the invention is to provide improve the efficiency of the methods of formation of a folded, pleated media stack.

An aspect of the invention is to provide an adhered pleated filter media that improves manufacturing efficiency in both static and non-static filter production. A still further aspect of the invention is to improve spacing control in non-static pleated filter media movement.

Yet another aspect is to reduce costs of production and operation of existing filters through the use of consistent, controllable, spaced, and adhered filter media stacks.

Another aspect is to reduce the overall costs of deploying filter media by providing an efficient and movable pleated filter media stack and method of manufacturing and using same.

The invention includes an article of manufacture, an apparatus, a method for making the article, a method for using the article; an article of manufacture and a method of adhering a pleated filtration media, a filter, and media filter stack or cartridge using same.

The article of manufacture and apparatus of the invention includes a replacement filter within a flow channel having a first frame portion of an at least two frame portions. An at least one movement device is included with an at least one motor coupled to and driving the at least one movement device. An at least one power source powers the at least one motor. A controller is coupled to the motor. A least one filter media stack is provided having a filter media, the filter media being pleated and folded and compactly stored in the stack. A second frame portion of an at least two frame portions is also provided that couples with the first frame portion of the at least two frame portions forming a housing with an at least one exposure slot through which the fluid channel passes. The first and second frame portions of the at least two frame portions coupling such that the at least one movement member engages the at least one filter media cartridge stack in one of the at least two frame portions and the at least one member moves the filter media upon instruction from the controller from a pleated, folded and compact state to extend across the at least one exposure slot to expose the pleated and extended filter media to the flow and through the movement of the at least one movement member to remove exposed filter media and restack and store the exposed filter media in a media cartridge stack.

The movement member can further comprise an at least one of a cord, wire, string, track, puller or pinch rollers, star, toothed, or pin roller, screw drive, threaded rod, or a take-up roller. The movement member can also comprise an at least one threaded rod threaded rod and may further include an at least one sweep bar, where the threaded rod engages the sweep bar and moves the filter material and each of the at least one sweep bars, where each of the at least one sweep bars is spaced such that the bar separates a length of filter media that fills the space across the exposure slot.

The pleated and folded and compactly stored filter media can further include an adhesive element where the adhesive bond strength of the at least one adhesive element permits removal of the pleats from the folded, pleated filter media stack by a selective removal device such that an at least one portion of the pleats at the point of contact with the adhesive element may remain adhered.

The at least one movement device and the at least one motor can be contained within the first frame portion. The at least one filter media stack can be contained in the second frame portion. The filter media stack can be at one end of the housing in a storage area. The exposed filter media is stored in a containment area. The containment area can be sealed. The containment area can be at a further end of the housing.

The filter media can be drawn from the filter media stack into a storage area and stored in a compact, pleated, and folded fashion. The containment area can within the filter media stack, such that the filter material is drawn back into the filter media cartridge after exposure. The first and second of the at least two frame portions can be of uniform thickness. The first of the at least two frame portions can have channel portions. The second of the at least two frame portions can have leg portions that sliding engage the channel portions to couple the first frame portion and second frame portion of the at least two frame portions.

The filter media stack can include an at least one portion of filter media of sufficient length to provide sufficient unexposed filter to cross the exposure slot and become exposed filter media. The sensor can report a condition of the exposed portion of the filter media to the controller and the controller upon receipt of the condition determines if movement of the movement member moves an amount of unexposed media into the exposure slot to cover the exposure slot. The filter can include several spacers or sweep bars to divide several lengths of unexposed media which are stored and moved into the exposure slot based on commands from the controller.

The first frame portion of the at least two frame portions can be a cartridge with the filter media stack therein and the second frame portion of the at least two frame portions is a frame, wherein the filter cartridge is placed within the frame and engaged by the movement member. The frame can be constructed of stiffened cardboard or plastic or metal. The frame can contain the at least one motor with the at least one power source and the controller. The at least one cartridge can contain the at least one movement member. The at least one motor can be coupled to the at least one movement member through a coupling that penetrates through the exterior of the filter cartridge. An at least one securement coupling can be provided wherein with the insertion of the filter cartridge into the frame the at least one securement coupling secures the filter cartridge and engages the coupling.

The first frame portion of the at least two frame portions can further comprise a supply cartridge and the second frame portion of an at least two frame portions can further comprise a collection cartridge and a third frame portion of an at least two frame portions couples to the first and second portions to form the housing with the first and second portions of the at least two portions extending from the housing. An at least one securement can be provided coupling the supply cartridge and the collection cartridge to the housing. The at least one securement coupling cane be an at least one of an at least one releasable straps, snaps, buckles, interlocking parts slidingly engaged, clasps, and friction fit elements.

The filter media stack can extend in the supply cartridge in the same plane as the housing with a movement bar dividing the pleated, folded and stacked filter media stack. The media stack is advanced and a further media stack having a sweep bar can be pulled down from the supply cartridge. An at least one guide member can be provided to assist in advancing the exposed folded, pleated media into the collection cartridge. The media stack can be withdrawn into the collection cartridge and the sweep bar is driven along a single threaded shaft as a movement member in the middle of the housing and then upward onto a further guide member into the collection cartridge. The collection cartridge can be U-shaped, straight horizontal, vertically stacked, or s-shaped. The collection cartridge can be an angled collection cartridge. An at least one guide rail can be included in the collection cartridge. The guide rail can be a turning screw mechanism and assist in driving an at least one sweep bar. The movement member can be an auger screw on the collection cartridge side of the exposure slot and a star wheel indexer on the supply cartridge side of the exposure slot.

An at least one processing module and an at least one transceiver module can be provided on the controller and an at least one sensor can be included, the controller communicating with the at least one sensor, the at least one sensor communicating data to the processing module and the controller, and the transceiver module transmitting data from the filter to a network or a storage device. The at least one sensor can be coupled to the controller and sensing an at least on operating parameter for the filter. The at least one sensor can measure temperature, mold count, carbon monoxide, carbon dioxide, Volatile Organic Compounds (VOCs), smoke, fire, noxious gases, and air particle concentrations or the at least one sensor measures air flow and reports estimated energy consumption to the network or storage device. The controller can communicate through the transceiver module with a further network interface device. The network interface device can be a Wi-Fi enabled device or an internet gateway to a network which in turn reports it to an alert device or a Network Operations Center or control center.

The apparatus of the invention also includes a replacement filter deployed within a flow channel having a housing with a first frame member of an at least two frame members and a second frame member of an at least two frame members that are detachable with an at least one exposure slot formed within the housing by the at least two frame members. An at least one filter media storage area is within the housing, having unexposed, folded, pleated filter media stored therein, the unexposed folded, pleated filter media being pleated, folded, and stacked to be compactly held within the at least one filter media storage area. An at least one motor is coupled to a power supply and in communication with a controller, the at least one motor moving an at least one movement member that advances an unexposed portion of the compactly held pleated, folded, and stacked pleated filter media into the at least one exposure slot, expanding and exposing the unexposed portion of the pleated filter media to the flow channel while retaining the pleats and creating an exposed portion of the at least one pleated filter media. And a containment area, wherein the exposed portion of the pleated filter media is collected folded, restacked and compactly stored and retained within the containment area.

The containment area can be a filter media cartridge, the filter media cartridge containing a folded pleated filter media stacked and stored so as to be in a compact state and, after being engaged by the at least one movement member, selectively removed from the compact state. The stacked filter media can be held with an at least one adhesive element having a separation force such that the separation force allows for separation of the folded, pleated filter media such that an element of the pleat remains adhered so as to prevent air flow around an edge of the unexposed portion of the filter media when it is in the exposure slot. An at least one processing module and an at least one transceiver module can be included on the controller and an at least one sensor, the controller communicating with the at least one sensor, the at least one sensor communicating data to the processing module and the controller, and the transceiver module transmitting data from the filter to a network or a storage device. The at least one movement member comprises a star wheel moving the material from a portion containing the unexposed filter media with pleats contained thereon and an at least one auger screw drive assisting in collecting the exposed, pleated filter media and further comprising an at least one support assisting in supporting the filter media on the pleats and assisting in producing a pleated pattern.

The first frame member can be a housing frame and the second frame member can be a filter. An at least one motor coupling can be provided, the at least one motor coupling engaging the at least one motor to the at least one movement member wherein the first frame member can contain the at least one motor, the at least one controller, and the at least one power source and the second frame member can contain the filter media stack and the at least one movement member. The first frame member can contain the at least one motor and the at least one controller and the second frame member can contain the filter media stack, the at least one movement member, and the at least one power source.

The at least one movement member can be an at least one of at least one cord, wire, string; track, puller or pinch rollers, star, toothed, or pin roller, screw drive, threaded rod, or a take-up roller. The at least one movement member can be an at least one screw drive or threaded rod.

The method of the invention includes method of manufacturing a selected spacing folded, pleated media stack by preparing a pre-pleated sheet of filter media having pleats with peaks and troughs throughout its length; applying an at least one adhesive element along the pre-pleated sheet of filter media applied to all of the pleats; advancing and cutting the pre-pleated sheet of material to specific length to form a cut length of pre-pleated sheet of filter media with the at least one adhesive element applied thereon; compressing the cut length of pre-pleated sheet of filter material, the process of compressing the cut length of pre- pleated sheet of filter media resulting in folding of the pleats and adherence of the pleats of the cut length of pre-pleated sheet of material into a folded, pleated filter media stack that is selectively separable; selectively separating the folded, pleated filter media stack and selecting a pleat spacing for a selected pleat spacing section, the size of the pleat spacing section corresponding to the selected pleat spacing; further application of an at least one spacing support element at the peaks of each pleat in adhesive contact with the selected pleat spacing section, adhering the peaks of the selected pleat spacing section to the at least one spacing support element to secure the selected pleat spacing in the cut pre-pleated filter media material that comprises the folded, pleated filter media stack; and refolding and recompressing the folded, pleated filter media stack and the at least one spacing support element into a selected spacing folded, pleated media stack wherein the media stack is adhered and can be selectively removed to extend the folded, compacted filter media pack from the folded, compacted state to a deployed state with the selected pleat spacing.

The step of applying the at least one adhesive element can include applying multiple adhesive elements at multiple application points across the pre-pleated sheet of filter media. The step of applying the multiple adhesive elements can include applying three lines of adhesive elements, wherein the adhesive elements are three lines of double sided tape with an adhesive The step of applying the multiple adhesive elements can include applying the three lines of adhesive lengthwise on the pre-pleated sheet of filter media with a first line being on a first edge of the pre-pleated sheet of filter media, a second line being at a middle point of the pre-pleated sheet of filter media, and a third being on a second edge of the pre-pleated sheet of filter media.

The method of applying multiple adhesive elements at multiple application points across the pre-pleated sheet of filter media can include applying perpendicular lies of multiple adhesive elements across the pre-pleated sheet of filter media.

The step of applying an at least one adhesive element can include the further step of varying at least one of the type, angle, distribution, location, and type of adhesive as between the at least one adhesive element. The method of claim 3, wherein applying three lines of adhesive elements further comprises the method step of varying the application of at least one of the angle, distribution, location, and type of adhesive as between the three lines of adhesive elements.

The method step of applying adhesive elements can further include applying an at least one adhesive element selected from the group comprising at least one of glue spots, adhesive tabs, liquid glue, hot melt, tape, spray on dispersion, pattern adhesives, adhesive single sided tape, adhesive double sided tape, contact adhesives, glue dots, adhesive gel, gel dots, adhesive cloth, tapes with adhesives, meshes with adhesives, any folding member with these adhesives, gelatin, and natural adhesive compounds.

The method can also include applying a hot melt adhesive that is pattern coated onto the length of the pre-pleated sheet of filter media. The step of applying multiple adhesive elements at multiple application points can include moving at least one of the applied multiple adhesive elements in an at least one direction to or from a center point of the pre- pleated sheet of filter media so as to vary a resulting point of adhesive contact on individual pleats of the pre-pleated sheet of filter media.

The method of claim further including applying an at least one protective liner component on the at least one adhesive component to selectively protect against adhesion of the pleats of the pre-pleated material during the manufacturing process. The method can include the step of removing the at least one protective liner applied to the at least one adhesive element.

The method where the step of selectively separating the folded, pleated filter media stack further comprises selectively separating each pleat the entire pleat, releasing the at least one adhesive element in contact therewith, prior to the selection of a pleat spacing section and the step of applying a spacing support element. The method can also include the step of selectively separating the folded, pleated filter media stack further comprises selectively separating each pleat along only a portion of the pleat, releasing only a portion of each pleat, prior to the selection of a pleat spacing section and the step of applying a spacing support element.

The method further include a method step of selectively separating the folded, pleated filter media stack along an at least one portion of the length of each adhered pleat for a selected pleat spacing section corresponding to a selected pleat spacing or pleat per inch further comprises application of a spacing selector device to select the selected pleat spacing section. The selected pleat spacing can be between about 0.5 to about 20. The selected pleat spacing can be between about 1 to about 10.

The method step of selecting the pleat spacing can include selecting a pleat spacing that is relate to at least one of the density of the liquid being filtered, the density of the gas being filtered, the duty rating of the filter media, and the type of filter material. The step of applying the at least one adhesive element and in the step of applying the spacing support element, dissimilar types of adhesive elements are utilized. The sheet of filter media can be a sheet of high loft filter media and the step of preparing a pre-pleated sheet of filter media having pleats with peaks and troughs throughout its length can further include preparing a high loft sheet of media, scoring an at least one support grid to allow for forming of pleats, adhering the support grid to the high loft sheet of media and folding the high loft sheet of media to form a pre-pleated sheet of high loft filter media.

The method of further application of an at least one spacing support element can further include application of a netting member across the width of the sheet of high loft filter media adhering the netting member to the peaks of the selected pleat spacing section to secure the selected pleat spacing in the cut pre-pleated high loft filter media sheet and the refolding and recompressing step further comprises refolding and recompressing the cut pre-pleated high loft filter media sheet such that the cut, pre-pleated high loft filter media sheet is folded and adhered and the netting is similarly folded to form the selected spacing folded, pleated media stack.

