WICK CARTRIDGE FOR AN EVAPORATIVE HUMIDIFIER

Abstract

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

Description

BACKGROUND

Evaporative humidifiers are used to provide humidity into a relatively dry room or space. This style of humidifier utilizes an air permeable homogenous absorptive material wick that is dipped in water and is positioned relative to a fan so that the air can pass by the wick and pick up moisture before being expelled into the room.

Known evaporative humidifiers, such as the one schematically depicted in FIG. 1, include a relatively larger water tank 10 fluidly connected with a relatively smaller water reservoir 12 in which a wick 14 is dipped. Water 20 in the water tank 10 is directed by gravity through a feed 22 connected to the reservoir 12, as allowed by a valve 24 in the feed 22. The valve 24 is operated to maintain a sufficient amount of the water 20 in the reservoir 12 for absorption by the wick 14 without overfilling the reservoir 12. Airflow caused by a fan (not shown) passes through the wick resulting in evaporation of water from the wick. These known styles of evaporative humidifiers result in transverse air flow, largely orthogonal to the wick, over a fixed height, which is defined by the amount of wick protruding from the water, and unrestricted, meaning the air is free to flow through the wick unobstructed. These humidifiers typically use two means for determining the output of humidity into a room—the total exposed area of the wick (depth and/or area) and air velocity (fan speed). The temperature and humidity of the air entering the unit is determined by the room conditions. As the room humidity begins to increase, the rate of output of the evaporative humidifier drops for a given air velocity and wick configuration, because moister air (higher relative humidity) will pick up less moisture than dryer air.

SUMMARY

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

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

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

BRIEF DESCRIPTION OF THE 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 wick assembly.

FIG. 4 is an exploded perspective view of the wick assembly.

FIG. 5 depicts an assembly method of a wick for use in the wick assembly.

FIG. 6 is an exploded perspective view of the wick and a wick cartridge, including a top cap, a mineral pad, and a holder.

FIG. 7 is an exploded view of a mineral collector for the wick assembly.

FIG. 8 is a partial cross-sectional view of the wick cartridge, including the top cap.

FIG. 9 is an exploded perspective view of the wick cartridge, including the top cap, the mineral pad, and the holder.

FIG. 10 is a partial cross-sectional view of the wick assembly.

FIG. 11 depicts a method of manufacturing an alternative embodiment of the wick assembly.

FIG. 12 is a perspective view of the wick assembly depicted in FIG. 11.

FIG. 13 is a back perspective view of an alternative embodiment of the wick assembly.

FIG. 14 is a front perspective view of the wick assembly depicted in FIG. 13.

FIG. 15 is a front perspective cross-sectional view of the wick assembly depicted in FIG. 13.

FIG. 16 depicts a method of manufacturing an alternative embodiment of the wick assembly.

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

FIG. 18 is a perspective view of the wick assembly depicted in FIG. 17.

FIG. 19 is a perspective view of an alternative embodiment of the wick 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 attached to the power unit housing 202. A blower assembly 212 includes at least one fan 214, and may further include at least one heater 220 disposed within the power unit housing 202. Electronics 222 may be disposed within the power unit housing 202. The electronics 222 can 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 further include power cord (not shown) to provide a power input to the electronics 222. The evaporative humidifier 200 may further include control knobs 224 to allow an operator to control different settings (e.g., humidity settings, fan speed, temperature) via the electronics 222. With reference back to FIG. 2, the electronics 222 can also be in electrical communication with sensors 230 to control operation of the evaporative humidifier 200. The water tank 204 defines a top opening 232, and the evaporative humidifier 200 includes a lid 234 covers the top opening 232.

