CN117651832A - Core barrel for evaporative humidifier - Google Patents

Abstract

A wick assembly for an evaporative humidifier, the wick assembly comprising a wick and a cartridge. The wick is made of a water absorbent material. The cartridge defines a chamber in which the cartridge is located and includes at least one water inlet opening through which water is to be absorbed by the core and at least one air inlet aperture positioned above the water inlet opening in a condition of use through which air enters the chamber to evaporate water absorbed from the core.

Description

Core barrel for evaporative humidifier

Background

Evaporative humidifiers are used to provide moisture to a relatively dry room or space. Humidifiers of this type utilize a breathable, homogeneous absorbent material core (wick) that is immersed in water and positioned relative to a fan so that air can pass through the core and absorb moisture before being expelled into a room.

A known evaporative humidifier, such as that schematically depicted in fig. 1, includes a relatively large water tank 10 fluidly connected to a relatively small water reservoir 12 of an immersion wick 14. The water 20 in the tank 10 is guided under gravity through a feed 22 (feed) connected to the tank 12, as allowed by a valve 24 in the feed 22. The valve 24 is operated to hold a sufficient amount of water 20 in the reservoir 12 to be absorbed by the wick 14 without overfilling the reservoir 12. An air flow caused by a fan (not shown) passes through the wick, causing water to evaporate from the wick. These known types of evaporative humidifiers result in a lateral air flow substantially perpendicular to the wick at a fixed height defined by the amount of wick protruding from the water and are unrestricted, meaning that air is free to flow through the wick unimpeded. These humidifiers typically use two means to determine the humidity output into the room—the total exposed area (depth and/or area) of the core and the air speed (fan speed). The temperature and humidity of the air entering the unit is determined by the room conditions. As room humidity begins to increase, the output rate of the evaporative humidifier decreases for a given air velocity and core configuration, as humid air (higher relative humidity) will absorb less moisture than dry air.

Disclosure of Invention

In view of the foregoing, a wick assembly for an evaporative humidifier includes a wick and a cartridge (wick). The wick is made of a water absorbent material. The cartridge defines a chamber in which the core is located and includes at least one water inlet opening through which water is to be absorbed by the core and at least one air inlet aperture positioned above the water inlet opening in a condition of use through which air enters the chamber to evaporate water absorbed from the core.

According to another aspect, a wick assembly for an evaporative humidifier includes a wick and a cartridge. The wick is made of a water absorbent material. The cartridge defines a chamber that is isolated from an external environment external to the cartridge, wherein the core is located in the chamber, and the cartridge defines a water inlet, an air inlet aperture, and an outlet passage. The water inlet opening is configured for transferring water from an external environment into the chamber. The air inlet aperture is configured to communicate air from an external environment into the chamber. The outlet passage is configured for conveying air and water vapor from the core and the chamber to the external environment. The air inlet aperture is positioned between the water inlet opening and the air outlet channel in a wicking direction of fluid flow through the wick from the water inlet opening toward the air outlet channel.

According to another aspect, a method of manufacturing a core assembly includes providing a core barrel defining a chamber, a water inlet, an air inlet aperture, and an air outlet passage. The method further includes positioning a core in the chamber such that the core is positioned to absorb water passing through the water inlet opening to receive air passing through the air inlet aperture and direct the air toward the air outlet passage.

Drawings

Fig. 1 is a schematic side view of a known evaporative humidifier.

Fig. 2 is a schematic side view of an evaporative humidifier including a wick assembly.

Fig. 3 is a perspective view of the core assembly.

Fig. 4 is an exploded perspective view of the core assembly.

Fig. 5 shows an assembly method for the core of the core assembly.

Fig. 6 is an exploded perspective view of the core and cartridge, including the top cap, mineral pad and retainer.

Fig. 7 is an exploded view of a mineral collector for a core assembly.

Fig. 8 is a partial cross-sectional view of a cartridge including a cap.

Fig. 9 is an exploded perspective view of a cartridge including a top cap, a mineral pad, and a retainer.

Fig. 10 is a partial cross-sectional view of the core assembly.

Fig. 11 illustrates a method of making an alternative embodiment of the core assembly.

Fig. 12 is a perspective view of the core assembly shown in fig. 11.

Fig. 13 is a rear perspective view of an alternative embodiment of a core assembly.

Fig. 14 is a front perspective view of the core assembly shown in fig. 13.

Fig. 15 is a front perspective cross-sectional view of the core assembly shown in fig. 13.

Fig. 16 illustrates a method of making an alternative embodiment of the core assembly.

Fig. 17 is a perspective view of an alternative embodiment of an evaporative humidifier including an alternative embodiment of a wick assembly.

Fig. 18 is a perspective view of the core assembly shown in fig. 17.

Fig. 19 is a perspective view of an alternative embodiment of a core assembly.

Detailed Description

Referring to fig. 2, an evaporative humidifier 200 includes a power unit housing 202 and a water tank 204. The water tank 204 may be removable from the power unit housing 202. The power unit housing 202 may have an extension 210 in which the water tank 204 rests when the water tank is attached to the power unit housing 202. Blower assembly 212 includes at least one fan 214 and may also include at least one heater 220 disposed within power unit housing 202. Electronics 222 may be disposed within power unit housing 202. The electronics 222 may be configured to control the delivery of power to the blower assembly 212 and the at least one heater 220. The evaporative humidifier 200 may also include a power cord (not shown) to provide power input to the electronics 222. The evaporative humidifier 200 may also include a control knob 224 to allow an operator to control different settings (e.g., humidity setting, fan speed, temperature) via the electronics 222. Referring back to fig. 2, the electronics 222 may also be in electrical communication with a sensor 230 to control the operation of the evaporative humidifier 200. The water tank 204 defines a top opening 232, and the evaporative humidifier 200 includes a cover 234 covering the top opening 232.

The core assembly 240 is disposed within the water tank 204. The core assembly 240 includes a core barrel 242 and a core 244 disposed within the core barrel 242. Core 244 includes a primary core 250 and may also include a reinforcing core 252. The primary wick 250 is made of a material configured to optimize evaporation. Instead, the reinforcing core 252 is made of a material configured to optimize wicking and water storage and/or transfer of water to the primary core 250. The reinforcing core 252 has lower air permeability than the main core 250. Thus, the reinforcing core 252 may have higher adsorptivity than the primary core 250 and/or other characteristics that make it suitable for these three functions. The reinforcing core 252 is formed from a material that also has a higher liquid storage capacity than the material from which the primary core 250 is formed. The reinforcing core 252 may be formed of a material having a higher wicking ability than the material forming the primary core 250. The reinforcing core 252 may also be formed of a material having a higher density than the material forming the primary core 250. In one embodiment, the reinforcing core 252 may also be formed of a substantially air impermeable material (e.g., unperforated or stretched).