The step of applying adhesive elements can further comprise applying an at least one adhesive element wherein the amount of adhesive in the adhesive element is inversely proportional to a desired spacing of the pleats in the pleated filter media.

The article of manufacture claims an article formed by the process which includes a folded, pleated media stack product manufactured by the method of the instant invention. A further article of manufacture claim is directed to a filter engaging a selected spacing folded, pleated media stack manufactured by the method of the invention.

The apparatus of the invention also includes a selected spacing folded, pleated media stack having a cut portion of pre-pleated filter media having pleats, each pleat having a top and a trough and a successive top. An at least one adhesive element is provided running along the length of the cut portion of pre-pleated filter media through each pleat from each top to trough to the successive top. An at least one adhered section between the top and successive top of the pleat being adhered by the at least one adhesive element is provided. An at least one pleat spacing section is located wherein the at least one pleat spacing section is selected and then an at least one spacing support element is adhered to each pleats top and successive top such that the at least one spacing support element maintains the spacing in the at least one pleat spacing section such that the at least one adhesive element selectively adheres the pleated material in a selected spacing folded, pleated media stack when compressed with the at least one spacing support element further folded and compacted and the selected spacing folded, pleated media stack allowing for selective release of each pleat from the compressed state to an operating state such that the at least one adhered section is retained and the spacing support element maintains the spacing when in the operating state.

The apparatus and article of manufacture of the invention includes A filter media cartridge having an at least one frame member having a pleated, folded filter media mounted therein. An at least one movement member having the pleated folded filter media mounted thereon and free to move thereon is also provided, wherein the pleated folded filter media mounted thereto has an at least one adhesive element attached which is compressed such that the pleats of the pleated folded filter media are adhered when in a compacted pleated folded media stack within the housing the filter media cartridge being deployed from the compacted pleated folded media stack when in a filter device and moved from the adhered compacted pleated, folded state to an expanded state while providing side sealing in the filter device.

The at least one movement member can be a motor. The at least one movement member can be a user manually moving the filter media stack within the filter media cartridge. The at least one movement member can further be a pull tab pulled by the user. A locking mechanism can be provided, wherein the movement member moves the filter media stack and the locking mechanism locks the media at a position whereby it is deployed. It should also be noted that the controller in the previous filter devices can be a push button activated by a user of the replacement filter to advance the unexposed portion of the pleated folded and stacked pleated filter media.

Moreover, the above aspects and advantages of the invention are illustrative, and not exhaustive, of those which can be achieved by the invention. Thus, these and other aspects and advantages of the invention will be apparent from the description herein, both as embodied herein and as modified in view of any variations which will be apparent to those skilled in the art.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments of the invention are explained in greater detail by way of the drawings, where the same reference numerals refer to the same features. Figure 1 shows a top/isometric view of an exemplary embodiment of the instant invention having a cartridge with a filter media stack therein.

Figure 2A shows a side view of the embodiment of Figure 1.

Figure 2B shows a sweep bar as used in an exemplary embodiment of the instant invention.

Figures 3A-3C show the operation of the exemplary embodiment of Figure 1.

Figures 4A-4C show the operation of a further exemplary method of operation of the exemplary embodiment of Figure 1.

Figure 5 shows a top/isometric further exemplary embodiment of the instant invention having a cartridge with a filter media stack therein.

Figure 6 shows an assembled filter of the exemplary embodiment of Figure 5.

Figure 7A shows an exemplary embodiment of the motor coupling member that engages the at least one motor in the exemplary embodiment of the filter of Figure 5.

Figure 7B shows a further exemplary embodiment of a filter similar to the exemplary embodiment shown in Figure 5.

Figure 8A, 8B and 8C show isometric of a still further exemplary embodiment of the instant invention having a cartridge with a first media stack in line with the housing and an additional vertical filter media stack.

Figure 9 shows an isometric of a still further exemplary embodiment of the instant invention having a cartridge with a first media stack inline and a magazine cartridge with multiple vertical filter media stacks therein.

Figure 10 shows a side cutaway view of another exemplary embodiment having a media stack that wraps into a U shaped magazine.

Figure 11 A shows an isometric view of a yet further exemplary embodiment having a rotary movement member to deploy a filter media stack and rollers to assist in guiding the folded, pleated filter media.

Figure 1 IB shows a configuration for a larger scale air filtration application, having four of the embodiment of the instant invention of the type shown in Figures8-10 with magazine input.

Figure 12 shows a plan view of an exemplary embodiment of the invention

communicating with other devices or a network or both. Figure 13 shows preparation of a pre-pleated filter media material in an exemplary embodiment of the method of adhering a pleated filter media in the instant invention.

Figures 14A-14D show various methods of applying at least one adhesive element to the pre-pleated filter media material in exemplary embodiments of the instant invention.

Figures 15 shows compression of the pre-pleated filter media material with an at least one adhesive element into a folded, pleated media stack in an exemplary embodiment of the instant invention.

Figure 16 shows a close up of the pleats being adhered with an at least one adhesive element as the pleats are compressed into the folded, pleated media stack in an exemplary embodiment of the instant invention.

Figure 17 shows a close up of the pleats being adhered with an at least one adhesive element selectively applied to only a portion of each pleat as the pleats are compressed into the folded, pleated media stack in an exemplary embodiment of the instant invention.

Figure 18 shows spacing a folded, pleated media stack, selectively engaging a spacing section, and applying an at least one spacing support element to maintain the selected spacing in an exemplary embodiment of the instant invention.

Figure 19 shows a selected spacing filter media with an at least one spacing support element prior to being compressed to a folded state for storage and transport.

Figure 20 shows a series of pleats being compressed into a selectively spaced, folded, pleated media stack in an exemplary embodiment of the instant invention.

Figure 21 shows an exemplary embodiment of an article of manufacture of a selectively spaced, folded, pleated media stack in a frame of the instant invention.

Figures 22A and 22B show an exemplary embodiment of a device having a selectively spaced, folded, pleated media stack of the instant invention.

Figure 23 shows a high loft filter media and a scored supporting grid.

Figure 24 shows the high loft filter media sheet and scored supporting grid of Figure 8A adhered to form a high loft media sheet.

Figure 25 shows a sheet of high loft filter media applying an at least one adhesive element thereon. Figure 26 shows a further step of spacing a high loft folded, pleated media stack, selectively engaging a spacing section, and applying an at least one spacing support element to maintain the selected spacing in an exemplary embodiment of the instant invention.

Figure 27 shows an exemplary embodiment of an article of manufacture of a high loft, selectively spaced, folded, pleated media stack in a frame of the instant invention.

DETAILED DESCRIPTION OF THE INVENTION

In describing the invention, the following definitions are applicable throughout.

A "computer" refers to any apparatus that is capable of accepting a structured input, processing the structured input according to prescribed rules, and producing results of the processing as output. Examples of a computer include: a computer; a general purpose computer; a supercomputer; a mainframe; a super mini-computer; a mini-computer; a lap top; a net book; a smart phone; a workstation; a micro-computer; a server; an interactive television; a hybrid combination of a computer and an interactive television; and application- specific hardware to emulate a computer and/or software. A computer can have a single processor or multiple processors, which can operate in parallel and/or not in parallel. A computer also refers to two or more computers connected together via a network for transmitting or receiving information between the computers. An example of such a computer includes a distributed computer system for processing information via computers linked by a network.

A "computer-readable medium" refers to any storage device used for storing data accessible by a computer. Examples of a computer-readable medium include: a magnetic hard disk; a floppy disk; an optical disk, such as a CD-ROM and a DVD; a magnetic tape; a memory chip; a thumb drive; and a carrier wave used to carry computer-readable electronic data, such as those used in transmitting and receiving e-mail or in accessing a network.

"Software" refers to prescribed rules to operate a computer. Examples of software include: software; code segments; instructions; computer programs; applications; and programmed logic.

A "computer system" refers to a system having a computer, where the computer comprises a computer-readable medium embodying software to operate the computer. A "network" refers to a number of computers, computer systems and associated devices that are connected by communication facilities. A network involves permanent connections such as cables or temporary connections such as those made through telephone or other communication links. Examples of a network include: an internet, such as the Internet; an intranet; a local area network (LAN); a wide area network (WAN); a cellular network; a Wi- Fi enabled network of computers; a network of security systems; and a combination of networks, such as an internet and an intranet or a WAN enabled Wi-Fi network through a wireless provider or any similar network element or network.

An "information storage device" refers to an article of manufacture used to store information. An information storage device has different forms, for example, paper form and electronic form. In paper form, the information storage device includes paper printed with the information. In electronic form, the information storage device includes a computer- readable medium storing the information as software, for example, as data.

The instant invention in a first exemplary embodiment is directed generally to a replacement filter having an at least one cartridge replacement with a pleated, folded media stack. In the exemplary embodiments, the housing fits standard width for filters so as to be a replacement filter for existing filtration systems. The replacement filter contains, at least in part, an at least one motivator or movement element, a motor, and a power source, all of these elements being green friendly, a controller and a folded, pleated filter media stack. The product is therefore both replaceable and disposable with minimum environmental impact. The replacement filter being further located within a channel in the filtration unit wherein the fluid or gas agent is passed within the channel and passed through the pleated filter media.

The exemplary embodiments of the invention shown utilize a compacted "clean" portion of the filter media that is in a deployable folded, pleated media stack that is deployed, exposed, and collected within the device. In most of the exemplary embodiments shown, the filter media is folded or pleated and stored in a storage section. A movement element in the exemplary embodiments is attached to the media when the folded, pleated media stack is inserted into the filter device frame. The folded, pleated media stack is engaged with the movement element. In response to the controller the motor moves the movement element. The movement element in turn moves the media into the fluid or gas flow channel. When the controller determines a change of filter media is necessary, the movement element again moves and the exposed media, which is moved from the flow channel into a collection section where it folds and is stored and draws an unexposed portion into the exposure area. This movement of the filter media is produced by the movement element in these exemplary embodiments. This movement and storage of the media results in an extended length of operation for the replacement filter that does not require special installation, minimizes environmental impact after disposal, and is self-contained, thus minimizing readmission of containments while allowing for replacement of the cartridge media. The filter media is a pleated, folded filter media, the pleats providing added surface area in the exposure area. The filter media is stored in pre-pleated stacks and is collected and stored in a containment area preventing re-admission and re-exposure of the contaminants collected in the exposed media. As noted below, safeguards in the system can be used to further prevent readmission or re-exposure during replacement of the cartridge or filter media stack as described below.

Figure 1 shows an isometric view of an exemplary embodiment of the instant invention shown in shadow and having a cartridge with a filter media stack therein. A replacement filter 1 is shown. The replacement filter is located such that it is in a path or channel of the flow of the agent or material being filtered (not shown). The filter 1 has a first frame portion 10 of an at least one frame portion. The first frame portion 10 having channel portions 16, 18. The channel portions 16, 18 can be any shape but in the exemplary embodiment the channel portions 16, 18 are C channel portions which interlock with leg portions as described herein below to form a completed housing 200.

In the exemplary embodiment shown the first of the at least one frame portions 10 contains at least one motivator or movement device or movement member or element 20, in this instance a pair of threaded rod shafts or screw drives, the at least one movement member 20 being driven by an at least one motor 40 with a power source 50, and a controller 60. Other movement members may be utilized in further exemplary embodiments. Some non- limiting examples of movement members include but are certainly not limited to at least one cord, wire, string; track, puller or pinch rollers, star, toothed, or pin roller, screw drive, threaded rod, a take-up roller, or similar movement device or member. Although reference is made to these elements being in a first of an at least one frame portion 10, some or all of the elements may be located in other frame portions as shown in the further embodiments described herein or as would be otherwise understood by one of ordinary skill in the art. Further, reference is made to a controller wherein the controller is an electronic controller with programmed responses. It can also include a simple manual input, for instant a push button, to instigate the operations specified herein. In this instance the controller 60 is a combination of the user and the user command input (not shown), the result being the same as the operational instructions sent by a fully integrated electronic controller.

A second frame portion 15 is provided in the exemplary embodiment shown. The second frame portion has two leg elements 17, 19 which fit within the channel elements 16, 18 of the first frame portion 10. Stored with the second frame portion 15 is an at least one pleated filter media stack 100, 101, 102. The at least one pleated filter media stack 100, 101, 102 is formed by stacking a filter media in a pleated fashion such that it is easily compressed and then deployed. For example, by the process shown herein below and applicants further patent applications which are incorporated by reference or other methods of creating the filter media stack and may include adhesive portions or elements 340. In the exemplary embodiment, a cut length of pre-pleated filter media sheet is compressed and separated into lengths that effect a full change of the material in the exposure slot 7 of the instant invention. The resulting pleats in the folded, pleated filter media stack 100 are thus selectively removable from the media stack 100. In other words, the adhesive bond strength of the at least one adhesive element permits removal of the pleats from the folded, pleated filter media stack 100 by a selective removal device, like the movement member 20 of the instant invention. Further embodiments may omit the adhesive strips 340 and simply provide a very tightly compacted filter media stack 100. In addition, as provided further herein, the movement member may be mad such that it is manually operated, whereby each change of filter media is moved into position manually.

A power source 50 is provided in this exemplary embodiment, here the non- limiting example being shown as two batteries. The power source 50 provides power to the at least one motor 40, in this exemplary embodiment a non-limiting example having two motors, and the controller 60. The exemplary embodiment utilizes a folded pleated filter media 70 stored in one side of the completed housing 200 forming the at least one pleated filter media stack 100, 101, 102 of uncontaminated filter media 72 in the filter media storage area 95. The folded at least one pleated filter media stack 100, 101, 102 is stored and, optionally, the pleats are adhered in at least a portion of the space between the tops or peaks and troughs or valleys of each pleat as noted above.