A wick assembly 240 is disposed within the water tank 204. The wick assembly 240 includes a wick cartridge 242 and a wick 244 disposed within the wick cartridge 242. The wick 244 includes a primary wick 250 and may further include a booster wick 252. The primary wick 250 is made from a material configured to optimize evaporation. In contrast, the booster wick 252 is made from a material configured to optimize wicking and water storage and/or transferring water to the primary wick 250. The booster wick 252 has a lower air permeability than the primary wick 250. Accordingly, the booster wick 252 may have a higher sorptivity than the primary wick 250 and/or other characteristics that make it suitable for these three functions. The booster wick 252 is formed from a material that can also have a higher liquid storage capacity as compared to a material forming the primary wick 250. The booster wick 252 can be formed from a material having a higher wicking capacity as compared to a material forming the primary wick 250. The booster wick 252 can also be formed from a material having a higher density as compared to a material forming the primary wick 250. In an embodiment, the booster wick 252 can also be formed from a material that is largely impervious to air (e.g. non-perforated or stretched).

The booster wick 252 has two primary functions. First, it helps move water to an evaporation zone 254 at a top portion of the wick 244, which is particularly important when the water levels are low. It does this through a combination of wicking water and then laterally transferring it to the primary wick 250. Second, the booster wick 252 serves as a means for water storage that can supply the primary wick 250 with moisture during operation, and keep the primary wick 250 moist, even when the water level is at or near the bottom. The material from which the booster wick 252 is made can be considerably more dense than materials typically used for the wick in configurations where there is no need for air to travel through the material forming the booster wick 252. The material from which the booster wick 252 is made should have enough wet strength to withstand an extended (6+ month) bath in water, which may be at a variety of PH levels. The material from which the booster wick 252 is made can also be treated with anti-microbial agents. The booster wick 252 is made from a material and configured to be compliant, so that it can conform to the geometry of the primary wick 250 (e.g. slitted/stretched/perforated) and properly transfer moisture to the primary wick 250. The material selected for forming the booster wick 252 should have an internal pore structure and surface energy to allow for the transport of water vertically through the process of capillary action. Porous structures of the material forming the booster wick 252 could be formed by the aggregation of particles or fibers. Hydrophillic woven and non-woven structures or papers could be utilized for this application. Particles of hydrophilic polymers, carbons, or metals could be formed into structures or prepared to act as substrates for the material forming the booster wick 252. Examples of such materials from which the booster wick 252 can be made include one or more layers of paper towels such as those sold under the Bounty or Scott's trademarks, and a commercial paper offered from Ahlstrom labeled 272. The primary wick 250 can be made from slitted/stretched paper materials.

While the booster wick 252 is configured to improve evaporation performance in the wick 244 by both accelerating the flow of water to and above the evaporation zone 254, and by storing water that can be delivered to the primary wick 250 as water levels become lower in the water tank 204, an embodiment of the wick 244 not including the booster wick 252 may otherwise deliver humidified air to the air outlet passage 304. In such an embodiment of the wick 244, other means of increasing the wicking performance in the wick 244 can be utilized, including increasing a thickness of a stretched material used in making the evaporative wick material of the primary wick 250.

With continued reference to FIG. 2, the booster wick 252 is disposed along the primary wick 250 from the water tank 204 to a chimney 260 formed from the wick cartridge 242, and is configured to transport water in the water tank 204 to the evaporation zone 254 and the chimney 260 via capillary action faster than the primary wick 250, then laterally transfer moisture to the primary wick 250. In this manner, the booster wick 252 is configured to maintain moisture in the primary wick 250, even when the water level in the water tank 204 is at or near a bottom of the water tank 204.

In an embodiment, the booster wick 252 is formed from a material where none of the relatively dry, warmer air travels through the booster wick 252 and instead travels through the wick 244 via the primary wick 250. In an embodiment, the booster wick 252 is formed from at least one layer of material, and in a further embodiment, the booster wick 252 is formed from 2-3 layers of material for easier forming and handling.

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

The wick cartridge 242 defines an air inlet aperture 272 at a location aligned with an air exit 274 of the power unit housing 202. The air exit 274 is a duct configured to deliver air from the blower assembly 212 into the air inlet aperture 272. As such, the blower assembly 212 is configured to deliver relatively dry, warmer air to the wick 244 at the air inlet aperture 272 as indicated by arrows 280. The air directed through the wick 244 exits the wick 244 at a top surface 282 of the wick 244.

