Air filter devices with gap sealing unit

Abstract

An air filter device including an air filter unit and an expansion unit. The air filter unit includes a filter media assembly maintained by an outer frame assembly. The outer frame assembly defines exterior length, width and depth dimensions of the air filter device in an initial state. The expansion unit provides one or more of an expanded length, width or depth in an expanded state of the air filter device. Portions or an entirety of the expansion unit can provided apart from the air filter unit in a deliver condition of the air filter device, or can be assembled to the air filter unit prior to delivery to a user. The air filter devices of the present disclosure are useful with a wide variety of differently size air handling devices, able to readily seal with an air handling device compartment via the expansion unit.

What is claimed is: 
     
         1 . An air filter device comprising:
 an air filter unit including:
 a filter media assembly defining a perimeter, 
 an outer frame assembly arranged about the perimeter and establishing exterior length,
 width and depth dimensions of the air filter device in an initial state; and 
 
   an expansion unit configured to effect an expanded state of the air filter device;   wherein at least one of the exterior length, width and depth dimensions of the air filter device is greater in the expanded state than in the initial state.   
     
     
         2 . The air filter device of  claim 1 , wherein the at least a portion of the expansion unit is configured for selective assembly to the outer frame assembly. 
     
     
         3 . The air filter device of  claim 1 , further comprising packaging containing the air filter unit and the expansion unit in the delivery condition. 
     
     
         4 . The air filter device of  claim 1 , wherein an entirety of the expansion unit is provided apart from the air filter unit in the delivery condition. 
     
     
         5 . The air filter device of  claim 1 , wherein the expansion unit includes at least a first standoff configured for selective mounting to the outer frame assembly, and wherein the first standoff includes a standoff body and an adhesive disposed on a face of the standoff body. 
     
     
         6 . The air filter device of  claim 5 , wherein the first standoff is sized for mounting to an end frame member of the outer frame assembly in the expanded state, and further wherein upon mounting of the first standoff to the air filter unit, the length dimension of the expanded state is greater than the length dimension of the initial state or the width dimension of the expanded state is greater than the width dimension of the initial state. 
     
     
         7 . The air filter device of  claim 1 , wherein the outer frame assembly includes a first frame member covering a first edge of the perimeter, and further wherein the expansion unit includes a first flange configured to project from the first frame member in the expanded state. 
     
     
         8 . The air filter device of  claim 7 , wherein the first side flange defines a fixed end attached to the first frame member and a free end opposite the fixed end, and further wherein the expanded state includes the free end laterally spaced from the first frame member. 
     
     
         9 . The air filter device of  claim 7 , wherein outer frame assembly further includes a second frame member covering a second end of the perimeter, and further wherein the expansion unit further includes a second flange configured to project from the second frame member in the expanded state. 
     
     
         10 . The air filter device of  claim 9 , wherein the expansion unit further includes a deflection device configured to bias the free end away from the first frame member. 
     
     
         11 . The air filter device of  claim 10 , wherein the deflection device includes a deflection body configured for placement between the first frame member and the first flange. 
     
     
         12 . The air filter device of  claim 11 , wherein the deflection device further includes an adhesive disposed on a face of the deflection body for selectively securing the deflection body to the first frame member. 
     
     
         13 . The air filter device of  claim 8 , wherein the first flange defines a fold line between the fixed and free ends, wherein the first flange includes a first portion between the fixed end and the fold line, and a second portion between the fold line and the free end, and further wherein the expanded state includes second portion overlapping the first portion. 
     
     
         14 . The air filter device of  claim 7 , wherein the first flange includes a panel and a first tab, wherein the panel defines a fixed end pivotably connected to the first frame member, a free end opposite the fixed end, and opposing, first and second sides, further wherein the first tab projects from the first side. 
     
     
         15 . The air filter device of  claim 14 , wherein the first tab terminates at a leading end opposite the first side, the leading end configured to selectively interface with respective ones of a plurality of slots. 
     
     
         16 . The air filter device of  claim 15 , wherein the outer frame assembly includes a second frame member covering a second edge of the perimeter, the second frame member arranged orthogonal to the first frame member, and further wherein the plurality of slots are defined in the second frame member. 
     
     
         17 . The air filter device of  claim 16 , wherein the first tab and the plurality of slots are configured to selective lock the panel at a plurality of different angular orientations of the panel relative to the first frame member. 
     
     
         18 . The air filter device of  claim 1 , wherein the perimeter includes opposing, first and second side edges and opposing, first and second end edges, and further wherein the outer frame assembly includes first and second side frame members covering the first and second side edges, respectively, and first and second end frame members covering the first and second end edges, respectively, and further wherein the expansion unit includes a first flange configured to project from the first side frame member in the expanded state, a second flange configured to project from the second side frame member in the expanded state, a third flange configured to project from the first end frame member in the expanded state, and a fourth flange configured to project from the second end frame member in the expanded state, wherein each of the flanges includes a fixed end connected to the corresponding frame member and a free end opposite the fixed end. 
     
     
         19 . The air filter device of  claim 18 , wherein adjacent ones of the flanges are slidably connected. 
     
     
         20 . The air filter device of  claim 1 , wherein the filter media assembly includes a pleated filter media defining a plurality of pleats.