In an exemplary embodiment, several of the media stacks 100, 101, 102 are provided with a specific pleat density or pleat per inch measurement. The pleats per inch can be, for example and certainly not limited to, between about 0.1 and 10 pleats per inch, particularly between 0.5 and 4 pleats per inch is typical but the concentration of pleats is certainly not limited in this way. The media stacks 100, 101, 102 are stored in the completed housing 200, comprised of at least two frame portions 10, 15. In the exemplary embodiment shown the second frame portion 15 contains leg sections 17, 19 and the filter media stacks 100, 101 , 102 contained thereon. The filter media stacks 100, 101, 102 in the exemplary embodiment shown further include sweep bars 205, 206, 207 each separating enough material such that the material between the spaced sweep bars corresponds to a complete change of the material in the exposure slot when deployed. As shown, the first media stack 100 is deployed in the exposure slot 7.

One end of the folded, pleated filter media stack 100-102 is coupled to the second frame portion 15. Thus the folded, pleated filter media stack 100-102 is moved from its compacted position to an extended or operating position to replace the exposed filter media 77. Upon command and operation from the controller 60, the exemplary embodiment of Figure 1 shows the filter as it has deployed a first media stack 100 along the at least one movement member 20, here the pair of threaded rod screw drives. The movement imparted by the movement member 20 removes the at least one folded, pleated filter media stack 100, 101, 102 from its compact stored state, separating the pre-selected pleats per inch spacing into an operational position across the exposure slot 7. This is done by engaging the at least two frame portions 15, 17, which include an at least one frame portion forming a cartridge containing the filter at least one filter media stack 100, 101, 102 thereon. In the exemplary embodiment this is shown as frame portion 15, however it is understood it could also be frame portion 10 or a further frame portion.

After a determination is made by the controller 60 that a change of the media stack 100 is needed, the at least one movement member 20 is engaged by the motor 40 moving the sweep bar 205 and the remainder of the media in the exposure slot 7 through to the containment area 95. The at least one support member 105 is pulled toward the motors 40 in this exemplary embodiment as shown by the arrows denoting movement. The sweep bar or support member 205 in a non-limiting example used in the exemplary embodiment is a plate threaded onto each of the threaded rod screw drives 20. The resulting movement pulls the second media stack 102 and the associated sweep bar 206 along the at least one movement member 20 and moves the media stack 102 from the storage area 95 into the exposure slot 7 to deploy the clean media 72 therein. Of course, this is only one method of operation and several such methods may be utilized to move clean media, for instance those shown herein below in relation to Figures 3A-4C. These methods may be utilized to affect a partial or a complete change of the filter material in the exposure slot 7 and move the exposed filter media portion 77 into the containment area 95. The containment area 95 and/or the storage area 90 may also provide a seal (not shown) to help prevent readmission of contaminants when all the filter media in the filter becomes exposed and the media stack contained in the cartridge or frame portion 15 needs to be changed. Again the specific movement can be varied and the at least one media stack 100, 101, 102 may be store in any of the at least two frame portions to form a replaceable cartridge with media stack. The filter media 70 has an unexposed portion that is folded and compactly stored in filter media stacks 100, 101, 102 in the media storage area 95 of the completed frame, the unexposed, folded portion of the filter media 72 when exposed to the flow channel is oriented such that the pleats are matched against collapse and withstand the pressure exerted by the passing flow.

In the exemplary embodiment shown, the completed housing 200 is provided in the exemplary embodiment by slidingly engaging the leg portions 16, 18 of the first frame portion 10 with the channel portions 17, 19 of the second frame portion 15. Thus the filter 1 has a completed housing 200 which contains an at least one motivator or movement device 20, in this instance a threaded rod or shaft or screw drive, having the filter media stack 100 coupled thereto. In this instance, the at least two frame portions 10, 15, contain in one portion the controller 60, the motor 40, the at least one movement device 20, and the power supply 50 in the first frame portion 10. The cartridge containing the at least one media stack 100, 101, 102, is here shown as the second frame portion 15. The elements could equally be swapped or certain components, for instance the power supply, can be located in other of the at least two frame portions 15, 10, as shown herein in relation to the further embodiments below. Likewise the number of media stacks can be varied, providing longer or shorter operational times per cartridge.

Similarly, the specific construction of the elements may be varied to fit design parameters, cost constraints or environmental concerns. It should be noted that the power source 50 is in this case can be an environmentally friendly disposable battery, such as but certainly not limited to a lithium ion battery. Similar alkaline batteries may be utilized, for instance. Additional provisions can also be made for an external power source, such as a plug element or set of electrical connectors (not shown) to engage the filter 1 with a conventional power source or use a conventional battery as well.

Thus together, in the exemplary embodiment shown, the first and second frame portions 10, 15 are combined to form the filter 1 and a completed housing 200. An exposure area, vent, opening, or slot 7 is provided within the completed housing 200, the exposure area 7 being of sufficient size to permit flow from the flow channel to be sent there through. The housing 10 contains an at least one motivator or movement device 20, in this instance a pair of threaded rod screw drives, the movement device 20 being driven by a motor 40 with a power source 50, a controller 60. A filter media 70 is provided to deploy as an at least one pleated, folded, compact filter media stack 101, 102, 103.

The thickness of the filter 1 is specific to design constrains, but typically being a standard width for filters so as to be a replacement in existing filtration applications, such as in air handlers. The thickness can be for example but is certainly not limited to about 0.25 inches to 10 inches, more specifically about one to five inches (l"-5") in thickness for residential and commercial filtration systems. An exposure area, vent, opening, or slot 7 is provided within the multi-section frame formed by combining the at least two frame elements 10, 15, the exposure area 7 being of sufficient size to permit flow from the flow channel to be sent there through. The frame and other components can be, in an exemplary embodiment, for example but certainly not limited to, environmentally friendly stiffened plastics, paper or cellulose product, organic plastic like compounds, or similarly green materials.

The controller 60 selectively powers the motor 40 in each instance to effect a change in the media 70 in the exposure slot 7. In this instance, as described above and further in relation to Figures 3A-4C below, the controller 60 may be programmed to advance or a user may advance a first section of the media stack 100 upon engaging the first and second frame portions 10,15. Alternatively, a user may manually thread the media 70 or engage a selection mechanism, such as a button (not shown), to start the filter media stack 100. The controller 60 also advances the media 70 when the media in the exposure slot 7 is full of contaminants. One non-limiting example would be to advance the filter media 70 based on inputs from an at least one sensor 80 in the exemplary embodiment.

In further embodiments, additional non-limiting examples of sensors and/or inputs can include pressure, flow, light, or similar sensors or indicators. The sensors and controller can further communicate with additional elements of the filter or a network or both. The controller 60 can, for example, comprise a printed circuit board having a microprocessor in communication with the at least one sensor 80. The at least one sensor 80 can for instance be a magnetic sensor that determines the position of the filter media 70 based on imbedded magnetic tags in the filter media 70. It can also be a turn counter on a screw drive or a clock or similar mechanism for determining distance and/or time may be utilized as a sensor input 80. Any number of sensors 80 may be utilized to provide sensed input as to the state of the filter media 70 and the operation of the filter 1. In the exemplary embodiment, the controller 60 is activated at installation and tracks days or hours in operation.

Software on the controller 60 determines when these measurements are made and the threshold levels of obstruction or color change on or similar change in a metered variable in relation to the exposed filter media 77. Each of the threaded rod screw drives making the movement members 20 are engaged by their respective motors 40 when initiated by the controller 60. The operation of the controller 60 and the signals of the sensors are further discussed herein below in relation to Figures 3A-4C. However, the determination on advancing the filter via the motor 40 may be based on any of the aforementioned manners, including but not limited to a timer or a sensor 80 output/input.

In the exemplary of Figure 1 , the controller 60 can count, for example but certainly not limited to, up to three months and activate the motivator or movement device 20, in this case the threaded rod or shaft, with the at least one motor 50. In such an exemplary embodiment shown in Figure 1 , the length of the filter media 70 paid out may be monitored by a counter or other device based on the number of revolutions of the at least one movement device 20 or based on the aforementioned magnetic tags or similar devices. In a further exemplary embodiment, the sensor input 80 can be in communication with the controller 60 that can determine the position of the media filter 70 and stop when a "clean" element or measured portion of filter media 70 is in position, for example one of the at least one media stacks 100, 101, 102. The controller 60 can also be used to sense a condition of the air, the filter media 70, or a combination of both through communication with the at least one sensor 80. The controller 60 can also be used to advance the at least one movement member 20 based on the sensed conditions or as a timed or pre-programmed operating profile or based on sensor data in further embodiments

Thus, in the advance of the threaded rod or shaft of the at least one movement member 20 the first of the at least one sweep bars 205 the at least one filter media pack pays out or unfolds the uncontaminated filter media 72 on a first or feed side including a containment area 95. To aid in the operation of this embodiment and the differences with other embodiments, this side is designated by "A" in Figure 1 on the completed housing 200. While simultaneously on the opposite side, a filter media take-up compartment or containment area 90 is located on a second or take up side, designated by "B" in Figure 1 collecting the spent or contaminated filter media 75 in a designated containment area 95.

Figure 2A shows a side view of the embodiment of Figure 1. As seen in the side view, the at least one filter media stack 100, 101, 102 is provided with the at least one sweep bar 205, 206, 207, 208 on one side of the filter 1 within the second frame portion 15. The completed filter frame 200 being engaged through the sliding engagement of leg portions 17,19, on a second frame portion 15 and channel sections 16, 18, on first frame portion 10, it should be noted that the side view shows only elements 18, 19 but is mirrored on the other side by elements 17,16. The controller at least one motor 40 is shown and engages and drives the at least one movement member 20, here shown as a screw shaft or threaded rod which engages the at least one sweep bar 205-208 in this exemplary embodiment. The at least one sweep bar 205 is shaped such that it engages the at least one movement member 20, here the threaded rod or screw shaft. Further embodiments provide various shapes to facilitate stacking and or move the support or sweep bars 205-208 to non-threaded portions of the rods for storage. However, in this instance, the threads are continued into the containment area as shown. The filter media 70 is folded such that there are just enough residual pleats at the end of the span of filter media 70 in the change being drawn out with the first of the at least one sweep bars 205 such that the second of the at least one sweep bars 206 is drawn onto the at least one movement member 20 and continues to be fed out as the second change of the filter media 70 in the filter 1.

Additional movement members can include for example an at least one cord, wire, string, set of pinch rollers, star roller, star gear, toothed roller, worm drive, or similar device or devices to move the folded, pleated filter media 70 from the media stack 100 and into the exposure slot 7. Additionally, the position of the screw drive or threaded rod can also be above or below the pleated material, such that the pitch of the screw drive or threaded rod can move the individual pleats in the exemplary embodiment shown in Figure 1. Similarly, the at least one movement member 20 can run through the filter media and be used in conjunction with or without a support member or other device such as the sweep bars 205- 208 shown in the exemplary embodiment.

In the instant embodiment the contaminated filter media 77 is folded on itself and thereby stores and captures the collected particulate matter in storage area 90. In additional embodiments, the contaminated filter media 77 is contained in a containment area 90 having a seal (not shown) to retain the contaminated filter media and any captured contaminants. In both cases, the contaminated filter media 77 is being collected within the containment area 90 and further within the completed housing 200 so as to minimize exposure for reintroduction of the contaminants from the exposed or contaminated filter media 77 and, simultaneously, preventing contact of the containments with the operator or the environment during replacement. The filter media 70 is provided with a greater amount of filter material 70 stored in the filter media storage area 75 than existing rigid frame, stationary filters, allowing for extended life. For example, sufficient uncontaminated filter 72 media can be provided to make for example a multi-month, six or twelve month for example, filter. In other embodiments, several changes or cycles of filter media may be stored and utilized, such as in the exemplary embodiments described herein below with magazine cartridges.

Once the uncontaminated filter media in the filter media stack 100 is emptied or the last available change of filter media has been spent, the controller can activate an indicator element 120. The indicator element can be, but is not limited to an audible alarm or visual indicator element or LED. Similarly, a scent material may be utilized on all but the last piece of the uncontaminated filter 72 media such that the absence or presence of the scent is an indicator that the filter needs to be replaced. Either after a specified time period or once the indicator element 120 is activated, the user simply removes and replaces the cartridge or second of the at least one frame portions. The spent or contaminated filter media 77 is contained and the re-admission of the filtered contaminants is minimized, as described in more detail in regards to Figures 3A-4C showing the operation of the exemplary embodiment in Figure 1. The expired filter media stack 100 can then be safely disposed of with minimal environmental impact.

Figure 2B shows a sweep bar as used in an exemplary embodiment of the instant invention. As seen in Figure 2B, the sweep plate is generally rectangular as shown, however a circular or ovoid shape is also contemplated as is a flat bar. The sweep plate 205 has a body 202, with two guide ports 204. The guide ports 204 may be circular or may be horseshoe or U shaped as shown. Guide ports 204 that are U-shaped may also be provided with a spring member 213 to aid in retaining the sweep arm 205 on the movement element 20. The guide ports 204 typically match with the number of movement members 20 and engage them for movement in the frame 1. The guide ports 204 may also be threaded themselves to match the thread or screw pitch on the threaded rod or screw drive in Figure 1. Similarly, the sweep bar 205 may be similarly shaped or otherwise adjusted to engage with any of the listed movement members. The sweep bars 205 connect the charges of clean filter media 70 for each change within the frame 1. When the first sweep bar is advanced it unfolds the clean filter media 70 from the stack. In an exemplary embodiment, a small amount of adhesive is used to keep the folded, pleated clean filter media in the stack. The movement member detaches the adhesion in this exemplary embodiment. In further embodiments the folded, pleated filter media may be mechanically held or otherwise held in place with the movement device releasing the clean filter material. The operation of the exemplary embodiment is further described in relation to Figures 3A-3C and Figures 4A-4C herein below. It should be noted that the component frame portions making up the frame in the exemplary embodiments may be themselves composed of sub components that separate and/or are selectively engaged or coupled so as to render the whole frame collapsible and compact about the media stack 100. This would provide for compact transportation of the filter, while allowing for full extraction and configuration of the first and second of the at least two housing members. Figures 3A-3C shows the operation of the embodiment of Figure 1. In the Figure 3 A, the first and second of the at least one frame portions 10, 15 are joined as described above to form the completed housing 200. The media is in the second portion 15 is provided as a media stack 100 with multiple sweep bars 205, 206, 207 segmenting the media stack 100 into charges or cycles or the amount of filter media 70 sufficient to be used in the exposure void or slot 7. In Figure 3 A the media stack is mounted such that the first change of media and the first sweep bar 205 is queued up on the movement member. In this instance, the controller 60 can be instructed, for instance through a push button user input, to begin the advance of the new media stack 100 for the cartridge. Alternatively, the filter media stack 100 may be manually engaged with the at least one movement member 20 during installation. A sealing member 216 can be provide to help prevent admission of contaminants. The media stacks move from the storage side "A" to the containment side "B", the final process before removing the cartridge bringing the exposed media back to storage side "A" for final removal.