The reinforcing core 252 has two main functions. First, it helps to move water to the evaporation zone 254 at the top of the core 244, which is particularly important when the water level is low. This is accomplished by a combination of wicking water and then transferring the water laterally to the primary core 250. Second, the reinforcing core 252 serves as a water storage device that can provide moisture to the main core 250 during operation and can keep the main core 250 moist even when the water level is at or near the bottom. In configurations where air is not required to pass through the material forming the reinforcing core 252, the material from which the reinforcing core 252 is made may be of a much greater density than the materials typically used for cores. The material from which core 252 is made should have sufficient wet strength to withstand a prolonged (6+ month) water bath, which may be at various pH levels. The material from which the reinforcing core 252 is made may also be treated with an antimicrobial agent. The reinforcing core 252 is made of a compliant material and is configured such that it conforms to the geometry of the primary core 250 (e.g., is slit/stretched/perforated) and properly transfers moisture to the primary core 250. The material selected for forming the reinforcing core 252 should have an internal pore structure and surface energy to allow water to be transported vertically through the capillary process. The porous structure of the material forming the reinforcing core 252 may be formed by aggregation of particles or fibers. Hydrophilic woven and nonwoven structures or papers may be used for such applications. Particles of hydrophilic polymer, carbon, or metal may form a structure or be prepared as a substrate for the material forming the reinforcing core 252. Examples of such materials from which the reinforcing core 252 may be made include one or more plies of tissue, such as those sold under the trademark Bounty or Scott, and commercial paper supplied by Ahlstrom under reference numeral 272. The primary core 250 may be made of slit/stretched paper material.

While booster wick 252 is configured to improve evaporation performance in wick 244 by accelerating the flow of water to and above evaporation zone 254, and by storing water that may be delivered to main wick 250 when the water level in water tank 204 becomes low, embodiments of wick 244 that do not include booster wick 252 may deliver humidified air to outlet channels 304 in other ways. In such embodiments of the wick 244, other methods of increasing the wicking properties in the wick 244 may be used, including increasing the thickness of the stretched material of the evaporation core material used to make the primary wick 250.

With continued reference to fig. 2, the reinforcing wick 252 is disposed along the primary wick 250 from the water tank 204 to the chimney 260 formed by the wick 242 and is configured to wick water in the water tank 204 to the evaporation zone 254 and the chimney 260 faster than the primary wick 250 and then to transfer the water laterally to the primary wick 250. In this way, the reinforcing core 252 is configured to retain moisture in the main core 250 even when the water level in the water tank 204 is at or near the bottom of the water tank 204.

In one embodiment, the reinforcing core 252 is made of a material wherein relatively dry, warm air does not pass through the reinforcing core 252, but rather passes through the core 244 through the primary core 250. In one embodiment, the reinforcing core 252 is formed from at least one layer of material, while in another embodiment, the reinforcing core 252 is formed from 2-3 layers of material for easier formation and handling.

The bottom of the tank 204 may include a well 262 formed around the bottom 264 of the core 244 along the bottom inner surface 270 of the tank 204 such that water at the bottom of the tank 204 is concentrated around the core 244. With this configuration, the cartridge 242 is configured to receive water from the well 262, including when the water level in the water tank 204 is at the bottom inner surface 270 of the water tank 204.

The cartridge 242 defines an air inlet aperture 272 at a location aligned with the air outlet 274 of the power unit housing 202. The air outlet 274 is a conduit configured to convey air from the blower assembly 212 into the air inlet aperture 272. As such, blower assembly 212 is configured to deliver relatively dry, warm air to core 244 at air inlet aperture 272, as indicated by arrow 280. Air directed through core 244 exits core 244 at top surface 282 of core 244.

A cavity 284 is defined between the core barrel 242 and the core 244 below the air inlet aperture 272 in the height direction of the core barrel 242. The core barrel 242 may be spaced apart from the core 244 in the cavity 284 such that, as shown in fig. 2, the length of the core 244 extending below the air inlet aperture 272 is exposed to relatively dry, warmer air from the blower assembly 212, which circulates down the core 244.

The length of the core 244 extending over the air inlet aperture 272 forms an additional area for evaporation/humidification. The length of the wick 244 extending above the air inlet aperture 272 is immersed in the humidified air to prevent it from drying out in a manner that the minerals precipitate out of solution, deposit themselves in the wick 244, and adversely affect capillary action through the wick 244.

As shown in fig. 3, the cartridge 242 extends outwardly from the periphery of the air inlet aperture 272, forming a channel 290 extending from the core 244. With this configuration, relatively dry, relatively warm air from blower assembly 212 is injected directly into core 244 through air inlet aperture 272 and passageway 290 formed by core barrel 242. Since the channels 290 extend straight outward from the core 244 toward the air outlet 274, the overall size of the air cavity around the cartridge 242 is filled with warm air and heated, and conversely, the warm air is injected directly into the wet core 244 in the cartridge 242 where it is to enter.

The cartridge 242 may be made of a material that is impermeable to air and water, such as plastic, metal, or other material or combination of materials that impedes or largely impedes air and water. For example, the cartridge 242 is made of a material and geometry that impedes or largely impedes air except for openings that are intended to be air paths that include the air inlet aperture 272. In one embodiment, the core barrel 242 is made of polypropylene or other polymeric material such as polyethylene terephthalate (PET).

Referring to fig. 3 and 4, the cartridge 242 includes a front portion 292 and a rear portion 294 configured to engage one another, thereby forming an interior of the cartridge 242 that houses the core 244. The front portion 292 and the rear portion 294 define a chamber 300 that is isolated from the external environment outside of the cartridge 242, with the core 244 positioned in the chamber 300. The front 292 and rear 294 portions of the cartridge 242 define a water inlet opening 302. The water inlet opening 302 defines a water inlet configured to communicate water from the external environment into the chamber 300 for absorption by the core 244. The front portion 292 of the cartridge 242 also defines an air inlet aperture 272 at a location downstream of the water inlet 302 in a wicking direction of water through the core 244 from the water inlet 302 toward the air outlet channel 304. When in use, air enters the chamber 300 from the external environment to evaporate water absorbed from the core 244.

Although the depicted embodiment includes a cartridge 242 formed of a gas-and water-impermeable material that defines the water inlet 302, the cartridge 242 may alternatively be formed of a water-permeable material. In an alternative embodiment, the water permeable material defines a plurality of water inlet openings through which water permeates as a water inlet, wherein the water inlet functions in a similar manner to water inlet opening 302 to introduce water from water tank 204 into chamber 300.

The front 292 and rear 294 portions of the cartridge 242 define an air outlet passage 304 disposed at a first cartridge end 310 that includes the top of the cartridge 242. The air outlet passage 304 is configured to communicate air and water vapor from the core 244 and the chamber 300 to the external environment. When in use, the air outlet passage 304 is positioned downstream of the water inlet opening 302 and the air inlet aperture 272 in a wicking direction through the core 244. As such, the air inlet aperture 272 is positioned between the water inlet opening 302 and the air outlet passage 304 in a wicking direction of the water inlet opening 302 through the core 244 toward the air outlet passage 304.

In the illustrated embodiment, and with particular reference to FIG. 4, the illustrated cartridge 242 includes a plurality of contoured walls 312 formed by the front 292 and rear 294 that define the chamber 300. Although four contoured walls 312 are shown, the cartridge 242 may have any number of contoured walls 312, or even be round or flat.

As shown in the illustrated embodiment, the cartridge 242 includes a second cartridge end 314 extending from the first cartridge end 310 in the longitudinal direction of the cartridge 242. The water inlet 302 is defined in the cartridge 242 at a position closer to the second cartridge end 314 than the first cartridge end 310. The air outlet passage 304 is defined in the cartridge 242 at a position closer to the first cartridge end 310 than the second cartridge end 314, and the air inlet aperture 272 is defined in the cartridge 242 at a position between the water inlet opening 302 and the air outlet passage 304 in the longitudinal direction of the cartridge 242.