A cavity 284 is defined between the wick cartridge 242 and the wick 244 underneath an air inlet aperture 272 in a height direction of the wick cartridge 242. The wick cartridge 242 may be spaced from the wick 244 in the cavity 284 such that, as depicted in FIG. 2, a length of the wick 244 extending below the air inlet aperture 272 is exposed to the relatively dry, warmer air from the blower assembly 212, which circulates down the wick 244.

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

As shown in FIG. 3 the wick cartridge 242 extends outward from a perimeter of the air inlet aperture 272, forming a channel 290 extended from the wick 244. With this construction, the relatively dry, warmer air from the blower assembly 212 is directedly injected into the wick 244 through the air inlet aperture 272 and the channel 290 formed by the wick cartridge 242. With the channel 290 extending straight outward from the wick 244 toward the air exit 274, an overall size of an air cavity around the wick cartridge 242 be filled with warm air and heated, and instead the hot air is directly injected where it is intended to go, into the moist wick 244 in the wick cartridge 242.

The wick cartridge 242 can be made from an air and water impermeable material such as plastic, metal, or another material or material combination that obstructs or largely obstructs air and water. For example, the wick cartridge 242 is made from a material and geometry that obstructs or largely obstructs air with the exception of openings, including the air inlet aperture 272, that are intended as air paths. In an embodiment, the wick cartridge 242 is made from a polypropylene or other polymeric material such as polyethylene terephthalate (PET).

With reference to FIGS. 3 and 4, the wick cartridge 242 includes a front portion 292 and a back portion 294 configured to engage each other, forming an interior of the wick cartridge 242 that accommodates the wick 244. The front portion 292 and the back portion 294 defines a chamber 300 from an external environment outside the wick cartridge 242, where the wick 244 is located in the chamber 300. The front portion 292 and the back portion 294 of the wick cartridge 242 define a water inlet opening 302. The water inlet opening 302 defines a water inlet configured for passing water into the chamber 300 from the external environment to be absorbed by the wick 244. The front portion 292 of the wick cartridge 242 also defines the air inlet aperture 272 in a position downstream from the water inlet opening 302 in a wicking direction of water through the wick 244 from the water inlet opening 302 toward the air outlet passage 304. When in a use, air enters the chamber 300 from the external environment to evaporate the absorbed water from the wick 244.

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

The front portion 292 and the back portion 294 of the wick cartridge 242 define an air outlet passage 304 disposed at a first cartridge end portion 310 including a top of the wick cartridge 242. The air outlet passage 304 is configured for passing air and water vapor from the wick 244 and the chamber 300 to the external environment. The air outlet passage 304 is positioned downstream from the water inlet opening 302 and the air inlet aperture 272 in the wicking direction through the wick 244 when in the use condition. As such, the air inlet aperture 272 is positioned between the water inlet opening 302 and the air outlet passage 304 in the wicking direction through the wick 244 from the water inlet opening 302 toward the air outlet passage 304.

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

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

With this construction, the wick cartridge 242 is configured for receiving water in the chamber 300 at the water inlet opening 302, where the water travels through the wick cartridge 242 in the longitudinal direction of the wick cartridge 242 from the second cartridge end portion 314 toward the first cartridge end portion 310. The wick cartridge 242 is also configured for receiving the relatively dry, warmer air in the chamber 300 at the air inlet aperture 272, where the relatively dry, warmer air contacts the relatively moist surface of the wick 244, evaporating the water from the surface of the wick 244, and humidifying the air. The air then moves vertically through the wick 244, continuing to pick up moisture from the surface of the wick 244, and exits the chamber 300 at the air outlet passage 304 defined by the first cartridge end portion 310.