Figure 3B shows the filter media 70 being moved out of the exposure slot 7 and the third change or cycle of material being advanced with the second sweep bar 206 into and across the exposure slot. The exposed filter material 77 is then stacked, refolding the material at its pleats and compressing same. The folded, pleated filter media is unstacked and moved into the exposure slot 7 by the at least one movement member while maintaining the pleat spacing or PPI in the exemplary embodiment. The material in this exemplary embodiment is coupled to the sweep bar 205, 206, 207 and the advancement of each bar extends a new cycle of material into the exposure slot 7, as noted above. The movement member and method of moving the filter material may be varied, and is well within the scope and spirit of the invention. Two exemplary, non-limiting methods are provided herein below as shown in Figures 3A-3C and 4A-4C, however, additional methods may be utilized to provide the necessary movement of the filter media stack 100 from the compressed/stored state to a deployed state in the filter 10. The at least one movement member 20 in this instance is a threaded rod that engages the sweep bar 205, 206, 207. A small non threaded rod or portion of the same rod may be used to store the non-advancing sweeper bars 205, 206,207 as shown. Similarly, within the collection of the spent filter media, a similar non-threaded member on the end of the media for storage, as shown in shadow. Figure 3C shows the completed filter being backed out and the media stack 100 being reformed for disposal. The final cycle or change of clean filter material 70 for the exposed media filter 77 is shown in this instance. The movement member 20 is reversed, as shown by the arrows, and the material is returned to the state from which it started and can be removed and replaced. The second frame portion 15 is removed from the first frame portion 20, the leg portions 16, 18 are slid out from the channel portions 17, 19 and a new media pack 100 in an identical second frame portion 15 is installed and the process repeated.

Figures 4A-4C show the operation of a further exemplary method of operation of the exemplary embodiment of Figure 1. As shown in Figure 4A, the filter 1 is substantially the same as that used in Figure 3 A. The filter media stack 100 in the second frame portion 15 is installed in the same fashion as that shown in Figure 3A. Again, the controller 60 may load the material by engaging the at least one motor 50 to advance the at least one movement member 20 to engage the filter media stack 100 and queue the first sweep bar 205. However, unlike the exemplary embodiment of the method of operation of Figure 3A-3C, the media is first moved across the filter 1 in this instance in its entirety.

Figure 4B shows this principal operational difference. In this instance, the entirety of the media stack 100 is removed from the installation position shown in Figure 4A and all the sweep bars 205,206, 207 are moved across the filter 1, effectively moving them from the second frame portion 15 onto the first frame portion 10. In this way the first exposed portion is the last exposed portion in the previous method of operation. The filter media 70 is restacked as a filter media stack 100, 101, 102 on the opposing side in the side labeled "a" and referred to as the storage area 90. It is then moved back toward its starting position as shown in Figure 4C. The movement is again A to B, but this movement is reverse from that seen in Figures 3A-3C.

Figure 4C shows the final movement of the last sweep bar 205 back into the starting position having exposed all the charges or cycles or changes in the media pack 100. The final sweep bar 205 is moved across the filter 1 width and stacked and stored. In this manner the second frame portion 15 is likewise removed and replaced bringing a clean filter media stack 100. Effectively, this returns the media stack to its starting position, the same as that shown in Figure 3 A. The media stack 100 can be sealed off by a sealing member (not shown), an exemplary embodiment being a rubberized gasket or similar material or other sealing element.

Figure 5 shows a top/isometric further exemplary embodiment of the instant invention having a cartridge with a filter media stack therein. In the exemplary embodiment shown a filter cartridge 301 is shown inside a frame 305. The frame 305 can be constructed of stiffened cardboard or a more durable material such as a plastic or metal. The frame 305 in the exemplary embodiment shown in Figure 5 contains an at least one motor 40 with a power source 50, and a controller 60. The motor 40 is coupled to the movement device or element 20 through a coupling 320 that penetrates through the exterior of the filter cartridge 301.

As seen in Figure 5, the filter cartridge 301 is separate and apart from the frame 305 and the filter 1 requires assembling these two pieces together. In addition to the coupling 320, the filter cartridge 301 in this exemplary embodiment includes the movement device 20, here two threaded rods or screw drives. The movement device 20 engages a filter media stack 100 stored in the filter cartridge 301. The operation of the filter 1 is thereafter similar to the other embodiments described herein, whereby the filter media 70 is separated into distinct media stacks 101, 102, 103 with sweep bars 205, 206, 207 in storage area 90 is reduced and changes of the filter media 70 in an exposure slot 7 are accomplished, with the filter media being restacked as a folded, pleated, exposed filter media stack in the containment area. In this instance, this occurs all within the filter cartridge 301. The exposed filter media 77 is restacked within the filter cartridge in containment area 90. It should be noted that any of the previously disclosed drive mechanism or those that would be obvious to one of ordinary skill in the art can be used to move the filter media 70 from the filter media stack 100.

Figure 6 shows an assembled filter of the exemplary embodiment of Figure 5. The filter cartridge 301 is shown secured inside the frame 305. A securement coupling 330 is provided to secure the filter cartridge 301 inside the frame 305. The securement coupling 330 here is shown as a pair of securement couplings 330, for instance a pair of metal springs or sliding metal members that can be deployed after assembly of the filter 1. The securement coupling 330 can also be an additional cross-member or a friction fit element, so long as the filter cartridge 301 is secured in the frame 305 and the motor coupling member 320 is engaged to allow for operation of the filter 1. The securement coupling 330 may be optional or incorporated into the geometry of the filter cartridge 301 and the frame 305 such that the insertion of the filter cartridge 301 into the frame 305 secures the filter cartridge 301 and engages the motor coupling member 320.

Figure 7A shows an exemplary embodiment of the motor coupling member that engages the at least one motor in the exemplary embodiment of the filter of Figure 5. As seen in Figure 7 A, the frame 305 is shown in shadow providing a view of the filter cartridge 301 which is shown approaching the frame 305. In this instance, a motor coupling member 320 is shown as a male protrusion 322 extending from the end of the movement member 20, here a threaded rod. The male protrusion 322 is in a slot 303 within the filter cartridge 301. The slot 303 matches an extension shaft 43 extending from the motor 40. The slot 303 slides around the extension shaft 43 and a female receiving portion 47 in the extension shaft 43 mates with the male protrusion 322. Once the male protrusion 322 and the extension shaft 43 are engaged, the motor 40 can drive the extension shaft 43 and thereby drives the movement member 20, here threaded shaft screw drive, when power is provided by the power source 50. This moves the filter media 70 from the filter media stack 100 in the fashion described above. The various filter media stacks 101, 102, 103 are moved across the exposure slot 7, the previous media stack being separated by a sweep or spanning or separating member 205, 206, 207 respectively. Each sweep member 205, 206, 207 pulls the previous member further along a non-threaded portion 37 of the drive member 20 as shown until it is engaged on the threads. The advancement of the media stacks is controlled by the controller as described herein.

Figure 7B shows a further exemplary embodiment of a filter. Figure 7B shows a variation on the embodiment shown in Figures 5 -7 A, having a similar filter cartridge 301 and a frame 305 in which the filter cartridge 301 is secured. A similar slot 303 is provided with male protrusion 322 for forming coupling 320 to engage with a motor (not shown). The filter cartridge 301 differs in that the power source 50, shown as batteries, is moved from the frame 305 into the filter cartridge 301. Additional components provide electrical coupling of the power source 50 to the at least one motor 40. In this instance, the batteries are the power source 50 and these are coupled to an at least one battery contact 340. The battery contact 340 has a matching at least one motor contact (not shown). These can be for instance typical electrical metal contacts which electrically couple the motor 40 and the power source 50. This facilitates changing the power source 50 when driving movement member 20 and changing the filter media 70. Figure 8A and 8B show isometric views of a still further exemplary embodiment of the instant invention having a cartridge with a first media stack inline and an additional vertical filter media stack. Figure 8A shows an exemplary embodiment of a replacement extended life filter 1 is provided. The exemplary embodiment of Figures 8 A shows a frame or housing 10 with a supply cartridge 150 and a collection cartridge 180. The supply cartridge 150 and the collection cartridge 180 are removable from the frame 10. They are held in place with coupling members 800. In this embodiment, these are simply releasable straps. Other non- limiting examples of coupling members can include snaps, buckles, interlocking parts slidingly engaged, clasps, or similar mechanisms to selectively release the cartridges 150, 180. These and any other appropriate coupling device is well within the spirit of the invention.

In this embodiment, a full first stack of folded, pleated media stack, shown already extended in Figures 8A and 8B, it initially extends in the same plane as the frame or housing 10 with a sweep bar 205 coupled and moved to one end. This initial media stack 101 is advanced as shown and a further media stack 102 having a sweep bar 206 is pulled down from the vertical magazine or supply cartridge 150. Although both cartridges are shown on a single side, variations in the orientation of the magazine in the vertical, i.e. above or below the frame with the exposure slot, is fully contemplated. In particular, it may be advantageous utilize the force of gravity to assist in feeding or removing/collecting the filter stacks. As such, the embodiment shown is a non-limiting exemplary embodiment.

An at least one guide member (not shown) can be added to assist in advancing the folded, pleated media stack 102 downward. As seen in Figure 8 A, the initial media stack is deployed and has been effectively used and the controller 60 is advancing the at least one movement member 20 to effectuate a change of the media 70. The media stack 102 is being deployed as the sweep bar 206 is being moved along the at least one movement member 20, here a single threaded shaft in the center and two screw drives on either side. A further media stack 103 is provided with sweep bar 207 and media stack 103 for a further change after the media stack 102 is exposed.

The first media stack is being withdrawn into the collection cartridge 180, as the sweep bar 205 is driven along the middle threaded shaft and upward onto a further guide member 5. The collection guide member 220 may simply be a non-threaded portion onto which the exposed filter media stack 77 is drawn onto. It can also be coupled to the drive shaft through a universal joint, such as a spring member, in such a fashion as to continue to provide a driven motion to the sweep bar 205 and thereby continue to assist in repacking the exposed filter media 77 in the collection cartridge. Additionally, the collection cartridge 180 can have a sealing member (not shown), a non-limiting example being for instance a rubber gasket, to aid in sealing off the collection area and avoid recontamination or release of contaminants upon removal. Figure 8B shows substantially the same embodiment but utilizing only a set of threaded rods as the at least one movement member 20.

The operation of the embodiment shown in Figures 8A and 8B functions similar to those previously described. For brevity, reference will be made to similar steps and some steps are abbreviated, but reference is made to the previous methods of operation and there steps are equally functional herewith. In operation, the frame 10 is coupled to a supply cartridge 150, the initial media stack (shown in deployed form) being supplied and extending below the supply cartridge 150 in the same plane as the frame 10. The media stack has a sweep bar 205 which is engaged by the at least one movement member 20, here for instance a central threaded rod, which begins to advance the media 70 from the media stack. The media stack is deployed across the exposure slot 7. The media 70 is exposed to the flow in the flow channel. The controller 60 is signaled or signals a media change. The media change is commenced and a further media stack 102 is drawn from the supply cartridge 150 and sweep bar 206 is advanced to draw the media 70 from the further media stack 102. As further media stack 102, 103 are withdrawn, the exposed media stack is collected and restacked in the collection cartridge 180.

Figure 8C shows a further isometric view from below of the collection cartridge of the exemplary embodiment of Figure 8B. As shown in Figure 8C, the at least one movement member further includes a driven threaded shaft 211 along the bottom of the frame 10 as well. The figure shows that the threaded shaft 211 that is part of the at least one movement member 20 is bent and does have a spring member 5 that bends upward to provide further guide member 220 providing locomotion. The sweep bar 205 is shown being lifted into the collection cartridge 180 together with the exposed pleated filter material 77.

Figure 9 shows an isometric of a still further exemplary embodiment of the instant invention having a cartridge with a first media stack inline and a magazine cartridge with multiple vertical filter media stacks therein. Again, similar to the exemplary embodiment of the replacement filter shown in figure 8A-8C, the exemplary embodiment of Figure 9 shows a frame 10, exposure slot 7 with a supply cartridge 150. However, in the supply cartridge of the embodiment shown, there are 3 stacks of folded, pleated, filter media 101, 102, 103, separated by sweep bars 205, 206, 207 respectfully sitting atop an initial media stack which is shown as deployed in the frame.

As with previous embodiments, the first media stack is engaged by a movement member. A non-limiting example of the movement member 20 can be, for example, a thread rod screw drive or a string pulley drive or similar. The at least one media stack, 101, 102, 103 are expanded by the movement member 20. The additional media stacks 101, 102, 103 are coupled to one another through the sweep bars 206, 207 such that the end of one stack is coupled to the respective sweep bar which is also coupled to the start of the next stack. In this way the stacks are drawn out of the supply cartridge 150. The embodiment is then operated in the same fashion as the previous embodiments, moving the filter material from the media stacks through the exposure slot and stacking them in the collection cartridge 180.