With this configuration, the cartridge 242 is configured to receive water in the chamber 300 at the water inlet 302, wherein the water travels through the cartridge 242 in a longitudinal direction of the cartridge 242 from the second cartridge end 314 toward the first cartridge end 310. The cartridge 242 is also configured to receive relatively dry, hotter air in the chamber 300 at the air inlet aperture 272, wherein the relatively dry, hotter air contacts the relatively moist surface of the core 244, evaporating water from the surface of the core 244, and humidifying the air. The air then moves vertically through the core 244, continues to pick up moisture from the surface of the core 244, and exits the chamber 300 at the air outlet passage 304 defined by the first cartridge end portion 310.

During assembly, the core 244 may be inserted into the chamber 300 through the air outlet passage 304 or sandwiched between one or more components that are brought together to form the cartridge 242. In one embodiment, core 244 may be removed from core barrel 242 through air outlet passage 304; however, core barrel 242 and core 244 may be assembled and sold together as a unit similar to that shown in fig. 3, core 244 may fill the entire chamber 300 up to air outlet passage 304 such that top surface 282 of core 244 is coplanar with upper surface 322 of core barrel 242 at first core barrel end 310. In another embodiment, not shown, the core 244 is disposed in the chamber 300, and the top 324 of the core 244 shown in fig. 4 extends through the air outlet passage 304 at the first barrel end 310 and protrudes from the chamber 300.

With continued reference to fig. 4, the reinforcing core 252 covers one side of the core 244 along the longitudinal direction of the core barrel 242. The main core 250 and the reinforcing core 252 are folded together by a series of alternating folds 330 interposed between a plurality of separate panels 332 of similar dimensions to one another. The reinforcing core 252 covers the main core 250 such that the reinforcing core 252 is interposed between and separates portions of the continuous panel 332, and separates the alternating folds 330 formed by the main core 250 in the width direction of the cartridge 242. The front portion 292 and the rear portion 294 are configured to engage one another to form an interior of the cartridge 242 housing the core 244, with the faceplate 332 being located within the interior of the cartridge 242.

Although the panels 332 are depicted as flat sections having a flat shape of the core 244, the panels 332 may additionally or alternatively feature a non-planar shape without departing from the scope of the present disclosure. Although the fold 330 is described as having a circular segment of the semi-circular shaped core 244, the fold 330 may additionally or alternatively have the following features.

Fig. 5 illustrates a method of forming core 244 from primary core 250 and reinforcing core 252. As shown in fig. 5, the reinforcing core 252 may be placed on top of the main core 250 or adhered thereto in a planar configuration. Next, the main core 250 and the reinforcing core 252 are folded into an overlapping pattern while still in contact to form the panels 332 as inner walls separated from each other by the air gap 334. The main core 250 and the reinforcing core 252 are folded to form air gaps 334 between successive panels 332 and to form alternating folds 330 in the core 244.

Referring to fig. 4, the main core 250 and the reinforcing core 252 are folded together to form a panel 332 in the chamber 300 of the cartridge 242. The panels 332 are arranged to overlap in the width direction of the core barrel 242, and the reinforcing cores 252 are interposed between and separate portions of the main cores 250, which form a continuous panel 332 in the width direction of the core barrel 242. The faceplate 332 extends in the longitudinal direction of the cartridge 242, parallel to the wicking direction from the water inlet opening 302 toward the air outlet passage 304, and parallel to the wicking direction from the air inlet aperture 272 toward the air outlet passage 304.

The relatively dry, hotter air gap 334 disposed in the core barrel 242 to face the ingress from the air inlet aperture 272 provides for direct ingress of air to the deeper regions of the fold 330 and panel 332 and uniformity of air flow through the core 244 as the air travels toward the air outlet passage 304 defined by the first barrel end portion 310. As such, this configuration of core 244 in core barrel 242 minimizes the extent to which air tends to flow into the portion of core 244 closer to air inlet aperture 272, as the air follows a path of least resistance through core 244 to air outlet passage 304.

As shown in fig. 5, the reinforcing core 252 may be laminated to the main core 250 with an adhesive such that the reinforcing core 252 extends continuously along a surface on the back surface 336 of the main core 250 from the first side 338 of the main core 250 to the second side 340 of the main core 250 in the width direction of the cartridge 242. The reinforcing core 252 is disposed along the main core 250 from a position closer to the top end 342 of the main core 250 than the bottom end 344 of the main core 250 to a position closer to the bottom end 344 of the main core 250 than the top end 342 of the main core 250. In the illustrated embodiment, the reinforcing core 252 extends from a position spaced from the top end 342 of the main core 250 to a position at the bottom end 344 of the main core 250.

With this structure, as shown in fig. 2, the reinforcing core 252 is provided along the main core 250 from a position in the water tank 204 to a position above the water tank 204 in the height direction of the evaporative humidifier 200 without restricting evaporation of the main core 250 in the vicinity of the air outlet passage 304. Although, as shown in fig. 5, the reinforcing core 252 extends along the back side 336 of the primary core 250, the reinforcing core 252 may additionally or alternatively extend continuously along a surface on at least one of the first lateral side 338, the second lateral side 340, and the front side 346 opposite the back side 336 of the primary core 250 without departing from the scope of the present invention.

Referring to fig. 6, the core assembly 240 may include a mineral collector 350 having a mineral pad 352, a retainer 354, and a cap 360 secured with the core barrel 242 at the upper surface 322 of the core 242. The mineral pad 352 is secured with the retainer 354, and the retainer 354 is configured to engage the cap 360 with the cap 360 disposed in the core assembly 240 such that the retainer 354 retains the mineral pad 352 in the core assembly 240 against the cap 360. A retainer 354 is connected with the cartridge 242 for retaining the mineral pad 352 on the core 244 adjacent the air outlet passage 304.

The cap 360 is configured to receive the core 244 through the cap 360 such that the retainer 354 retains the mineral pad 352 against the cap 360 and the core 244. The retainer 354 and mineral pad 352 are supported by the cartridge 242 and secured to the first cartridge end portion 310 by a top cap 360. Cap 360 is also configured to conform to core 244 so that air flow through air outlet passage 304 is forced to move vertically through core 244 to draw moisture from core 244 before exiting cartridge 242.

The purpose of the mineral pad 352 is to attract and concentrate the minerals in the water and move through the main core 250 and booster core 252 through the weathering process. Efflorescence is caused by the transport of minerals in the water by capillary action and their final deposition upon evaporation. In this way, the mineral pad 352 acts as a dump ground for minerals so that minerals do not collect in the main core 250 or booster core 252, thereby adversely affecting their performance. Although as depicted, core assembly 240 includes mineral pad 352 held by retainer 354 on core 244 and cap 360 for collecting minerals from core 244, core assembly 240 may additionally not include mineral pad 352 and retainer 354 as a complete assembly without departing from the scope of the present disclosure.

Referring back to fig. 4, a seal 364 is disposed on the distal end of the channel 290, surrounding the air inlet aperture 272, and is configured to engage a portion of the power unit housing 202 surrounding the air outlet 274 to be in fluid communication with the blower assembly 212 and receive relatively dry, warmer air. A seal 364 is positioned between and in contact with the cartridge 242 and the portion of the power unit housing 202 surrounding the air outlet 274 and forms a seal fluidly connecting the air outlet 274 to the air inlet aperture 272 through the passage 290. The seal 364 is secured to the cartridge 242, for example, with an adhesive, and is configured to slide into engagement with the air outlet 274, wherein each of the seal 364 and the adhesive is capable of withstanding continuous temperatures up to 230 degrees Fahrenheit. In this manner, the seal 364 is configured to seal the air outlet 274 in fluid communication with the air inlet aperture 272 for receiving air into the chamber 300.