The wick 244 can be inserted into the chamber 300 through the air outlet passage 304 during assembly or sandwiched between one or more parts that come together to create the wick cartridge 242. In an embodiment, the wick 244 can be removable from the wick cartridge 242 through the air outlet passage 304; however, the wick cartridge 242 and the wick 244 can be assembled and sold together as a unit similar to what is shown in FIG. 3. The wick 244 may fill the entirety of the chamber 300 up to the air outlet passage 304 so that the top surface 282 of the wick 244 is coplanar with an upper surface 322 of the wick cartridge 242 at the first cartridge end portion 310. In another embodiment not shown, the wick 244 is disposed in the chamber 300, and a top portion 324 of the wick 244 depicted in FIG. 4 extends through the air outlet passage 304 at the first cartridge end portion 310, and out of the chamber 300.

With continued reference to FIG. 4, the booster wick 252 overlays a side of the wick 244 along the longitudinal direction of the wick cartridge 242. The primary wick 250 and the booster wick 252 are folded together with a series of alternating folds 330 which are interposed between and separate multiple panels 332 having a similar size as each other. The booster wick 252 overlays the primary wick 250 such that the booster wick 252 is interposed between and separates portions of consecutive panels 332, and separates alternating folds 330 formed from the primary wick 250 in a width direction of the wick cartridge 242. The front portion 292 and the back portion 294 are configured to engage each other, forming an interior of the wick cartridge 242 that accommodates the wick 244, with the panels 332 positioned in the interior of the wick cartridge 242.

While the panels 332 are depicted as planar segments of the wick 244 having a flat shape, the panels 332 may additionally or alternatively feature nonplanar shapes without departing from the scope of the present disclosure. While the folds 330 are depicted as rounded segments of the wick 244 having a semicircular shape, the folds 330 may additionally or alternatively feature

FIG. 5 depicts a method of forming the wick 244 from the primary wick 250 and the booster wick 252. As shown in FIG. 5, the booster wick 252 may be laid on top of or adhered to the primary wick 250 in a planar configuration. Next, the primary wick 250 and the booster wick 252 are folded, while still in contact, in an overlapping pattern to form the panels 332 as internal walls separated from each other by air gaps 334. The primary wick 250 and the booster wick 252 are folded to form the air gaps 334 between consecutive panels 332 and alternating folds 330 in the wick 244.

With reference to FIG. 4, the primary wick 250 and the booster wick 252 are folded together to form the panels 332 in the chamber 300 of the wick cartridge 242. The panels 332 are arranged overlapping in the width direction of the wick cartridge 242, and the booster wick 252 is interposed between and separates portions of the primary wick 250 forming consecutive panels 332 in the width direction of the wick cartridge 242. The panels 332 extend in the longitudinal direction of the wick 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 air gaps 334 arranged in the wick cartridge 242 to face the incoming relatively dry, warmer air from the air inlet aperture 272 provide the air direct access to deeper regions of the folds 330 and the panels 332, and provide uniformity in the flow of the air through the wick 244 as the air travels toward the air outlet passage 304 defined by the first cartridge end portion 310. As such, this construction of the wick 244 in the wick cartridge 242 minimizes a degree to which the air is predisposed to flow in portions of the wick 244 that are closer to the air inlet aperture 272 as the air follows a path of least resistance through the wick 244 to the air outlet passage 304.

As shown in FIG. 5, the booster wick 252 can be laminated to the primary wick 250 with adhesive such that the booster wick 252 extends continuously along a surface on a back side 336 of the primary wick 250 from a first lateral side 338 of the primary wick 250 to a second lateral side 340 of the primary wick 250 in the width direction of the wick cartridge 242. The booster wick 252 is disposed along the primary wick 250 from a position located closer to a top end 342 of the primary wick 250 as compared to a bottom end 344 of the primary wick 250, to a position located closer to the bottom end 344 of the primary wick 250 as compared to the top end 342 of the primary wick 250. In the depicted embodiment, the booster wick 252 extends from a position spaced from the top end 342 of the primary wick 250, to a position at the bottom end 344 of the primary wick 250.