Figure 10 shows a side cutaway view of another exemplary embodiment having a media stack that wraps into a U shaped magazine. Again, similar to the exemplary embodiment of the replacement filter shown in figure 8A-9, the exemplary embodiment of Figure 10 shows a frame 10, with a supply cartridge 150. However, in the supply cartridge of the embodiment shown, the media stacks 101, 102, 103 are contained in a U shape supply cartridge 150 end to end with the sweeper bars 205, 206, 207 coupled thereto. The advancement of the media deployed in the exposure slot draws the material out and around in the U shape supply cartridge 150. In this way the stacks are drawn out of the supply cartridge 150. In addition, movement member 20 is shown as a screw drive atop the media 70 together with a driven cord 217. The embodiment is then operated in the same fashion as the previous embodiments, moving the filter material from the media stacks through the exposure slot and stacking them in the collection cartridge.

Figure 11 A shows an isometric view of a yet further exemplary embodiment having a rotary movement member to deploy a filter media stack and rollers to assist in guiding the folded, pleated filter media. The embodiment shown is similar to the embodiment of Figure 9 having a frame 10 with an exposure slot 7, a supply cartridge 150 and a collection cartridge 180. The controller, at least one motor and similar components are also present but not shown for the sake of brevity and clarity. In the embodiment shown, the at least one movement device is a star wheel or paddle wheel 23 with further shortened auger screw drives 310 that are near the containment or collection end of the filter 1. Further embodiments may include alone or in part an at least one of cord, wire, or string; track, puller or pinch roller, star, toothed, or pin roller; screw drive and/or threaded rod; take-up roller or similar drive member providing movement of the media 70 from a media stack 100 to an operational position.

Although shown here for use in this embodiment, the disclosed at least one movement device can also be utilized with any of the other exemplary embodiments of the invention as disclosed herein. In this instance, the stack of media 101 stored in the supply cartridge is moved from the stored folded, pleated stack 101 into the filter 1 and across the exposure slot 7 by the movement of the star wheel 23. Further motive force is provided by the auger screw drives 310 which also push the exposed media into the collection cartridge 180. Thus, the embodiment of Figure 11A moves the folded, pleated media stored in a supply cartridge 150 in a folded, pleated filter media stack 101 into the frame 10 and the exposure slot 7, exposes the filter media 70 to a flow to remove contaminants, and moves the exposed media to a collection cartridge 180 where it is collected and stacked again.

Figure 11B shows a configuration for a larger scale air filtration application, having four of the embodiment of the instant invention of the type shown in Figures8-10 with magazine input. As shown, the system can be used in a plenum or as a pre-filter application for an air handling or scrubbing unit 11 with mountings 12 for several filter frames 10. In the exemplary embodiment shown, four "magazine" style embodiments of the instant invention 1 are shown with vertical box magazines 150,180. In this instance, the magazines are easily approached by service personnel and can be used to aid in installation of the individual filter frames 10. Thus the application of the instant invention can be scaled to address most commercial applications.

Figure 12 shows a plan view of an exemplary embodiment of the invention. The inclusion of electronics and a controller 60 in any of the exemplary embodiments contained herein, on for example, a printed circuit board on the filter 1 provides an opportunity for added functionality in addition to extended operating length. As noted above with respect to Figure 1 , the controller 60 can also be used to sense a condition of the air, the filter media 70, or a combination of both through communication with the at least one sensor 80. The exemplary version shown in Figure 12 can utilize any of the filter advance systems previously discussed to provide Flow Quality Management (FQM) features. FQM is a system designed to be incorporated into the filter 1 to monitor the quality of the flow as it passes through the filter 1 and interact with a network system to monitor the flow quality at the point of filtration.

The FQM system is comprised of an at least one flow quality sensor 80, with added processor modules 62 and data transceiving modules 63 on the controller 60. The at least one sensor is incorporated into the filter frame such that it is in the path of flow as it is drawn though the filter frame 10 at the exposure slot 7. The processor module 62 and transceiver module 63 are housed within the filter frame 10 near the drive motor and are powered from the same power supply as the motor. The controller 60, processor modules 62, and transmitting modules 63 have software on them to measure and report flow quality parameters from the at least one sensor 80. They may report the flow quality parameters to an internal storage device (not shown), wirelessly 1010, or via wired communication 1020 directly to a network 1000. Alternatively, in other embodiments an external device which may store the data and/or be enabled to communicate with the network 1000 via wire 1020 or wirelessly 1010 and thereby may report the parameters to the network 1000 as shown in Figure 9 and described herein below. These can be powered by an onboard, independent power supply or, for example, be powered by a dedicated external power supply in for instance an industrial or commercial application like a paint spray booth.

The at least one sensor 80 allows the system to monitor the air and in conjunction with the processor, collects data regarding air contaminants along with flow quality, for example air quality. These sensors may include but are not limited to sensors that detect and report temperature, mold, carbon monoxide, carbon dioxide, Volatile Organic Compounds, smoke, fire, Noxious Gases, Air Particle Concentration and other potentially dangerous compounds. The at least one sensor 80 can also detect pressure drops and communicate that info back to the filter 1 so that the filter 1 can set the changing cycle accordingly and advance the filter media 70 accordingly. For example, if the filter 1 is pre-set to change the filter media 70 every ninety days and last twelve months but the media is being contaminated at a higher rate as detected by the at least one sensor 80, it will move up the next change to facilitate a consistently clean filter. This change can also be reported out from the filter 1 through the controller 60 and the transmitting modules 63. This real time monitoring can be incorporated in residential unit applications or in industrial and commercial unit applications.

In addition to monitoring flow quality, performance measures can also be communicated as part of the data retrieved from the at least one sensor. A non-limiting example, as noted in the previously described embodiments of Figures 1-11, a flow meter can be included in the at least one sensor 80. This would allow, in conjunction with the processing modules 62 on the controller, a measurement of estimated energy usage. This can be reported through the network 1000 by the transceiver module 63 and reported to an alert device, including for example but not limited to a cell phone, a computer, a network operations center or the like. Additionally, as part of the programming on the processing modules 62, the controller 60 can download program guides through the network and notify users and allow for additional configuration options of the filtration system.

All of this information can be stored or sent in real-time or both. The information can be sent, for example but certainly not limited to, to a reporting station, internet access portal, network interface device or internet cloud server via wireless signal, cellular or WI- Fl/Internet Wireless Protocol technology or similar signal convention, that is accessible to the user via computer or smart phone or similar device, as shown in Figure 12. The quality parameters and data on the operation of the filter can also be retrieved directly from the filter via a communications port 67 located on the filter frame, for example but certainly not limited to a USB port or a mini-USB port or similar communications port. Reports can be generated that can be retrieved showing the status of the filter and the flow quality over time. This can also be available for review by a report device accessed by the homeowner and/or building management or to a Network Operations Center (NOC) of the type typically found in industrial or commercial applications or provided as a function of an alarm or alert service in a residential setting or commercial setting.

The network 1000 can then transmit the information to a wireless device or wired device as a network interface 1030, for example, but certainly not limited to a smart phone or hand held computer or netbook or similar device 1060. The network 1000 can also report the data to a computer or other device 1040, wired 1010 or wirelessly 1020 coupled to the network 1000, to report flow quality or other aspects of the filter 1. Finally, the data can be communicated to a Network Operations Center (NOC) or master control center 1050, all of these options happening alone or in conjunction with one another, the NOC which is actively monitoring the filter 1 and the quality in the flow in the filtration system. A non-limiting example of the operation of the Network Operations Center 1050 can be a third party alarm monitoring company which is monitoring flow quality for a customer or several customers. Another non-limiting example can also make the NOC part of a manufacturing facilities control center as part of a commercial or industrial process whereby the filter unit is being monitored by the control center, for instance in chemical production or commercial painting booths.

Notification or alerts, including those previously described in relation to Figures 1-8, may be sent to the homeowner or building management or NOC of urgent conditions. These can include emergency alerts that may require immediate attention. This may be a part of the design of a monitoring system enabled via the network or as a paid third party monitoring service. This service may be offered for a monthly fee or reported to a security monitoring company, for example, either via internet, email, cellular, text message or telephone or any other fashion that fits the service providers reporting network. Other responses can involve communication from the filter or from other elements in the network which may, in case of sensing certain parameters i.e. dense smoke, take action with other network components. A non-limiting example of such an action is having the filtration controller turn off the circulation system via communication with the thermostat or similar device to prevent smoke circulation when a smoke or fire or other dangerous substances are detected in the flow.

Thus, in addition to providing a unique filter with the ability to provide and extended useful life with the movement of the filter media, the instant invention includes a method for alerts for replacement and possibly delivery of replacement filters. Additionally, a method of monitoring services is also conceived hereby for use in conjunction with or apart from the method of alerting and replacement.

An inventive method of seamless replacement delivery can be accomplished by employing the filter of Figures 1-8 with or without the FQM system. By including just the transceiver modules 63, with or without the additional processor modules 62, an enhanced convenience for filtration unit owners can be incorporated into the sale of the filter. The filter 1 , which as noted above can send a signal when the uncontaminated media 72 has been completely dispensed, with the transmission module 63 can send an alert to a user through one of the alert devices 1040, 1050, or 1060 and a replacement filter can be sent. This can of course be conditioned on confirmation from the owner of the filtration unit or can be provided as part of a monthly service. Additionally, the alert can be sent to a center and service personnel dispatched as part of a standard maintenance response or as part of a paid for maintenance service.

In yet another application, as noted above by incorporating the at least one sensor 80 and the processor modules 63, in addition to sending a signal at the completion of the distribution of the uncontaminated filter media 72, real time monitoring can be completed and sent as part of a monthly service contract or as part of a regular maintenance screening or as part of an emergency response. The at least one sensor 80 can transmit data through the controller 60 and the processor modules 62 and transceiver modules 63, the data can be routed to a third party service provider that maintains the filtration unit and monitors flow quality for a subscriber. The data can also be transmitted as part of a regular maintenance monitoring or screening system in an industrial or commercial application to a NOC or similar central control 1050. Also, as noted, the data may also be transmitted as part of an emergency response to a third party or emergency responder or both and additional signals could be transmitted through a network to shut an flow off and prevent promulgation of hazardous contaminants.

In preparing a replaceable filter with a movable pleated filter component in a filter or the like a need arises for a method of retaining the pleated material in a stacked position and selectively moving an amount of the stacked pleated material into an area for exposure to an airstream while maintaining a specific pleat density or pleat per inch (PPI) and providing for enhanced or reduced seepage of air from the sides of the pleated material when exposed. Reference is made to the steps and processes used in manufacture, construction and/or assembly of the invention. These are presented in no particular order and variations in the order of the processes may be used without departing from the spirit of the invention.

The instant invention further comprises a length of pre-pleated filter material. The material is typically used in air filtration and reference is made herein throughout to air filtration, but the process may be adapted to filter other gasses and/or fluids. One non- limiting example is water filtration assuming appropriate non-reactive adhesives are used. The instant invention is directed to an article of manufacture and a method for manufacturing, a method of using and a filter using a pleated filter media which is selectively adhered as a pleated filter media stack and then is selectively engaged and deployed by a filter while retaining a specified density of pleats or pleats per inch (PPI) or pleat spacing. In addition, the selective adhesion in the completed process also helps prevent excess leakage of the media around the filter and in particular from the ends of the pleated filtration material when deployed.

Figure 13 shows preparation of a pre-pleated filter media material in an exemplary embodiment of the instant invention. As seen in Figure 13, a pre-pleated sheet of material 10A is provided. The sheet is shown cut to length, but a continuous roll or stream of media is contemplated as well. The pre-pleated sheet of pleated material sheet 10A has pleats 30A therein. The pleats are continuous and provide a valley or trough 40 in between successive tops or peaks 50A. The pleated material sheet 10A is fully reversible, effectively making the lowest, trough or valley points the highest or tops or peaks on the reverse side.

In further embodiments, as discussed herein below, additional components, for instance a wire or plastic mesh, can be applied or similar support structures applied. In addition to structural components, additional treatments or processes may be applied to the pre-pleated sheet 10A. Some non- limiting examples of such process include electro-static charging, chemical treatments, or the like and similar processes and applications. In each instance, additional processing is contemplated, as noted below, to allow the material to be compacted in the instant invention, for instance as noted below in relation to the addition of a mesh in the further embodiment of Figures 23-27 herein below.

Figures 14A, 14B, 14C, and 14D show a further step of applying at least one adhesive element to the pleated filter media material in an exemplary embodiment of the instant invention. An at least one adhesive element 20A is provided along a location on the media. In the exemplary embodiment of Figure 13 these are an at least one line of adhesive 20A, though the pattern may be varied as discussed herein throughout in relation to the exemplary embodiments as shown for instance in Figure 14C. Reference is made to an adhesive element 20A; this can be simply an adhesive or a structural element with adhesive. Similarly reference is made to support spacing element 60A, herein below, and likewise it can be simply an adhesive or a structural element with adhesive or a structural element that is coupled to an already placed adhesive.

Multiple adhesive application points can be provided anywhere along the width and length of the pre-pleated sheet of material as described in the exemplary embodiments of the invention without departing from the spirit and intent of the invention. In this instance, as seen in Figure 14A the at least one adhesive element 20 A is comprised of three lines of adhesive elements are provided 22A, 24A, 26A, in the form of a double sided tape adhesive. Variations in the configuration of the adhesive elements are herein contemplated, for instance in further non-limiting exemplary embodiments of the adhesive elements, the middle line of adhesive elements 24A of the pre-pleated sheet of material 10A running lengthwise is shown in Figure 14B is omitted in Figure 13 below and in the embodiment of Figure 14C herein.