Conversely, the seal 364 may be included on the blower assembly 212 as an air generating unit of the evaporative humidifier 200. With this configuration, the channel 290 is a sealing interface provided on the cartridge 242 and is configured to engage the seal 364 when the cartridge 242 is assembled with the device to seal the air outlet 274 in fluid communication with the air inlet aperture 272 for receiving air into the chamber 300.

As shown in fig. 6, panel 332 of core 244 and the portion of reinforcing core 252 disposed along panel 332 are disposed between and separated by upper separator 370 and lower separator 372, which are walls in cartridge 242 disposed along core 244. The upper separator 370 is a fin extending from the top cover 360 and the lower separator 372 is a fin extending from the front 292 of the cartridge 242. The upper separator 370 is integrally formed with the top cover 360, while the lower separator 372 is integrally formed with the front portion 292 of the cartridge 242.

The upper separator 370 and the lower separator 372 are located above and below the air inlet hole 272 in the height direction of the core barrel 242, respectively, such that the panels 332 are spaced apart from each other in the width direction of the core barrel 242. In this manner, the panels 332 form air channels between the successively arranged panels 332 for receiving relatively dry, hotter air at the air inlet apertures 272. An upper separator 370 is disposed along core 244 downstream of air inlet aperture 272 to limit air movement through core 244 at first barrel end 310.

Inside the cartridge 242 between the upper separator 370 and the lower separator 372, the core 244 is compressed in all directions except the longitudinal direction of the cartridge 242, so that fluid passing through the cartridge 242 must pass through the core 244. Upon exiting the evaporation zone 254, air is forced through these relatively thin portions of the core 244 by features included in the core assembly 240, which in the case of fig. 3 are provided by the cap 360. The cap 360 has channels to ensure that air cannot take any "shortcuts" and flow through the entire length of the wet core material. If the primary core is too thick (e.g., a thick rectangle), the airflow will be uneven and a shorter preferred path will be found, thereby underutilizing the separation of the wet core and creating an inefficient design. In one embodiment, the volume of the primary core 250 may be compressed by 10% to 15% in the core assembly 240 by the reinforcing core 252 as compared to the original uncompressed volume of the primary core 250.

As shown in fig. 7, mineral pad 352 is supported on top cover 360 and is configured to contact core 244, wherein core 244 protrudes through the space between upper separator 370. The retainer 354 includes prongs 376 configured to secure the retainer 354 and the cap 360 to the mineral pad 352 in a snap-fit assembly. As such, the cartridge 242 includes a retainer 354 secured to the cap 360 to retain the mineral pad 352 to the cap 360 and the core 244.

As shown in fig. 8, the mineral pad 352 is disposed through the core 244 toward the wicking direction of the air outlet passage 304. The top cover 360 defines a cover passage 374 from the core 244 around the mineral pad 352 toward the air outlet passage 304 for directing the primary air flow from the core 244 through the air outlet passage 304. Mineral collector 350 is configured to absorb and collect minerals in fluid moving through core 244 toward air outlet passage 304.

Mineral collector 350 is configured to concentrate water-soluble minerals and contaminants in mineral pad 352 to prevent mineral accumulation in core assembly 240 by continuing to wick water out of core 244 and then concentrate those minerals or contaminants in mineral pad 352 by evaporation, keeping the capillary passages in core 244 free of minerals or contaminants. The mineral collector 350, including the top cover 360, is made of plastic, metal, or another material or combination of materials that impedes or largely impedes air. The mineral collector 350 includes a retainer 354 configured to retain the mineral pad 352 relative to the top cover 360, with the prongs 376 extending from the retainer 354.

The mineral pad 352 is placed in contact with the top surface 282 of the core 244 such that the mineral pad 352 adsorbs minerals or contaminants from the water in the core 244 and concentrates the minerals or contaminants in the mineral pad 352 by advection and weathering at the evaporating surface of the mineral pad 352. The core 244 and mineral pad 352 are distinct components of the core assembly 240, and the mineral pad 352 is removable from the core assembly 240. In this way, mineral pad 352 may be removed from core assembly 240 to clean out collected minerals or contaminants, or replaced with a new mineral pad 352 without removing other portions of core 244 from core assembly 240. The top surface 380 of the mineral pad 352 in the mineral collector 350 is in communication with air to facilitate evaporation of water therefrom. Pressure may be applied between the mineral pad 352 and the main core 250 to ensure good contact and proper transfer of the mineral, and may be achieved by including a spring element between the mineral pad 352 and the retainer 354. In one embodiment, the spring element is a compliant, breathable layer of material or spring feature attached to or integrally formed with the retainer 354.

In core assembly 240, weathering causes minerals or contaminants to accumulate at the surface of mineral pad 352 and core 244 where water evaporates, clogging the pore structure of mineral pad 352 and core 244, reducing the volume of core 244 available for delivering water. As shown in fig. 8, the cartridge 242 includes a mineral pad 352 supported on a top cap 360 and disposed in a wicking direction on a top surface 282 of the core 244. The mineral pad 352 is configured to collect minerals in water that moves through the core 244 toward the air outlet passage 304.

Contact between mineral pad 352 and core 244 at top surface 282 of core 244 causes liquid water in core 244 to transfer to mineral pad 352. As water evaporates directly from the wick 244 and follows the air flow through the lid passage 374, the remaining water in the wick 244 continues to wick up to the mineral pad 352 along with the dissolved minerals. The remaining water with dissolved minerals flows to the mineral pad 352, where the remaining water evaporates from the mineral pad 352 and the concentrate of advection minerals and contaminants collect on the mineral pad 352 instead of on the core 244. The humidified air also moves from the core 244 in the cover passage 374 around the mineral pad 352 so that the mineral pad 352 does not impede the primary air flow. As such, the cartridge 242 defines a cover passage 374 at the air outlet passage 304 from the core 244, around the mineral pad 352, and to the external environment for directing the primary air flow from the core 244. Mineral pad 352 is formed from a material having a relatively high wicking ability, which is controlled by the pore size, surface chemistry, pore volume, and total pore volume of mineral pad 352 relative to core 244, and is denser than core 244. The mineral pad 352 may have perforations that provide an additional outlet path for air. The mineral pad 352 may also be made of a breathable material that allows some air to flow through the mineral pad 352.

The mineral content in core 244 may be measured by extracting minerals from the water in core 244. In one embodiment, the water from core 244 is analyzed by inductively coupled plasma emission spectrometry (ICP-OES) to measure the ion concentration associated with core 244, however, alternative or additional means of analyzing the water from core 244 may be used without departing from the scope of the invention. In another embodiment, at least one of core 244 and mineral pad 352 changes color to indicate water quality from core 244 and mineral pad 352 and to indicate substantial use or aging of at least one of core 244 and mineral pad 352. A portion of the mineral pad 352 or an additional element may also be configured such that the original color of the mineral pad 352 is maintained as a means of highlighting the difference between the original color and the color used. In another embodiment, at least one of core 244 and mineral pad 352 is formed to have a natural color, such as tan or brown, configured to conceal similarly colored minerals or contaminants collected therefrom.

The mineral pad 352 may be flexible such that the mineral pad 352 conforms to the shape and texture of the primary core 250 in the core assembly 240, with the mineral pad 352 being pressed against the core 244. The mineral pad 352 has a structure with a density of 10-50% and may be formed from a paper product such as tissue, however, other additional or alternative materials of various densities may be included in the mineral pad 352 without departing from the scope of the present disclosure. In one embodiment, mineral pad 352 has a density of 20-50%, and in another embodiment, mineral pad 352 has a density of 30-50%.