With this construction, as shown in FIG. 2, the booster wick 252 is disposed along the primary wick 250 from a position in the water tank 204 to a position above the water tank 204 in a height direction of the evaporative humidifier 200, without constraining evaporation from the primary wick 250 near the air outlet passage 304. While, as depicted in FIG. 5, the booster wick 252 extends along the back side 336 of the primary wick 250, the booster wick 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 a front side 346 of the primary wick 250 opposite the back side 336 without departing from the scope of the present disclosure.

With reference to FIG. 6, the wick assembly 240 may include a mineral collector 350 having a mineral pad 352, a holder 354, and a top cap 360 fixed with the wick cartridge 242 at the upper surface 322 of the wick cartridge 242. The mineral pad 352 is fixed with the holder 354, and the holder 354 is configured for engaging the top cap 360 with the top cap 360 disposed in the wick assembly 240 such that that the holder 354 retains the mineral pad 352 in the wick assembly 240 against the top cap 360. The holder 354 is connected with the wick cartridge 242 for retaining the mineral pad 352 on the wick 244 adjacent the air outlet passage 304.

The top cap 360 is configured for receiving the wick 244 through the top cap 360 such that the holder 354 retains the mineral pad 352 against the top cap 360 and the wick 244. The holder 354 and the mineral pad 352 are supported by the wick cartridge 242 and fixed to the first cartridge end portion 310 through the top cap 360. The top cap 360 is also configured to conform to the wick 244 such that the air flow through the air outlet passage 304 is forced to move vertically through the wick 244, thereby picking up moisture from the wick 244 before exiting the wick cartridge 242.

The purpose of the mineral pad 352 is to attract and concentrate minerals in the water and moving through the primary wick 250 and booster wick 252 through a process of efflorescence. Efflorescence results from the transport of minerals in water through capillary action and their eventual deposition upon evaporation. In this manner, the mineral pad 352 acts as a dumping ground for minerals, so the minerals do not collect in the primary wick 250 or the booster wick 252, adversely affecting their performance. While, as depicted, the wick assembly 240 includes the mineral pad 352 retained on the wick 244 and the top cap 360 by the holder 354 for collecting minerals from the wick 244, the wick assembly 240 may otherwise not include the mineral pad 352 and the holder 354 as a complete assembly without departing from the scope of the present disclosure.

With reference back to FIG. 4, a seal 364 is disposed on a distal end of the channel 290, around the air inlet aperture 272, and is configured to engage a portion of the power unit housing 202 surrounding the air exit 274 to be in fluid communication with the blower assembly 212 and receive the relatively dry, warmer air. The seal 364 is positioned between and contacts the wick cartridge 242 and the portion of the power unit housing 202 surrounding the air exit 274, and forms a seal that fluidly connects the air exit 274 to the air inlet aperture 272 through the channel 290. The seal 364 is fixed to the wick cartridge 242 with an adhesive, for example, and is configured to slide into engagement with the air exit 274, where each of the seal 364 and the adhesive is able to withstand continuous temperatures of up to 230 degrees Fahrenheit. In this manner, the seal 364 is configured to seal the air exit 274 in fluid communication with the air inlet aperture 272 for receiving air into the chamber 300.

Conversely, the seal 364 can be included on the blower assembly 212, which is the air producing unit of the evaporative humidifier 200. With this construction, the channel 290 is a seal interface disposed on the wick cartridge 242, and configured to engage the seal 364 when the wick cartridge 242 is assembled with the device to seal the air exit 274 in fluid communication with the air inlet aperture 272 for receiving air into the chamber 300.

As shown in FIG. 6, the panels 332 of the wick 244 and portions of the booster wick 252 disposed along the panels 332 are interposed between and separated by upper separators 370 and lower separators 372 that are walls in the wick cartridge 242 disposed along the wick 244. The upper separators 370 are fins extending from the top cap 360, and the lower separators 372 are fins extending from the front portion 292 of the wick cartridge 242. The upper separators 370 are integrally formed from the top cap 360, and the lower separators 372 are integrally formed from the front portion 292 of the wick cartridge 242.