Furthermore, the type, angle, distribution, location, type of the at least one adhesive element 20A and other variables in the selection and/or location of the at least one adhesive element 20A may be varied to suit a particular application without departing from the aspects of the invention. For example, Figure 14C shows a crossed pattern of the at least one adhesive element 20. Some non-limiting examples of other forms of adhesive are provided in the further exemplary embodiments described herein below in relation to Figures 14A- 14D. These include but are certainly not limited to liquid glues, glue spots, adhesive tabs, hot melt, tape, spray on dispersion, pattern adhesives, adhesive single sided tape, adhesive double sided tape, contact adhesives, glue dots, adhesive gel, gel dots, adhesive cloth, tapes with adhesives, meshes with adhesives, any folding member with these adhesives, gelatin, natural adhesive compounds and the like and similar mechanisms of controlled application of an adhesive. The adhesive itself may be any adhesive suited for the particular liquid or gas media being filtered and the requirements for the mechanism selectively removing the pleats from the selected spacing folded, pleated media stack.

For example, in addition to utilizing the selective application of a double sided tape as an adhesive as shown in Figures 14A and 14B, another non-limiting example can be found in the use of a hot melt adhesive that is pattern coated onto the length of pre-pleated sheet of material and a still further non-limiting example shown in Figure 14D having a measured glue dot placed in the trough of each pleat to adhere a section of the pleats in a similar fashion as that shown in Figure 14D. In the case of selectively applied adhesives, such as pattern adhesives or glue dots, the size of the adhesive element will be inversely proportional to the size of the adhesion element, e.g. bigger dot smaller spacing. Such processes would allow for targeted application of adhesive on sections of the individual pleats, allowing use of the process to provide adhesive on a selected portion of the pleat, as discussed above, to vary along any section from peak to trough and back to a peak. Similarly, in conjunction with a connecting material, the uses of a hot melt adhesive on the peaks can be used to adhere the connecting material and secure the spacing through the pleat spacing support element in the filter material.

Similarly, the angle of the application of the adhesive element or adhesive and the process or method of the application of same may be varied to suit the particular needs of the application. In this instance, the application is done as a perpendicular running line on the left, center, and right sides of three lines 22 A, 24 A, 26 A, respectively in Figure 14 A, of double sided tape on the pre-pleated sheet of material 10A. In other non-limiting examples of the application, a product may require that the adhesive be applied in a running line at another angle to the pre-pleated material or the line may be moved in and out from the center to vary the points of contact and potentially adjust the adhesion characteristics of the resulting filter media stack 100A. One example of such an embodiment is shown in Figure 14C showing the application of two lines of double sided tape 22 A, 24 A in a crisscrossed pattern.

Additionally, the process may include the use of protective liner components used in conjunction with the adhesive to selectively protect against adhesion during any handling processes. For instance, one non-limiting example would be a protective layer that is typically retained on one side of the tape and can be removed during or after processing. Similarly, though not shown, non-adhesive components or protective liner elements can be placed on the adhesive to selectively render these sections non-adhesive, making a pattern in the adhesive sections.

As best seen in Figure 14B, the at least one adhesive element 20A, here the lines of double sided adhesive tape 22 A, 24 A, 26 A are adhered to each pleat 30A so as to contact each trough 40A and each top 50A on one side of the pre-pleated filter material 10A. This allows for coverage of the entire length of pre-pleated filter material 10A. The at least one line of adhesive element 20A is applied to all of the pleats in the pleated filter media stack 100A. It should also be noted that the media filter 10A and media cartridge 100A can also be deployed as a cartridge with folded frame portions that is deployed only as a maintenance function. The collapsed filter media, for instance pleated filter media.

Figure 15 shows compression of the pre-pleated filter media material with an at least one adhesive element into a folded, pleated media stack in an exemplary embodiment of the instant invention. The pleated filter media stack 100A is formed by advancing and cutting the pre-pleated sheet of material 10A shown in Figure 2 and cutting it to specific length to form a cut length of pre-pleated filter media sheet 15A and then compressing the now cut length pre-pleated sheet of material 15A into the folded, pleated filter media stack 100A as shown in Figure 15. In the process of compressing the pleated filter media stack 100A, the at least one adhesive element 20A is compacted and adheres the pleats in the cut length of pre- pleated sheet of material 15A in the pleated filter media stack 100A. The adhesive of the at least one adhesive element 20A is chosen so that it renders the pleats in the folded, pleated filter media stack 100A selectively removable from the stack. In other words, the adhesive bond strength of the at least one adhesive element permits removal of the pleats from the folded, pleated filter media stack 100 A by a selective removal device. The folded, pleated filter media stack 100A lacks, however, a specific spacing. That is, to ensure a specific pleat density additional processing of the folded, pleated filter media stack 100A must be undertaken. Additionally, in an exemplary embodiment, the spacing and selective removal from the folded, pleated filter media stack 100A will result in retention of a adhesion along a portion 45 A of each pleat 3 OA in the folded, pleated filter media stack 100 A as it is removed, as described herein below.

Figure 16 shows a close up of the pleats being adhered with an at least one adhesive element as the pleats are compressed into the folded, pleated media stack in an exemplary embodiment of the instant invention. The pleated filter media stack 100A is selectively separated in a further process to transform the filter media stack 100A into the selectively spaced, folded, pleated filter media stack 300 A herein described below in relation to Figures 18-20. In the exemplary embodiment shown, the pleated filter media stack 30A is selectively separated leaving an adhered portion 45A along only a select part of the length of each adhered pleat. However, separation along the entire pleat and/or shorter or longer portions of the pleats is contemplated and within the spirit of the invention. The adhered portion 45A as show acts as a barrier to leakage around the filter media when in a deployed state after being removed from the selectively spaced, folded, pleated filter media stack 300 A. In addition, the spacing of the filter media making up the folded, pleated filter media stack 100A is set.

Figure 17 shows a close up of the adhered pleats with an at least one adhesive element selectively applied to only a portion of each pleat as the pleats are compressed into the folded, pleated media stack in an exemplary embodiment of the instant invention. In this instance, an adhesive method is applied such that the pleat tops 50A are not covered by an adhesive element, such as the use of glue dots shown in Figure 14C or a pattern spray adhesive that is selectively applied.

As the individual pleats in the folded, pleated filter media stack 100A are removed they are separated for a specific filter media density or pleat per inch (PPI). This can be accomplished through a number of methods, so long as the identified or desired number of pleats is selected and an end or peak or fold 50 A of each pleat is exposed. A non- limiting method of selecting a PPI in the exemplary embodiment is through the use of a spacing selector device 200A in Figure 18 shown here as a fork mechanism with a specific tine spacing. Additional spacing device may be used, including but not limited to, helical devices or similar spacing selector devices. The spacing selector device 200A is set to accommodate a specific pleat spacing or PPI and concentrate the selected number of pleats in that spacing within each of the spaces between the tines.

The spacing selector device 200A selects the specified amount of pleats for the pleat density from the pleated filter media stack 100A to form a selected pleat section 70A. Pleat density can be, for instance but are certainly not limited to about 0.5 to 20 PPI, preferably about 1 to 10 PPI. This density can be adjusted based on any number of variables, including but not limited to the particular liquid or gas being filtered, the duty rating of the resulting filter, the type of filter material and the like. The pleat ends 50A of the selected pleat section 70A are then adhered by a further adhesive 60A as shown in Figures 18-20.

Figure 18 shows spacing a folded, pleated media stack, selectively engaging a spacing section, and applying an at least one spacing support element to maintain the selected spacing in an exemplary embodiment of the instant invention. The spacing support element 60 can be a similar or disparate adhesive element or adhesive as compared with the at least one adhesive element 20A. The spacing support element 60A may be applied in any suitable manner and can be varied in any manner as previously noted in relation to the at least one adhesive element 20A. The at least one support element 60A should be adhered to the tops of the pleats 50A as shown, however the support element 60A may be adhesive on one side, both sides, or may be adhered by a further adhesive element or component to said pleat tops 50A.

Figure 19 shows a selected spacing filter media with an at least one spacing support element prior to being compressed to a folded state for storage and transport. In the exemplary embodiment of Figure 19, the at least one spacing support element 60A is shown as three lines of spacing support elements having 62A, 64A, 66A respectively adhesive elements adhering the spacing support elements to the cut sheet of pre-pleated filter media 15 A. The at least one spacing support member or adhesive spacing support member can be for instance, but is certainly not limited to, adhesive cloth, adhesive mesh, adhesive single sided tape, adhesive double sided tape, glue applied to a folding structure, hot glue applied to a folding spacing support, glue dots applied to a folding spacing support, gels applied to a folding spacing support, gel dots applied to a folding spacing support, gelatin applied to a folding spacing support, natural adhesive compounds applied to a folding spacing support and the like. The spacing support element 60 A should likewise be suitable and non-reactive for the application and liquid or gas being filtered.

In the exemplary embodiment shown, the three lines of spacing support element 62A, 64A, 66A are single sided tape. The three lines of spacing support elements 62A, 64A, and 66 A each contact each of the pleat tops 5 OA. In this instance, the three lines of spacing support elements 62 A, 64 A, 66 A are in adhesive contact with the pleat tops 50 through pressure sensitive adhesive on the same side of the cut filter media sheet 15A making up the folded, pleated filter media stack. Further spacing support elements 60A may be applied to either side of the cut filer media sheet 15 A. Any of the at least one spacing support elements 60A can be adhered to the same side or the opposite side from the at least one adhesive element 20A. Thus, if applied to the reverse side, they are in adhesive contact with the troughs 40A in the previous application of the at least one adhesive element 20A in that configuration. The respective pleat tops 50A or troughs 40 A, depending on orientation, or both are engaged by the spacing support element 60A to lock in the desired spacing as set by the at least one spacing section 70A selection. In addition to locking in the spacing, the spacing support element 60 A aids in supporting the pleats 30A from being collapsed in the flow of the medium being filtered. As noted above, adhesion to the tops 50A of the pleats in either orientation is contemplated herewith and will function in a similar fashion.

The at least spacing support element 60A, in this case spacing support elements 62A, 64 A, 66 A, are applied such that each of the pleat tops 50A is secured thereto. The attachment of the spacing support elements 62A, 64A, 66A is not intended to be released from this point of contact as it secures the proper spacing when the at least one filter media stack 100A is moved to an open or operating position as shown in relation to Figures 7A and 7B. The at least one spacing support element 60 A remains in adhesive contact with the pleat tops 50 after release from the folded, pleated media stack 300A. This "locks in" or secures the pleat spacing or PPI for the selected pleat section 70A. The process is repeated for the length of the filter media stack 100A.

Figure 20 shows a series of pleats being compressed into a selectively spaced, folded, pleated media stack in an exemplary embodiment of the instant invention. Figure 5C shows a series of pleats in an exemplary embodiment of the instant invention. As noted above, as shown in the Figures 18 and 19 describing the exemplary embodiment, the pleat ends 50A hold the PPI for the filter media to provide a filter media stack with the selected PPI 300. In addition, the individual pleats 30A remain adhered at a bottom portion or trough 45 and up along a section of the pleat 3 OA. The adhered section 45 A along the individual pleats 30A can be provided along the edges or sides of the filter media stack 300 A, as shown, to prevent seepage around the ends of the media and effectively seal the ends when extended in an operational state while providing for the adhering of the filter media stack 300A. This spacing can be removed, as noted above. Additionally, as noted in Figure 17, in some applications the pleat tops may be free of adhesive. In these instances, the at least one spacing support element 60A should be affixed through its own adhesive or application of an additional adhesive to the pleat tops to lock in the spacing. The cut sheet of filter media 15A with its pleats 3 OA, having had the pleat tops 50A adhered to an at least one spacing support element 60, are compacted into a selectively spaced, folded, pleated media stack 300A.

Figure 21 shows an exemplary embodiment of an article of manufacture of a folded, pleated media stack in a frame of the instant invention. Following the adhesion of the pleat ends 50A to the spacing support element 60A, the folded, pleated filter media stack 100A is returned to a compressed state as show in Figure 18 with the spacing support element likewise now folded and adhesively attached to retain the selected spacing. The filter media stack 100A is then prepared to be engaged by a filter that utilizes and dispenses the folded, pleated filter media stack 100A into an exposure zone. Applicants co-pending U.S. Patent Applications, patents, and the description herein describe some exemplary embodiments of such filters and an exemplary embodiment is shown herein below. The article of manufacture of the instant invention shown in Figure 6 shows the folded, pleated filter media stack 100A with the pleats 40A being adhered by an at least one adhesive or adhering element 20A and the spacing being secured by an at least one spacing support element or spacing adhering element as described herein above in relation to Figures 13-20. The folded, pleated filter media stack 100A being placed in a frame 17A. The folded, pleated filter media 100 A being transportable in the frame or directly deployable in a filtration operation or in a filtration device or application.

In such an application, the at least one adhesive element 20A of each of the pleats 40A is engaged along at least a portion of the pleat 45A between successive peaks 50A and along a trough 40A there between with an adhesive. The pleats 40A are each selectively removable from the folded, pleated filter media stack 100A. In an exemplary embodiment, the at least one adhesive element 20A is applied at or near a side 16A, 18A of the frame 15 A. With such a distribution, the folded pleated filter media stack 100A can have the individual pleats 40A selectively removed from the adhesion in such a fashion that each pleat 40A retains an adhered portion 45 A and the adhered portion 45 A forms a seal along said ends 16A, 18 A, as noted above. The extent of the adhered portion 45A of the pleat 40A can be varied based on the implementation or the adhered portion 45A may be avoided based on the application of the spacing support element 60A and the pleat spacing in the particular folded, pleated media filter stack 100A or filter using folded, pleated media filter stack 100A. Similarly, as noted herein, the type of adhesive can be varied. Some non-limiting examples of variables used in selecting the adhesive can include release strength, the gas or liquid medium in the flow, reactivity with the medium in the flow, and similar parameters for the folded, pleated media filter stack 100A or filter using folded, pleated media filter stack 100A.

Figures 22A and 22B show a top view and side cutaway view respectively of a further exemplary embodiment of the instant invention. A power source 5000 A is provided, here the non- limiting example being shown as two batteries. The power source 5000 A provides power to the at least one motor 4000A, in this exemplary embodiment a non-limiting example having two motors, and a controller 6000A. The exemplary embodiment utilizes a folded pleated filter media 7000A stored in one side of the housing or frame structure 1000A forming a pleated filter media stack 300 A of uncontaminated filter media 7200 A in the filter media storage area 7500 A.