In one embodiment, the mineral pad 352 may include features such as pleats, folds, holes, grooves, ribs, and protrusions that provide additional surface area of the mineral pad 352 compared to a planar surface to facilitate additional evaporation from the mineral pad 352. In another embodiment, the mineral pad 352 may additionally or alternatively be formed from multiple layers of connected material for increasing mineral holding capacity while maintaining flexibility.

Mineral pad 352 is formed of a relatively dense material compared to core 244. The mineral pad 352 may be formed of a flexible material such that the mineral pad 352 conforms to the shape and texture of the core 244, wherein the mineral pad 352 is pressed against the core 244. With this configuration, premature aging of core 244 due to mineral deposition into core 244 may be avoided.

Notably, the densities of core 244 and mineral pad 352 described herein refer to the densities of the final assembly of core 244 and mineral pad 352, respectively, and the original densities of the assembly materials used to form core 244 and mineral pad 352 are not necessarily described. In this way, the paper used to form the core 244 may have a higher original density prior to assembly into the core 244, wherein the paper has a density that is higher than the density of the mineral pad 352, and the paper is slit, stretched, and layered such that the density of the core 244 formed from the paper is lower than the density of the mineral pad.

Fig. 9 and 10 illustrate an alternative embodiment of the core assembly 240 of fig. 3, 4 and 6, with elements common to the core assembly 240 of fig. 3, 4 and 6 being indicated by like reference numerals in the embodiment of fig. 9 and 10, but with a primed suffix ('). As shown in fig. 9, an embodiment of the core assembly 240 includes a core barrel 382 having a first core barrel sidewall 384 defining a first opening 390 as a water inlet and defining an air inlet aperture 272' as a second opening. The cartridge 382 also includes a second cartridge sidewall 392 that is pivotally secured to the first cartridge sidewall 384 and is configured to rotate relative to the first cartridge sidewall 384 between an open position and a closed position.

When the second cartridge sidewall 392 is disposed in the closed position, the second cartridge sidewall 392 forms a side of the cartridge 382 opposite the first cartridge sidewall 384. First cartridge sidewall 384 and second cartridge sidewall 392 are configured to enclose core 244 'in chamber 300' such that core 244 'is at least partially compressed in chamber 300' and fluid passing through chamber 300 'from first opening 390 and air inlet aperture 272' toward air outlet passage 304 'passes through core 244'. When the second cartridge sidewall 392 is disposed in the closed position, the first and second cartridge sidewalls 384, 392 define the air outlet passage 304'.

The first and second cartridge sidewalls 384, 392 are configured to receive the core 244' and mineral collector 350' in the chamber 300' when the second cartridge sidewall 392 is in the open position. The first and second cartridge sidewalls 384, 392 are also configured to close and lock the core 244' and mineral collector 350' contained in the chamber 300' when the second cartridge sidewall 392 is rotated to the closed position. The core 244' and mineral collector 350' may also be removed from the chamber 300' when the second barrel sidewall 392 is in the open position. With this configuration, core 244 'and mineral collector 350' may be replaced in core assembly 240 by rotating second barrel sidewall 392 toward the open position, removing at least one of core 244 'and mineral collector 350', disposing a corresponding core or mineral collector similar to core 244 'and mineral collector 350', respectively, in core assembly 240, and rotating second barrel sidewall 392 toward the closed position. Alternatively, the first and second barrel sidewalls 384, 392 may be sealed with the core 244 'and mineral collector 350' secured therein as a consumable unit that may be handled or recycled in its entirety.

As shown in fig. 9, the mineral collector 350 'includes a mineral pad 352', wherein a retainer 354 'is disposed on the mineral pad 352' and engages a top cover 360 'to retain the mineral pad 352' on the core 244 'on the top cover 360'. In this way, the mineral pad 352' is disposed on the top 324' of the core 244' at the air outlet channel 304' in the longitudinal direction of the core barrel 242' and along the top surface 282' in the width direction of the core barrel 242 '.

The first cartridge sidewall 384 defines a recess 394 at the first opening 390, the recess 394 being configured to receive the water regulator 400. The water conditioner 400 may include a mechanism for dispersing a chemical agent, such as a magnesium oxide (MgO) container disposed in the recess 394. The water regulator 400 is complementary to the recess 394 for fitting the recess 394 in a snap-fit assembly to secure the water regulator 400 in the first cartridge sidewall 384 at the first opening 390. The water regulator 400 may also be removable from the recess 394 and in this way may be replaced with a similar water regulator in the core assembly 240.

The water regulator 400 may be configured to react with water in the water tank 204 and raise the pH level of the water in the water tank 204 to inhibit biological growth in the water tank 204 and the core assembly 240. The water regulator 400 may also raise the pH of the water in the water tank 204 sufficiently to precipitate minerals from solution. In one embodiment, the water conditioner 400 contains 30-50 grams of magnesium oxide per gallon of water in the water tank 204 in a mesh system, the magnesium oxide having a particle size that can be contained in the mesh system, and the water conditioner is further configured to maintain the pH of the water in the water tank 204 at 9.5 or higher in order to inhibit the growth of biological systems in the water tank 204 and the core assembly 240. In a further embodiment, the water regulator 400 maintains an equilibrium pH of at least 10 in the water tank 204. In another embodiment, the magnesium oxide cartridge maintains an equilibrium pH level in the water tank 204 of at least 10.5.

The core assembly 240 may include a region containing a chemical that may be dispensed into the water to alter its characteristics. These methods may include altering the pH to minimize bacterial growth. These chemicals include calcium oxide, calcium hydroxide, magnesium oxide, magnesium hydroxide, and sodium hydroxide. One method is to precipitate the minerals using sodium carbonate, sodium bicarbonate, calcium oxide, magnesium oxide, calcium hydroxide, magnesium hydroxide, and sodium hydroxide. The wick assembly 240 may include an area containing chemicals that may be dispensed into the water to alter the solubility of minerals or heavy metals in the water. These chemicals may also include antimicrobial materials to prevent growth of biological materials. The core assembly 240 may also include materials that bind minerals and prevent them from being absorbed by the core material, thereby extending its life. Chelating or sequestering agents such as ethylenediamine tetraacetic acid, nitrilotriacetic acid, and diethylenetriamine pentaacetic acid may be used. Citric acid and phosphates, including polyphosphates such as sodium polyphosphate, may also be used. These chemical zones can be designed below the water level so that they are continuously dispersed. The rate of dispersion can be limited by limiting the amount of water that can circulate around these areas or by reaching a maximum saturation level, whereby no more chemicals are released. For example, polyphosphate beads, such as SPER manufactured by SPER chemical company, may be used Dissolving polyphosphate beads (SPER +)>Dissolving Polyphosphate Beads). These areas may be located near the top of the water level so that they disperse only when submerged in water. The humidifier may automatically lower the water level (by humidification) such that the amount of time these areas are immersed in water is time limited. In another embodiment, the conditioning element in the water tank 204 may be configured such that when water is added to the water tank 204, the water will rise high enough to enter the area where the polyphosphate beads are located. Bubbles will be created that isolate the water surrounding the polyphosphate beads from the rest of the water in the water tank 204. During use, the water level in the water tank 204 will drop and release air bubbles that dose polyphosphate into the water in the water tank 204. When water is added to the water tank 204 or refilled, it will begin the cycle again. This improves slow release as it limits the amount of water in contact with the polyphosphate beads. In another variation, these chemical regions may be above a maximum water level, but positioned such that the process of refilling the humidifier (e.g., through the cartridge) results in the chemicals being eluted into the passing water.