The upper separators 370 and the lower separators 372 are respectively positioned above and below the air inlet aperture 272 in the height direction of the wick cartridge 242 such that the panels 332 are spaced from each other in the width direction of the wick cartridge 242. As such, the panels 332 form air passages between consecutively arranged panels 332 for receiving the relatively dry, warmer air at the air inlet aperture 272. The upper separators 370 are disposed along the wick 244 downstream from the air inlet aperture 272 to constrain air to move through the wick 244 at the first cartridge end portion 310.

The wick 244 is compressed in all directions except the longitudinal direction of the wick cartridge 242 in the interior of the wick cartridge 242 between the upper separators 370 and the lower separators 372 such that fluids passing through the wick cartridge 242 must pass through the wick 244. The air is forced through these relatively thin sections of the wick 244 upon leaving the evaporation zone 254 via features that are included in the wick assembly 240, in the case of FIG. 3, provided by the top cap 360. The top cap 360 has channels to ensure that the air cannot take any “shortcuts” and sees a full length of moist wick material. If the primary wick is too thick (e.g, a thick rectangle), the air flow will not be uniform and will find shorter preferential paths, leaving partitions of the moist wick underutilized, and creating an inefficient design. In an embodiment, a volume of the primary wick 250 may be compressed with the booster wick 252 between 10 and 15 percent in the wick assembly 240 as compared to an original uncompressed volume of the primary wick 250.

As shown in FIG. 7, the mineral pad 352 is supported on the top cap 360 and configured for contacting the wick 244 where the wick 244 protrudes through spaces between the upper separators 370. The holder 354 includes prongs 376 configured to fix the holder 354 with the top cap 360, over the mineral pad 352, in a snap fit assembly. In this manner, the wick cartridge 242 includes the holder 354 fixed with the top cap 360, retaining the mineral pad 352 on the top cap 360 and the wick 244.

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

The mineral collector 350 is configured to concentrate water soluble minerals and contaminants in the mineral pad 352 to prevent buildup of minerals in the wick assembly 240 by continuing to wick water out of the wick 244, and then through evaporation concentrate those minerals or contaminants in the mineral pad 352, maintaining capillary channels in the wick 244 clear of the minerals or contaminants. The mineral collector 350, including the top cap 360, is made from plastic, metal, or another material or material combination that obstructs or largely obstructs air. The mineral collector 350 includes the holder 354, which is configured to retain the mineral pad 352 relative to the top cap 360 with the prongs 376 extended from the holder 354.

The mineral pad 352 is placed in contact with the top surface 282 of the wick 244 so that the mineral pad 352 adsorbs minerals or contaminants from water in the wick 244, and concentrate the minerals or contaminants in the mineral pad 352 through advection and efflorescence at evaporative surfaces of the mineral pad 352. The wick 244 and the mineral pad 352 are distinct components of the wick assembly 240, and the mineral pad 352 is removable from the wick assembly 240. In this manner, the mineral pad 352 can be removed from the wick assembly 240 for being cleaned of collected minerals or contaminants, or replaced with a new mineral pad 352 without removing other portions of the wick 244 from the wick assembly 240. A top surface 380 of the mineral pad 352 in the mineral collector 350 is vented to air so as to facilitate evaporation of water therefrom. Pressure may be applied between the mineral pad 352 and the primary wick 250 to ensure good contact and proper transfer of minerals and can be accomplished by including a spring element between the mineral pad 352 and the holder 354. In an embodiment, the spring element is a compliant, air permeable layer of material or spring features that are attached to or integrally formed with the holder 354.

In the wick assembly 240, efflorescence results in buildup of minerals or contaminants at surfaces of the mineral pad 352 and the wick 244 where water evaporates, blocking pore structures of the mineral pad 352 and the wick 244, reducing a volume of the wick 244 available for transporting water. As shown in FIG. 8, the wick cartridge 242 includes the mineral pad 352 supported on the top cap 360 and disposed on the top surface 282 of the wick 244, across the wicking direction. The mineral pad 352 is configured to collect minerals in water moving through the wick 244 toward the air outlet passage 304.