The folded pleated filter media stack 300 A is stored and the pleats are adhered in at least a portion of the space between the tops or peaks 3200A and troughs or valleys 3300A of each pleat 3100A sealing its sides. Additionally a specific spacing of the pleats or "pleats per inch" is provided in the pleated filter media 7000A. In this instance, the spacing is kept by an at least one pleat support member 3400A, for instance a running length of tape or similar adhesive element as shown running with the same axis as that of the movement of the device. Additional methods, as discussed above and evident to one of ordinary skill in the art, may be used to provide the folded, pleated filter media stack 300 A and the at least one pleat support member 3400A, so long as the folded, pleated filter media stack 300A is provided in the compact form and can be selectively removed by the at least one movement member 2000A in the direction shown with the motion arrow in the figures.

The at least one movement member 2000A moves the filter. In this instance the at least one movement member 2000A is a type of screw drive, a threaded rod screw drive. In this exemplary embodiment the at least one movement member 2000A is shown as two threaded rod screw drives 401 OA, 4020A. The pair of threaded rod screw drives 401 OA, 4020A are each supported on one end by a movement member support 4100A. The at least one motor 4000A, in this case a motor for each threaded rod screw drive 4010, 4020, engages the threaded rod screw drive 401 OA and turns the threaded rod screw drive 401 OA within the movement member support 4100A.

A support member 1050A is shown just outside of the at least one exposure slot 7000A inside the pleated filter media storage area 7500A. The support member 1050A is used to move the media from the filter stack 300A. The support member 1050A in a non-limiting example used in the exemplary embodiment is a plate threaded onto each of the threaded rod screw drives 401 OA, 4020A. Thus the folded, pleated filter media stack 300A is moved from its compacted position to an extended or operating position to replace the exposed filter, effecting a partial or a complete change of the filter material in the exposure slot. In the embodiment shown, there are caps shown in shadow (dotted lines) that cover the housing 1000A and define the exposure slot. In addition to the caps, an at least one housing support 1250A, hear a crossed set of members, is shown in shadow.

Each of the threaded rod screw drives 401 OA, 4020A is engaged by the respective motor 4000A when initiated by the controller 6000A. The controller 6000A signals the motor 4000A based on any of the aforementioned manners, including but not limited to a timer or a sensor 8000A output. The controller 6000A is provided to selectively determine when to advance the threaded rod screw drives 401 OA, 4020A by engaging the motors 4000A. The controller 6000A, as noted above, can be a simple timer. However, in a non-limiting example, as shown in this exemplary embodiment an optical sensor 800A is used to send signal the need for advancement of the pleated filter media.

In this exemplary embodiment the optical sensor 8000A is provided and communicates with the controller 6000A. The optical sensor 8000A sends a signal when a threshold measurement is reached. Software on the controller determines when these measurements are made and the threshold levels of obstruction or color change on the exposed filter media 7700A. In addition to the frame 10A and the threaded rod screw drives 401 OA, 4020A, as noted housing support members 125 OA are provided at an angle from one side to the other on the housing 1000A to provide additional structural support.

The threaded rod screw drives 401 OA, 4020A engage the support member 1050A when the controller 6000A signals the motor 4000A and begins a change of the filter media 7000A that has been exposed in the at least one exposure slot 7000A to create an exposed filter media 7700A portion. The at least one support member 1050A is pulled toward the motors 4000A in this exemplary embodiment as shown by the arrows denoting movement. The support member 105 OA can also be pushed from the side with the motors 4000 A without departing from the spirit of the invention. The folded, pleated filter media is unstacked and moved into the exposure slot 7000 A by the threaded rod screw drives 401 OA, 4020 A while maintaining the pleat spacing or PPL The threaded rod screw drives 401 OA, 4020 A then move the exposed pleated filter media 77A through the exposure slot 7000A and into a containment or storage area 9000A at an end of the housing or frame 1000A while simultaneously moving the unexposed pleated filter media 7200A from the filter media stack 4000A, selectively removing the pleats from their adhered and stored state to a deployed or extended or unstacked state for filtration of the flow within the flow channel.

In addition to the unitary frame embodiment shown above, the filter media stack may be provided as a separate article of manufacture for use in a cartridge type filter. A non-limiting example of such a filter would simply employ a rail in rail system in the frame or housing in the above example. In one half of the frame or housing that detaches from the other half the storage area would be contained. On the other half would be the containment area. The folded, pleated filter media stack could be replaced by simply separating the housing and replacing one half of the housing. Allowing of course for the backing out and release of the spent media. Other embodiments could also allow for separation of the containment area and the storage area separately, essentially a three part frame. The replacement and the article of manufacture of the instant invention therefore includes the folded, pleated storage media stack in a frame or as a cartridge.

Similarly, though a rectangular frame is contemplated, the movement and systems for moving the folded, pleated filter media stack or use of the folded, pleated and adhered filter media in a static deployed state in a non-rectangular filter is contemplated. Additionally, an embodiment utilizing similar components but simply omitting the controller and power source is hereby contemplated. The housing with a movement member, here a slide or other device, upon which the filter media stack 100A, is engaged. The movement member is moved by a user, for instance the filter media stack 100A may slide on rails or as part of a hand cranked screw. The movement member may have sweep bars, as disclosed above in relation to previously disclosed embodiments, and these may be used to keep multiple filter changes in the stack. Alternatively, each filter media stack 100A may be held in place by a release mechanism (not shown), for instance a pull tab. These may be paired with a locking mechanism (not shown) that would lock the expanded filter media stack 100A in its expanded state.

Figures 23 and 24 show a further exemplary embodiment of the invention for high loft material. High loft material is recognized in the industry as material with a higher width and almost "cotton" fluff like look and feel to it. These materials have less of a weave and no memory for retaining a pleat. A length of high loft material 100 A is provided in Figure 8. Current designs of filters for this material rely on a grid or other lattice like structure adhered across the entirety of the material. A support grid 105 A is provided in this embodiment with a sheet of high loft material 100 adhered thereto.

As noted, the support grid 105 A is attached to support the high loft material 100A and provide it with memory to retain a shape. In this instance, the support grid 105 A is scored with a scoring machine at a score line 115A at a specific point repeatedly across the width of the high loft material 100A to form pleats. The scoring process does not cut the high loft material 100A, but does cut or at least partially cut the grid 105 A along the score line 115 A.

Figure 25 shows a sheet of high loft filter media applying an at least one adhesive element thereon. The grid 105 A as scored along score line 115A is now foldable at the score line 115 A. The high loft material with the scored grid 120 A is processed in a manner similar to that above in Figures 12-20. Using an at least one adhesive element 200 A, the high loft material with the scored grid 120 A is then folded and compressed along the score lines 115A and adhere the pleats 25 OA formed by the high loft material with the scored grid 120 A. This forms the high loft pleated high loft filter media 110A. To further transform the cut pleated high loft filter media 117A into an analogous folded, pleated high loft filter media stack 300 A, in a manner similar to the steps as noted above in relation to the method of Figures 12- 20 an at least on spacing section is selected, an at least one spacing support member 600A is applied, and the media is folded and compressed. The materials and variables noted for the application of the at least one adhesive element 20A and the spacing support element 600A apply for the at least one adhesive element 200A. The type, angle, distribution, location, type of the at least one adhesive element 200A and other variables in the selection and location of the at least one adhesive element 200A may be varied to suit a particular application without departing from the aspects of the invention as noted above.

Figure 26 shows the at least one spacing support element 600A applied to the cut high loft filter media 117A. To achieve the desired folded, pleated high loft filter media stack 300A shown in Figure 27, the adhered pleats 250A of the cut high loft filter media 117A are selectively separated as above, for instance with a spacing selector device 200A shown in Figures 16-17 above. Although a similar application of an at least one line of tape may be used, another embodiment of the at least one spacing support member is shown in Figure 10. In the embodiment shown, an adhesive netting 61 OA is shown. The adhesive mesh or netting 61 OA is applied to hold the spacing of the pleats 61 OA as an at least one spacing support member 60A, in the same manner described above in relation to Figures 12-20, the adhesive mesh 61 OA contacting a number of points across the tops 50A of each pleat 3 OA. The end result is a folded, pleated high loft filter media stack 300 A that can be provided as an article of manufacture in an identical fashion to that of the exemplary embodiments of Figures 12- 21 above but using a high loft material.

Figure 27 shows a compressed folded, pleated high loft filter media stack. Similar to the final steps of the exemplary embodiment of Figures 12-20, the method provides for an article of manufacture from the method, a compressed folded, pleated high loft filter media stack 300 A. As noted, to achieve the desired folded, pleated high loft filter media stack 300 A, the adhered pleats 250A of the cut high loft filter media 117A are selectively separated as above, adhered at the pleat tops 500 A to the at least one spacing support member as shown in Figure 10. The adhesive mesh or netting 61 OA is applied in addition to the at least one adhesive element 200A to hold the spacing of the pleats, in the same manner described above in relation to Figures 12-20, the cut high loft filter media 61 OA is thus transformed to a folded, pleated high loft filter media stack 300 A. The end result being the folded, pleated high loft filter media stack 300 A that can be provided as an article of manufacture in an identical fashion to that of the exemplary embodiments of Figures 12-21 or used in a filter similar to the media stack of Figure 21 above but using a high loft material.

The embodiments and examples discussed herein are non-limiting examples. The invention is described in detail with respect to preferred embodiments, and it will now be apparent from the foregoing to those skilled in the art that changes and modifications may be made without departing from the invention in its broader aspects, and the invention, therefore, as defined in the claims is intended to cover all such changes and modifications as fall within the true spirit of the invention.

Claims

CLAIMS What is claimed is:

1. A replacement filter within a flow channel comprising:

a first frame portion of an at least two frame portions'

an at least one movement device

an at least one motor coupled to and driving the at least one movement device;

an at least one power source powering the at least one motor;

a controller;

an at least one filter media stack having a filter media, the filter media being pleated and folded and compactly stored in the stack;

a second frame portion of an at least two frame portions that couples with the first frame portion of the at least two frame portions forming a housing with an at least one exposure slot through which the fluid channel passes, the first and second frame portions of the at least two frame portions coupling such that the at least one movement member engages the at least one filter media cartridge stack in one of the at least two frame portions, the at least one member moves the filter media upon instruction from the controller from a pleated, folded and compact state to extend across the at least one exposure slot to expose the pleated and extended filter media to the flow and through the movement of the at least one movement member to remove exposed filter media and restack and store the exposed filter media in a media cartridge stack.

2. The filter of claim 1, wherein the movement member further comprises at least one of a cord, wire, string, track, puller or pinch rollers, star, toothed, or pin roller, screw drive, threaded rod, or a take-up roller.

3. The filter of claim 1, wherein the movement member comprises an at least one threaded rod threaded rod and further comprises an at least one sweep bar, wherein the threaded rod engages the sweep bar and moves the filter media and each of the at least one sweep bars, where each of the at least one sweep bars is spaced such that each bar separates a length of filter media that fills the space across the exposure slot.

4. The filter of claim 1, wherein the pleated and folded and compactly stored filter media further comprises an adhesive element wherein the adhesive bond strength of the at least one adhesive element permits removal of the pleats from the folded, pleated filter media stack by a selective removal device such that an at least one portion of the pleats at the point of contact with the adhesive element may remain adhered.

5. The filter of claim 1, wherein the at least one movement device and the at least one motor are contained within the first frame portion.

6. The filter of claim 5, wherein the at least one filter media stack is contained in the second frame portion.

7. The filter of claim 1, wherein the filter media stack is at one end of the housing in a storage area.

8. The filter of claim 1, wherein the exposed filter media is stored in a containment area.

9. The filter of claim 1, wherein the containment area is sealed.

10. The filter of claim 1, wherein the containment area is at a further end of the housing.

11. The filter of claim 1 , wherein the filter media is drawn from the filter media stack into a storage area and stored in a compact, pleated, and folded fashion.

12. The filter of claim 11, wherein the containment area is within the filter media stack, such that the filter material is drawn back into the filter media cartridge after exposure.

13. The filter of claim 1, wherein the first and second of the at least two frame portions are of uniform thickness.

14. The filter of claim 1, wherein the first of the at least two frame portions has channel portions.

15. The filter of claim 14, wherein the second of the at least two frame portions has leg portions that sliding engage the channel portions to couple the first frame portion and second frame portion of the at least two frame portions.

16. The filter of claim 1, wherein the filter media stack comprises an at least one portion of filter media of sufficient length to provide sufficient unexposed filter to cross the exposure slot and become exposed filter media.

17. The filter of claim 16, wherein the sensor reports a condition of the exposed portion of the filter media to the controller and the controller upon receipt of the condition determines if movement of the movement member moves an amount of unexposed media into the exposure slot to cover the exposure slot.

18. The filter of claim 17, further comprising several spacers or sweep bars which divide several lengths of unexposed media which are stored and moved into the exposure slot based on commands from the controller.

19. The filter of claim 1, wherein the first frame portion of the at least two frame portions is a cartridge with the filter media stack therein and the second frame portion of the at least two frame portions is a frame, wherein the filter cartridge is placed within the frame and engaged by the movement member.

20. The filter of claim 19, wherein the frame is constructed of stiffened cardboard or plastic or metal.

21. The filter of claim 19, wherein the frame contains the at least one motor with the at least one power source and the controller.

22. The filter of claim 19, wherein the at least one cartridge contains the at least one movement member.

23. The filter of claim 22, wherein the at least one motor is coupled to the at least one movement member through a coupling that penetrates through the exterior of the filter cartridge.

24. The filter of claim 19, further comprising an at least one securement coupling wherein with the insertion of the filter cartridge into the frame the at least one securement coupling secures the filter cartridge and engages the coupling.