With continued reference to fig. 9, the core 244' forms a faceplate 332' positioned in the chamber 300' of the cartridge 382. The top cover 360' forms an upper separator 370' in the chamber 300', which is disposed along the panels 332' and interposed between the panels 332' arranged in succession in the width direction of the cartridge 382. With this structure, the panels 332' arranged in succession are separated from each other across the upper separator 370', and an air passage is formed downstream of the air inlet hole 272' in the wicking direction. The panels 332' are arranged to overlap each other in the width direction of the cartridge 382, and the upper separator 370' is interposed between the panels 332' arranged in succession in the width direction of the cartridge 382.

Referring to fig. 10, when second cartridge sidewall 392 is in the closed position, first cartridge sidewall 384 and second cartridge sidewall 392 define air outlet passage 304'. In this manner, first and second cartridge sidewalls 384 and 392 are configured to selectively close cap 360, thereby securing cap 360' with first and second cartridge sidewalls 384 and 392. The first cartridge sidewall 384, the second cartridge sidewall 392, and the cap 360 'are configured to be selectively closed over the core 244' such that the core 244 'is at least partially compressed in the cartridge 382 and fluid passing through the cartridge 382 must pass through the core 244'. The first cartridge sidewall 384 is hinged with the second cartridge sidewall 392 to selectively close the top cap 360 'at the air outlet passage 304'. Unless otherwise indicated, cartridge 382 includes similar features and functions as cartridge 242.

The upper separator 370 'defines a curved surface that complements the geometry of the core 244' such that the cap 360 'conforms to the core 244' and restricts airflow in the first barrel end 310 'through the core 244'. With this configuration, when the cartridge 382 is closed over the core 244', the air flow through the first cartridge end 310' and the air outlet passage 304' is forced to move through the core 244' to draw additional moisture from the core 244' in the evaporation zone 254' between the air inlet aperture 272' and the top surface 282' of the core 244' before exiting the cartridge 382.

Fig. 11 shows a method 402 of manufacturing an alternative embodiment of the core assembly 240 of fig. 3, 4 and 6, fig. 12 shows a front perspective view of the embodiment of the core assembly 240 of fig. 11, in which the same elements as the core assembly 240 of fig. 3, 4 and 6 are denoted by the same reference numerals but with a suffix (') added.

As shown in fig. 11, the method includes a step 404 in which the primary core 250 'and the reinforcing core 252' are severed and aligned below the divider 410. The divider 410 presses onto the core 244' with sufficient force to hold the primary core 250' and the reinforcing core 252' together. In one embodiment, pins (not shown) are disposed through the main core 250 'and the reinforcement core 252' to clamp and manipulate the main core 250 'and the reinforcement core 252' together.

The method 402 further includes step 412, wherein the divider 410 is positioned closer together, folding the primary core 250 'and the synergistic core 252' to form the fold 330 'and the panel 332'. The method 402 further includes step 414, wherein the primary 250' and reinforcing 252' cores are placed on the front 420 of the cartridge 422 using the divider 410 such that the upper 370' and lower 372' dividers are placed between and separate the face plates 332' in the width direction of the cartridge 422, and the divider 410 is removed from the core assembly 240. The folded core 244' may also be inserted first into the rear portion 424 of the cartridge 422.

Method 402 further includes step 430, wherein rear portion 424 of cartridge 422 is positioned over core 244' and engaged with front portion 420. Although the depicted core assembly 240 includes a front portion 420 and a rear portion 424 secured together with snaps, other interlocking features or connection means, such as ultrasonic welding or thermal welding, may additionally be implemented in addition to or instead of snaps without departing from the scope of this disclosure.

As shown in fig. 12, the front portion 420 of the cartridge 422 includes an intermediate separator 432 that is interposed and separates between the upper separator 370 'and the lower separator 372' in the height direction of the cartridge 422. The intermediate separator 432 is formed by ribs that continue the surface shapes of the upper separator 370' and the lower separator 372', where the surface shapes engage the core 244' supporting the core 244' in front of the air inlet aperture 272 '. Unless otherwise indicated, cartridge 422 includes similar features and functions as cartridge 242'.

Fig. 13-16 depict an alternative embodiment of the core assembly 240 of fig. 3,4, and 6, wherein the core 434 includes a plurality of core segments 440 stacked along the width of the core barrel 442. In the embodiment of fig. 13-16, elements identical to those of the core assembly 240 of fig. 3,4 and 6 are designated by the same reference numerals, but with a prime (') added.

As shown in fig. 13-15, the core segments 440 are spaced apart from one another so as to form an air gap between the successively stacked core segments 440, and each core segment 440 is formed from layers of a reinforcing core 252 'disposed between and separating the layers of the primary core 250' in the laminated structure. As shown between fig. 14 and 15, the core barrel 442 is configured to receive relatively dry, relatively hot air from the blower assembly 212 through the air inlet holes 272', through the air gaps 444 between the successively stacked core segments 440 from the air inlet holes 272', and driven into the core segments 440.

Fig. 16 depicts a method 450 of manufacturing the core assembly 240 depicted in fig. 13-15. As shown in fig. 16, the method 450 includes a step 452 of placing a reinforcing core 252' portion formed of a pleated material in a fixture (not shown) and placing a pair of primary core 250' portions in slots defined in the pleated material of the reinforcing core 252 '. The method 450 further includes a step 454 of compressing the pair of primary 250 'and reinforcing 252' portions forming the core 434 in the width direction of the core 442 to mate with the core 442. The method 450 further includes a step 460 of sliding the core 434 into the barrel back 462, wherein the blades 464 formed by the clips 470 protrude through the barrel back 462 and are pressed into the pair of primary core 250 'portions to define a space between the pair of primary core 250' portions. The method 450 further includes the step 472 of positioning the cartridge front 474 over the core 434 to engage the cartridge rear 462, wherein the air spacers 480 contact the blades 464 of the fixture 470. The method 450 further includes a step 482 in which the clamp 470 is removed from the core assembly 240.

Unless otherwise indicated, core 434 and cartridge 442 include similar features and functions as core 244 and cartridge 242, respectively.

Fig. 17 shows an alternative embodiment of the evaporative humidifier 200 and the wick assembly 240 of fig. 2-7, fig. 18 shows a front perspective view of the embodiment of the wick assembly 240 of fig. 17, and in the embodiment of fig. 17 and 18, elements similar to those of the wick assembly 240 of fig. 2 are designated by the same reference numerals, but with a prime (') added thereto.

As shown in fig. 17, the evaporative humidifier 200 includes a cover 484 defining an aperture 490. Holes 490 extend through the cover 484 to allow humidified air to escape the water tank 204' into the environment. In another embodiment, the aperture 490 may be provided in at least one side wall 492 of the tank 204' and extend through the at least one side wall 492 of the tank 204' at a location sufficiently close to the cover 484 at the top 494 of the tank 204' to not allow liquid water to escape. The water tank 204' is in fluid communication with the ambient environment via the aperture 490. The water tank 204 'also includes an air inlet aperture 272' through which air (typically heated) from the power unit housing 202 'enters the water tank 204'. In addition, the water tank 204' also includes an air outlet in fluid communication with the ambient environment via the aperture 490.