Contact between the mineral pad 352 and the wick 244 at the top surface 282 of the wick 244 causes liquid water in the wick 244 to transfer to the mineral pad 352. While water evaporates directly from the wick 244 and follows the air flowing through the cap passages 374, remaining water in the wick 244, with dissolved minerals, continues to wick upward to the mineral pad 352. The remaining water with the dissolved minerals flows to the mineral pad 352, where the remaining water evaporates from the mineral pad 352, and a concentrate of advected minerals and contaminants collect on the mineral pad 352 instead of the wick 244. The humidified air also moves from the wick 244 in the cap passages 374 around the mineral pad 352 such that the mineral pad 352 does not impede a primary air flow. In this manner, the wick cartridge 242 defines the cap passages 374 from the wick 244 at the air outlet passage 304, around the mineral pad 352, and to the external environment for directing a primary air flow from the wick 244. The mineral pad 352 is formed from a material with a relatively high wicking capacity and is more dense as compared to the wick 244, where the wicking capacity is controlled by pore size, surface chemistry, pore volume and total pore volume of the mineral pad 352 relative to the wick 244. The mineral pad 352 can have perforations which provide additional exit paths for the air. The mineral pad 352 can also be made from an air permeable material that allows for some air flow through the mineral pad 352.

Mineral levels in the wick 244 can be measured by extraction of the minerals in water from the wick 244. In an embodiment, water from the wick 244 is analyzed by means of inductively coupled plasma optical emission spectrometry (ICP-OES) to measure ion concentration associated with the wick 244, however, alternative or additional means of analyzing the water from the wick 244 may be utilized without departing from the scope of the present disclosure. In another embodiment, at least one of the wick 244 and the mineral pad 352 changes color to indicate a water quality from the wick 244 and the mineral pad 352, and to indicate substantial use or aging in at least one of the wick 244 and the mineral pad 352. A portion of the mineral pad 352 or an additional element can also be configured such that the initial color of the mineral pad 352 is preserved as a means of highlighting the difference between the initial color and the used color. In another embodiment, at least one of the wick 244 and the mineral pad 352 is formed with a natural color, such as tan or brown, configured to hide similarly colored minerals or contaminants collected therefrom.

The mineral pad 352 may be flexible such that the mineral pad 352 conforms to a shape and texture of the primary wick 250 in the wick assembly 240 where the mineral pad 352 is pressed against the wick 244. The mineral pad 352 has a structure with a density of 10-50 percent, and may be formed from a paper product, such as paper towel, 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 an embodiment, the mineral pad 352 has a density of 20-50 percent, and in another embodiment the mineral pad 352 has a density of 30-50 percent.

In an embodiment, the mineral pad 352 may include features such as pleats, folds, holes, recesses, ribs, and projections which provide additional surface area of the mineral pad 352 as compared to a planar surface for facilitating additional evaporation from the mineral pad 352. In a further embodiment, the mineral pad 352 may be additionally or alternatively formed from multiple connected layers of material for increased mineral holding capacity while maintaining flexibility.

The mineral pad 352 is formed from a material that is relatively dense as compared the wick 244. The mineral pad 352 can be formed from a material that is flexible, such that the mineral pad 352 conforms to a shape and texture of the wick 244 where the mineral pad 352 is pressed against the wick 244. With this construction, premature aging of the wick 244 through mineral deposition into the wick 244 may be avoided.

Notably, the densities of the wick 244 and the mineral pad 352 described herein respectively refer to densities of the final assemblies of the wick 244 and the mineral pad 352, and do not necessarily describe original densities of assembly materials used in forming the wick 244 and the mineral pad 352. As such, paper used in forming the wick 244 may have a higher original density prior to assembly in the wick 244, where the density of the paper is higher than the density of the mineral pad 352, and the paper is slitted, stretched, and layered such that the density of the wick 244 formed from the paper is lower than the density of the mineral pad.