25. The filter of claim 1, wherein the first frame portion of the at least two frame portions further comprises a supply cartridge and the second frame portion of an at least two frame portions further comprises a collection cartridge and a third frame portion of an at least two frame portions couples to the first and second portions to form the housing with the first and second portions of the at least two portions extending from the housing.

26. The filter of claim 25, further comprising an at least one securement coupling the supply cartridge and the collection cartridge to the housing.

27. The filter of claim 26, wherein the at least one securement coupling is an at least one of an at least one releasable straps, snaps, buckles, interlocking parts slidingly engaged, clasps, and friction fit elements.

28. The filter of claim 27, wherein the filter media stack extends in the supply cartridge in the same plane as the housing with a movement bar dividing the pleated, folded and stacked filter media stack.

29. The filter of claim 28, wherein the media stack is advanced and a further media stack having a sweep bar is pulled down from the supply cartridge.

30. The filter of claim 29, further comprising an at least one guide member to assist in advancing the exposed folded, pleated media into the collection cartridge.

31. The filter of claim 30, wherein the media stack is withdrawn into the collection cartridge and the sweep bar is driven along a single threaded shaft as a movement member in the middle of the housing and then upward onto a further guide member into the collection cartridge.

32. The filter of claim 1, wherein the collection cartridge is U-shaped, straight horizontal, vertically stacked, or s-shaped.

33. The filter of claim 1, wherein the collection cartridge is an angled collection cartridge.

34. The filter of clam 1, further comprising an at least one guide rail in the collection cartridge.

35. The filter of claim 1, wherein the guide rail is a turning screw mechanism and assists in driving an at least one sweep bar.

36. The filter of claim 1, wherein the movement member is an auger screw on the collection cartridge side of the exposure slot and a star wheel indexer on the supply cartridge side of the exposure slot.

37. The filter of claim 1, wherein the controller further comprises an at least one processing module and an at least one transceiver module on the controller and an at least one sensor, the controller communicating with the at least one sensor, the at least one sensor communicating data to the processing module and the controller, and the transceiver module transmitting data from the filter to a network or a storage device.

38. The filter of claim 1, wherein the at least one sensor is coupled to the controller and sensing an at least one operating parameter for the filter.

39. The filter of claim 38, wherein the at least one sensor measures temperature, mold count, carbon monoxide, carbon dioxide, Volatile Organic Compounds (VOCs), smoke, fire, noxious gases, and air particle concentrations or the at least one sensor measures air flow and reports estimated energy consumption to the network or storage device.

40. The filter of claim 38, wherein the controller communicates through the transceiver module with a further network interface device.

41. The filter of claim 40, wherein the network interface device is a Wi-Fi enabled device or an internet gateway to a network which in turn reports it to an alert device or a Network Operations Center or control center.

42. A replacement filter deployed within a flow channel comprising:

a housing having a first frame member of an at least two frame members and a second frame member of an at least two frame members that are detachable with an at least one exposure slot formed within the housing by the at least two frame members;

an at least one filter media storage area within the housing, having unexposed, folded, pleated filter media stored therein, the unexposed folded, pleated filter media being pleated, folded, and stacked to be compactly held within the at least one filter media storage area;

an at least one motor coupled to a power supply and in communication with a controller, the at least one motor moving an at least one movement member that advances an unexposed portion of the compactly held pleated, folded, and stacked pleated filter media into the at least one exposure slot, expanding and exposing the unexposed portion of the pleated filter media to the flow channel while retaining the pleats and creating an exposed portion of the at least one pleated filter media; and

a containment area, wherein the exposed portion of the pleated filter media is collected folded, restacked and compactly stored and retained within the containment area.

43. The filter of claim 42, wherein the containment area is a filter media cartridge, the filter media cartridge containing a folded pleated filter media stacked and stored so as to be in a compact state and, after being engaged by the at least one movement member, selectively removed from the compact state.

44. The filter of claim 42, wherein the stacked filter media is held with an at least one adhesive element having a separation force such that the separation force allows for separation of the folded, pleated filter media such that an element of the pleat remains adhered so as to prevent air flow around an edge of the unexposed portion of the filter media when it is in the exposure slot.

45. The filter of claim 42, wherein an at least one processing module and an at least one transceiver module on the controller and an at least one sensor, the controller communicating with the at least one sensor, the at least one sensor communicating data to the processing module and the controller, and the transceiver module transmitting data from the filter to a network or a storage device.

46. The filter of claim 42, wherein the at least one movement member comprises a star wheel moving the material from a portion containing the unexposed filter media with pleats contained thereon and an at least one auger screw drive assisting in collecting the exposed, pleated filter media and further comprising an at least one support assisting in supporting the filter media on the pleats and assisting in producing a pleated pattern.

47. The filter of claim 42, wherein the first frame member is a housing frame and the second frame member is a filter.

48. The filter of claim 47, further comprising an at least one motor coupling, the at least one motor coupling engaging the at least one motor to the at least one movement member wherein the first frame member contains the at least one motor, the at least one controller, and the at least one power source and the second frame member contains the filter media stack and the at least one movement member.

49. The filter of claim 47, further comprising an at least one motor coupling, the at least one motor coupling engaging the at least one motor to the at least one movement member wherein the first frame member contains the at least one motor and the at least one controller and the second frame member contains the filter media stack, the at least one movement member, and the at least one power source.

50. The filter of claim 42, wherein the at least one movement member is at least one of at least one of a cord, wire, string; track, puller or pinch rollers, star, toothed, or pin roller, screw drive, threaded rod, or a take-up roller.

51. The filter of claim 42, wherein the at least one movement member is at least one screw drive or threaded rod.

52. The filter of claim 1, wherein the at least one movement member is an at least one screw drive or threaded rod.

53. A method of manufacturing a selected spacing folded, pleated media stack comprising: preparing a pre-pleated sheet of filter media having pleats with peaks and troughs throughout its length;

applying an at least one adhesive element along the pre-pleated sheet of filter media applied to all of the pleats;

advancing and cutting the pre-pleated sheet of material to specific length to form a cut length of pre-pleated sheet of filter media with the at least one adhesive element applied thereon; compressing the cut length of pre-pleated sheet of filter material, the process of compressing the cut length of pre-pleated sheet of filter media resulting in folding of the pleats and adherence of the pleats of the cut length of pre-pleated sheet of material into a folded, pleated filter media stack that is selectively seperable;

selectively separating the folded, pleated filter media stack and selecting a pleat spacing for a selected pleat spacing section, the size of the pleat spacing section corresponding to the selected pleat spacing;

further application of an at least one spacing support element at the peaks of each pleat in adhesive contact with the selected pleat spacing section, adhering the peaks of the selected pleat spacing section to the at least one spacing support element to secure the selected pleat spacing in the cut pre-pleated filter media material that comprises the folded, pleated filter media stack; and refolding and recompressing the folded, pleated filter media stack and the at least one spacing support element into a selected spacing folded, pleated media stack wherein the media stack is adhered and can be selectively removed to extend the folded, compacted filter media pack from the folded, compacted state to a deployed state with the selected pleat spacing.

54. The method of claim 53, wherein the step of applying the at least one adhesive element further comprises applying multiple adhesive elements at multiple application points across the pre-pleated sheet of filter media

55. The method of claim 54, wherein the step of applying the multiple adhesive elements further comprises applying three lines of adhesive elements, wherein the adhesive elements are three lines of double sided tape with an adhesive.

56. The method of claim 55, wherein step of applying the multiple adhesive elements further comprises applying the three lines of adhesive lengthwise on the pre-pleated sheet of filter media with a first line being on a first edge of the pre-pleated sheet of filter media, a second line being at a middle point of the pre-pleated sheet of filter media, and a third being on a second edge of the pre-pleated sheet of filter media.

57. The method of claim 54, wherein the step of applying multiple adhesive elements at multiple application points across the pre-pleated sheet of filter media further comprises applying perpendicular lies of multiple adhesive elements across the pre-pleated sheet of filter media.

58. The method of claim 53, wherein the step of applying an at least one adhesive element further comprises the step of varying at least one of the type, angle, distribution, location, and type of adhesive as between the at least one adhesive element.

59. The method of claim 55, wherein applying three lines of adhesive elements further comprises the method step of varying the application of at least one of the angle, distribution, location, and type of adhesive as between the three lines of adhesive elements.

60. The method of claim 53, wherein the step of applying adhesive elements further comprises applying an at least one adhesive element selected from the group comprising at least one of glue spots, adhesive tabs, liquid glue, hot melt, tape, spray on dispersion, pattern adhesives, adhesive single sided tape, adhesive double sided tape, contact adhesives, glue dots, adhesive gel, gel dots, adhesive cloth, tapes with adhesives, meshes with adhesives, any folding member with these adhesives, gelatin, and natural adhesive compounds.

61. The method of claim 53, wherein the step of applying an at least one adhesive element further comprises applying a hot melt adhesive that is pattern coated onto the length of the pre- pleated sheet of filter media.

62. The method of claim 54, wherein the step of applying multiple adhesive elements at multiple application points further comprises moving at least one of the applied multiple adhesive elements in an at least one direction to or from a center point of the pre-pleated sheet of filter media so as to vary a resulting point of adhesive contact on individual pleats of the pre- pleated sheet of filter media.

63. The method of claim 53, further comprising applying an at least one protective liner component on the at least one adhesive component to selectively protect against adhesion of the pleats of the pre-pleated material during the manufacturing process.

64. The method of claim 63, further comprising the method step of removing the at least one protective liner applied to the at least one adhesive element.

65. The method of claim 53, wherein the step of selectively separating the folded, pleated filter media stack further comprises selectively separating each pleat the entire pleat, releasing the at least one adhesive element in contact therewith, prior to the selection of a pleat spacing section and the step of applying a spacing support element.

66. The method of claim 53, wherein the step of selectively separating the folded, pleated filter media stack further comprises selectively separating each pleat along only a portion of the pleat, releasing only a portion of each pleat, prior to the selection of a pleat spacing section and the step of applying a spacing support element.

67. The method of claim 54, wherein the method step of selectively separating the folded, pleated filter media stack along an at least one portion of the length of each adhered pleat for a selected pleat spacing section corresponding to a selected pleat spacing or pleat per inch further comprises application of a spacing selector device to select the selected pleat spacing section.

68. The method of claim 53, wherein the selected pleat spacing is between about 0.5 to about 20.

69. The method of claim 53, wherein the selected pleat spacing is between about 1 to about 10.

70. The method of claim 53, wherein the method step of selecting the pleat spacing further comprises selecting a pleat spacing that is relate to at least one of the density of the liquid being filtered, the density of the gas being filtered, the duty rating of the filter media, and the type of filter material.

71. The method of claim 53, wherein in the step of applying the at least one adhesive element and in the step of applying the spacing support element, dissimilar types of adhesive elements are utilized.

72. The method of claim 53, wherein the sheet of filter media is a sheet of high loft filter media and the step of preparing a pre-pleated sheet of filter media having pleats with peaks and troughs throughout its length further comprises preparing a high loft sheet of media, scoring an at least one support grid to allow for forming of pleats, adhering the support grid to the high loft sheet of media and folding the high loft sheet of media to form a pre-pleated sheet of high loft filter media.

73. The method of claim 72, wherein the method of further application of an at least one spacing support element further comprises application of a netting member across the width of the sheet of high loft filter media adhering the netting member to the peaks of the selected pleat spacing section to secure the selected pleat spacing in the cut pre-pleated high loft filter media sheet and the refolding and recompressing step further comprises refolding and recompressing the cut pre-pleated high loft filter media sheet such that the cut, pre-pleated high loft filter media sheet is folded and adhered and the netting is similarly folded to form the selected spacing folded, pleated media stack.

74. The method of claim 53, wherein the step of applying adhesive elements further comprises applying an at least one adhesive element wherein the amount of adhesive in the adhesive element is inversely proportional to a desired spacing of the pleats in the pleated filter media.

75. A folded, pleated media stack product manufactured by the method of claim 53.

76. A filter engaging a selected spacing folded, pleated media stack manufactured by the method of claim 53.

77. A selected spacing folded, pleated media stack comprising:

a cut portion of pre-pleated filter media having pleats, each pleat having a top and a trough and a successive top;

an at least one adhesive element running along the length of the cut portion of pre-pleated filter media through each pleat from each top to trough to the successive top;

an at least one adhered section between the top and successive top of the pleat being adhered by the at least one adhesive element; and

an at least one pleat spacing section wherein the at least one pleat spacing section is selected and then an at least one spacing support element is adhered to each pleats top and successive top such that the at least one spacing support element maintains the spacing in the at least one pleat spacing section such that the at least one adhesive element selectively adheres the pleated material in a selected spacing folded, pleated media stack when compressed with the at least one spacing support element further folded and compacted and the selected spacing folded, pleated media stack allowing for selective release of each pleat from the compressed state to an operating state such that the at least one adhered section is retained and the spacing support element maintains the spacing when in the operating state.

78. A filter media cartridge, comprising:

an at least one frame member having a pleated, folded filter media mounted therein; and an at least one movement member having the pleated folded filter media mounted thereon and free to move thereon, wherein the pleated folded filter media mounted thereto has an at least one adhesive element attached which is compressed such that the pleats of the pleated folded filter media are adhered when in a compacted pleated folded media stack within the housing the filter media cartridge being deployed from the compacted pleated folded media stack when in a filter device and moved from the adhered compacted pleated, folded state to an expanded state while providing side sealing in the filter device.

79. The filter media cartridge of claim 78, wherein the at least one movement member is a motor.

80. The filter media cartridge of claim 78, wherein the at least one movement member is a user manually moving the filter media stack within the filter media cartridge.

81. The filter media cartridge of claim 80, wherein the at least one movement member is pull tab pulled by the user.

82. The filter media cartridge of claim 78, further comprising a locking mechanism, wherein the movement member moves the filter media stack and the locking mechanism locks the media at a position whereby it is deployed.

83. The replacement filter of claim 1 or 42, wherein the controller is a push button activated by a user of the replacement filter to advance the unexposed portion of the pleated folded and stacked pleated filter media.