The water tank 204' is configured to receive water. The side wall 492 of the water tank 204 'may include a fill indicator 502 (see fig. 2) to indicate the maximum water level at which the user should fill the water tank 204'. The fill indicator 502 may be disposed on an inner or outer surface of the side wall 492. The fill indicator 502 may be, but is not limited to, a notch, line, or protrusion on the side wall 492. The fill indicator 502 is positioned below the air outlet 274 'to prevent water from entering the power unit housing 202'.

A core assembly 240 included in a plurality of similar core assemblies disposed within the water tank 204'. Referring to fig. 17 and 18, the core assembly 240 includes a core barrel 504 and a core 510 disposed within the core barrel 504. The wick assembly 240 may also include an isolator 512 that seals against the inner surface of the water tank 204 'to provide a heated or hot air zone 514 between the isolator 512 and the upper level of water in the water tank 204', and a condensation zone 520 between the isolator 512 and the cover 484. The separator 512 also ensures that all air entering the water tank 204' passes through the wick 510 before exiting the evaporative humidifier 200, thereby humidifying the passing air.

With continued reference to fig. 17, at least one sidewall 522 of the plurality of sidewalls 522 forming the mandrel 504 may also include a protrusion 524, which may be in the form of a flange, for example, disposed on top of the at least one sidewall 522. In the illustrated embodiment, the protrusions 524 are disposed on the outer perimeter of the plurality of side walls 522. The protrusion 524 extends outwardly away from the at least one sidewall 522. The top surface of the protrusion 524 may coincide with the upper surface 322' of the core barrel 504.

In the illustrated embodiment, the cartridge 504 includes a plurality of air inlet holes 272' disposed in the sidewall 522 of the cartridge 504. It should be appreciated that any number of sidewalls 522 may include any number of air inlet apertures 272'. The plurality of air inlet holes 272' are disposed at the same height on the plurality of sidewalls 522. The width of each air inlet aperture 272' may span a majority of the width of the respective sidewall 522 through which it extends. When the longitudinal cross-section of the cartridge 504 is rectangular in shape and the cartridge 504 includes four sidewalls 522, one air inlet aperture 272' may be provided in each sidewall 522. Alternatively, when the longitudinal section of the cartridge 504 is rectangular in shape and the cartridge 504 includes four sidewalls 522, one air inlet aperture 272' may be provided on each of the two sidewalls 522. In one embodiment, one air inlet aperture 272' is provided in two parallel side walls 522.

As described above, at least one water inlet opening 302 'is provided in the cartridge 504 below the air inlet aperture 272' through which water is absorbed by the core 510. In one embodiment, the bottom 530 (see fig. 18) of the core 510 extends through the water inlet 302 'and out of the chamber 300'. Referring to fig. 18, the cartridge 504 may further include a plurality of lower legs 532 disposed near the bottom of the cartridge 504 configured to form a space 534 between a lower edge 540 of the cartridge 504 and a base 542 of the tank 204 'when the core assembly 240 is received in the tank 204'. The space 534 may coincide with the at least one water inlet opening 302'.

The core 510 is made of a water absorbent material or a combination of absorbent materials that may be arranged vertically (in the direction of water flow) or horizontally. In one embodiment, the core 510 includes absorbent fibers. In another embodiment, the core 510 may include holes (not shown) to allow air and water vapor to pass through the core 510. The core 510 may have any shape, although in the illustrated embodiment the core 510 is sized to fill the cavity 300' of the cartridge 504.

In use, the water tank 204 'is filled with water up to or anywhere below the upper edge 544' of each of the plurality of air inlet holes 272 'of the cartridge 504 and below the air inlet 500 of the water tank 204'. Thus, the fill indicator 502 is disposed at a lower position than the lower edge 550 of each of the plurality of air inlet holes 272'. Moreover, each sidewall 522 extends downwardly from a lower edge 550 of the air inlet aperture 272 'to an upper boundary of the water inlet 302'. Each sidewall 522 also extends downwardly from the upper surface 322 'of the core barrel 504 to an upper edge 544 of the air inlet aperture 272'.

Separator 512 is made of a gas-and water-impermeable material. In one embodiment, separator 512 comprises a polyurethane material. The separator 512 extends to the inner periphery of the water tank 204 'and seals the inner surface of the water tank 204'. The separator 512 may be removably placed in the water tank 204'. The water tank 204 'may include protrusions (not shown) that support the separator 512 such that the separator 512 is properly positioned in the water tank 204'. A hole 490 (which may also be in the sidewall 522 of the tank 204' as mentioned above) is positioned above the separator 512.

The separator 512 also includes at least one core-receiving aperture (wick-receiving aperture) 552 extending from a top surface 554 of the separator 512 to a bottom surface 556 of the separator 512. Each core barrel 504 is inserted into each core-receiving aperture 552. Each core-receiving aperture 552 has a shape similar to the longitudinal cross-section of the core barrel 504. A seal (not shown) may be provided on the inner circumference of each core-receiving bore 552 to prevent fluid from passing between the core barrel 504 and the separator 512 through the core-receiving bores 552. The core barrel 504 may be configured to extend above the top surface 554 of the separator 512. Alternatively, only the core 510 may extend above the top surface 554 of the separator 512. Separator 512 also includes an external seal 560 that seals against the inner surface of tank 204' to divide tank 204' into a warm or hot air zone 514 between separator 512 and the upper level of water in tank 204' and a condensation zone 520 between separator 512 and lid 484.

In embodiments where the core barrel 504 includes the protrusion 524, the core-receiving aperture 552 is large enough to allow the sidewall 522 of the core barrel 504 to be inserted through the core-receiving aperture 132, but small enough to prevent the protrusion 524 from being inserted into the core-receiving aperture 552. When the cartridge 504 is inserted into the core-receiving aperture 552, the bottom surface 562 of the protrusion 524 may contact the top surface 554 of the separator 512. The separator 512 may also include a recess 564 disposed within the top surface 554 of the separator 512 about the outer periphery of the core-receiving bore 552. The recess 564 may receive the protrusion 524 of the cartridge 504. In one embodiment, the recess 564 has the same height as the protrusion 524 such that the upper surface 570 of the protrusion 524 is in the same plane as the top surface 554 of the separator 512.

As shown in fig. 18, the cartridge 504 may be provided with a cartridge cover 572. The cartridge cover 572 may be configured separately from the sidewall 522 of the cartridge 504. The cartridge cover 572 covers the core 510 during shipping and may provide a location for branding.

Referring to fig. 17, when the evaporative humidifier 200 is used, a user fills the water tank 204' with water. In embodiments that include a fill indicator 502, the user fills the water tank 204' to the fill indicator 502. The user may insert the separator 512, in which the cartridge 504 and the core 510 are positioned, before or after filling the water tank 204' with water to an appropriate level. When the evaporative humidifier 200 is turned on, the heater 220 heats the air within the power unit housing 202. The fan 214 blows heated air from the power unit housing 202 into the water tank 204' through the air inlet 500.

Fig. 19 shows an alternative embodiment of the cartridge 504 of fig. 17 and 18, wherein the water inlet is defined by a water permeable material. In the embodiment of fig. 19, elements similar to the core barrel 504 of fig. 17 and 18 are designated by the same reference numerals, but with a suffix (') added.

As shown in fig. 19, the second barrel end 314' of the core barrel 504 is formed of a water permeable material that covers the bottom 530 (see fig. 18) of the core 510. The water permeable material of the cartridge 504 is porous, with the pores formed therein defining a plurality of water inlet openings 302' through which water permeates.

The plurality of water inlet openings 302' allow fluid to pass through the cartridge 504 and into the chamber 300', while the water permeable material of the cartridge 504 directs fluid to flow through the core 510 from the water inlet openings 302' toward the air inlet 272' and the air outlet channels 304 '. In this way, the water inlet 302' formed in the water permeable material of the cartridge 504 functions in a similar manner as the water inlet 302 to introduce water from the water tank 204 into the chamber 300.

Although in the depicted embodiment, the second cartridge end 314' is formed of a water permeable material, the water permeable material may form any or all of the cartridge 504 between the bottom end 574 of the cartridge 504 and the lower edge 550' of the air inlet aperture 272', without departing from this disclosure.

In an alternative embodiment, the evaporative humidifier 200 may be assembled in a tower configuration (not shown) with the water tank 204 'disposed on top of an engine configured to heat the water in the water tank 204'. In another embodiment, the water tank 204 'and the engine are substantially cylindrical and oriented in a vertical, upright position, wherein the engine produces heated air that travels from the engine through a tube in the center of the water tank 204'. In another embodiment, the cylindrical cartridge seals against the tube, with the bottom portion of the cylindrical cartridge immersed in the water tank 204'.

The wick assembly for an evaporative humidifier has been described in detail above. Modifications and alterations will occur to others upon reading and understanding the preceding detailed description. However, the present invention is not limited to the above-described embodiments. It will be appreciated that various of the above-described features and other features and functions, or alternatives or variations thereof, may be desirably combined into many other different systems or applications. Further, various presently unforeseen or unanticipated alternatives, modifications, variations or improvements therein may be subsequently made by those skilled in the art which are also intended to be encompassed by the following claims.

Claims (26)

1. A wick assembly for an evaporative humidifier, the wick assembly comprising:

a core made of a water absorbing material; and

a cartridge defining a chamber isolated from an external environment external to the cartridge, wherein the core is located in the chamber and the cartridge defines:

a water inlet configured to communicate water from an external environment into the chamber;

an air inlet aperture configured to communicate air from an external environment into the chamber; and

an air outlet passage configured to communicate air and water vapor from the wick and the chamber to an external environment,

Wherein the air inlet aperture is positioned between the water inlet and the air outlet channel in a wicking direction through the wick from the water inlet towards the air outlet channel.

2. The core assembly of claim 1, wherein the core barrel is made of plastic, metal, or other material or combination of materials that impedes or largely impedes air.

3. The core assembly of claim 1, wherein the core barrel includes a water inlet opening defining the water inlet,

the air inlet aperture is positioned downstream of the water inlet opening in the wicking direction when in use, and

the air outlet channel is positioned downstream of the water inlet opening and the air inlet aperture in the wicking direction when in use.

4. The core assembly of claim 1, wherein at least a portion of the cartridge is made of a water permeable material through which water permeates to define the water inlet.

5. The core assembly of claim 1, further comprising a seal or seal interface disposed on the core barrel about the air inlet aperture and configured to seal the air inlet aperture in fluid communication with a conduit for receiving air into the chamber.

6. The core assembly of claim 1, wherein the core barrel includes a wall along the core downstream of the air inlet aperture to restrict air movement through the core.

7. The core assembly of claim 6, wherein the core is folded to form inner walls in the core barrel, wherein the inner walls are arranged overlapping each other in a width direction of the core barrel and oriented parallel to the wicking direction from the air inlet aperture toward the air outlet channel, and the separator is located between the consecutively arranged inner walls in the width direction of the core barrel.

8. The core assembly of claim 6, wherein the core barrel includes a first barrel sidewall defining the air inlet aperture and includes a second barrel sidewall forming a side of the core barrel opposite the first barrel sidewall, and

wherein at least one of the first cartridge sidewall and the second cartridge sidewall defines the air outlet passage.

9. The core assembly of claim 1, wherein the core barrel includes a wall that compresses the core in the chamber such that fluid passing through the chamber from the water inlet and the air inlet aperture passes through the core.

10. The core assembly of claim 1, wherein the core barrel includes a mineral collector disposed on the core, the mineral collector configured to collect minerals in water moving through the core toward the air outlet passage.

11. The core assembly of claim 10, wherein the mineral collector is a mineral mat, the core assembly further comprising a retainer connected to the cartridge for retaining the mineral mat on the core adjacent the air outlet passage.

12. The core assembly of claim 10, wherein the mineral collector is a mineral mat and the cartridge defines a passage from the core toward the air outlet passage, around the mineral mat, to the external environment for directing a primary air flow from the core through the air outlet passage.

13. The core assembly of claim 1, wherein the core comprises a main core and a reinforcing core in contact with at least one side of the main core, the reinforcing core having a lower air permeability than the main core.

14. The core assembly of claim 13, wherein the reinforcing core is disposed between the water inlet and the air outlet passage along at least one side of the primary core in a wicking direction of fluid flow from the water inlet toward the air outlet passage.

15. The core assembly of claim 14, wherein the reinforcing core is disposed along the primary core between the air inlet aperture and the air outlet passage in a wicking direction of fluid flow from the water inlet toward the air outlet passage.

16. The core assembly of claim 13, wherein the reinforcing core is disposed along the main core and the reinforcing core are folded together to form a panel, wherein the panels are arranged overlapping each other in a width direction of the cartridge and the reinforcing core is interposed between and separates portions of the main core in the width direction of the cartridge.

17. The core assembly of claim 13, wherein the reinforcing core is laminated with the primary core and extends continuously along a surface of the primary core in the wicking direction and along at least a portion of the surface of the primary core in a width direction of the cartridge perpendicular to the wicking direction.

18. The wick assembly of claim 1, further comprising a separator made of a water impermeable material and configured to seal against an inner surface of a water tank of an associated evaporative humidifier, the wick assembly being housed within the water tank, wherein the separator includes at least one wick-receiving aperture for receiving the wick cartridge.

19. A method of manufacturing a core assembly, the method comprising:

providing a cartridge defining a chamber, a water inlet, an air inlet aperture, and an air outlet passage; and

positioning a core in the chamber such that the core is positioned to absorb water passing through the water inlet to receive air passing through the air inlet aperture and direct the air toward the air outlet passage.

20. The method of claim 19, further comprising: a mineral collector is positioned in contact with a first core end of the core adjacent the air outlet passage.

21. The method of claim 20, wherein positioning the mineral collector in contact with the first core end comprises inserting the mineral collector into a retainer and then connecting the retainer with the core barrel such that the mineral collector is disposed on and in contact with the first core end.

22. The method of claim 19, further comprising: folding the core to form panels in the chamber, wherein the panels are arranged to overlap each other such that the panels are oriented parallel to a wicking direction of fluid flow from the water inlet toward the air outlet channel.

23. The method of claim 22, further comprising: a top cover is positioned having separators interposed between consecutively arranged panels formed in the core.

24. The method of claim 19, further comprising: the core is formed by contacting a primary core against a reinforcing core, wherein the reinforcing core has a lower air permeability than the primary core, and wherein the primary core and the reinforcing core extend between the water inlet and the air outlet channel in a wicking direction of fluid flow from the water inlet towards the air outlet channel.

25. The method of claim 19, further comprising: the cartridge is assembled with a first cartridge sidewall defining the air inlet aperture and a second cartridge sidewall opposite the first cartridge sidewall.

26. The method of claim 25, further comprising: the first cartridge sidewall is connected to the second cartridge sidewall such that the first cartridge sidewall and the second cartridge sidewall compress at least a portion of the core in the core cartridge and fluid passing through the chamber from the water inlet and the air inlet aperture passes through the core toward the air outlet passage.