FIGS. 9 and 10 illustrate an alternate embodiment of the wick assembly 240 of FIGS. 3, 4, and 6. In the embodiment of FIGS. 9 and 10, like elements with the wick assembly 240 of FIGS. 3, 4, and 6 are denoted with the same reference numerals but followed by a primed suffix (′). As shown in FIG. 9, the wick assembly 240 embodiment includes a wick cartridge 382 having a first cartridge side wall 384 that defines a first opening 390 as a water inlet opening, and defines the air inlet aperture 272′ as a second opening. The wick cartridge 382 also includes a second cartridge side wall 392 pivotally fixed with the first cartridge side wall 384, and configured to rotate relative to the first cartridge side wall 384 between an open position and a closed position.

The second cartridge side wall 392 forms a side of the wick cartridge 382 opposite the first cartridge side wall 384 when the second cartridge side wall 392 is disposed in the closed position. The first cartridge side wall 384 and the second cartridge side wall 392 are configured to close over the wick 244′ in the chamber 300′ such that the wick 244′ is at least partially compressed in the chamber 300′ and fluids passing through the chamber 300′ from the first opening 390 and the air inlet aperture 272′ toward the air outlet passage 304′ pass through the wick 244′. The first cartridge side wall 384 and the second cartridge side wall 392 define the air outlet passage 304′ when the second cartridge side wall 392 is disposed in the closed position.

The first cartridge side wall 384 and the second cartridge side wall 392 are configured to receive the wick 244′ and the mineral collector 350′ in the chamber 300′ when the second cartridge side wall 392 is in the open position. The first cartridge side wall 384 and the second cartridge side wall 392 are also configured to close over and lock the wick 244′ and the mineral collector 350′ received in the chamber 300′ when the second cartridge side wall 392 is rotated to the closed position. The wick 244′ and the mineral collector 350′ are also removable from the chamber 300′ when the second cartridge side wall 392 is disposed in the open position. With this construction, the wick 244′ and the mineral collector 350′ may be replaceable in the wick assembly 240 by rotating the second cartridge side wall 392 toward the open position, removing at least one of the wick 244′ and the mineral collector 350′, disposing a corresponding wick or mineral collector respectively similar to the wick 244′ and the mineral collector 350′ in the wick assembly 240, and rotating the second cartridge side wall 392 toward the closed position. Alternatively, the first cartridge side wall 384 and the second cartridge side wall 392 may be sealed with the wick 244′ and the mineral collector 350′ fixed therein as a consumable unit that may be disposed as a whole or recycled.

As shown in FIG. 9, the mineral collector 350′ includes the mineral pad 352′ with the holder 354′ disposed on the mineral pad 352′ and engaged with the top cap 360′, thereby retaining the mineral pad 352′ against the wick 244′, on the top cap 360′. As such, the mineral pad 352′ is disposed over the top portion 324′ of the wick 244′ in the longitudinal direction of the wick cartridge 242′, and along the top surface 282′ in the width direction of the wick cartridge 242′, at the air outlet passage 304′.

The first cartridge side wall 384 defines a recess 394 at the first opening 390, the recess 394 being configured for receiving a water conditioner 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 conditioner 400 is complementary with the recess 394 for fitting the recess 394 in a snap-fit assembly, fixing the water conditioner 400 in the first cartridge side wall 384 at the first opening 390. The water conditioner 400 is also removable from the recess 394, and in this manner replaceable in the wick assembly 240 with a similar water conditioner.

The water conditioner 400 may be configured to react with water in the water tank 204 and raise a pH level of water in the water tank 204 to inhibit biological growth in the water tank 204 and the wick assembly 240. The water conditioner 400 may also raise the pH level of water in the water tank 204 enough to cause minerals to precipitate out of solution. In an embodiment, the water conditioner 400 holds 30-50 grams of MgO per gallon of water in the water tank 204 in a mesh system, with the MgO having a particle size containable in the mesh system, and is configured to maintain the pH level of the water in the water tank 204 at 9.5 or greater to inhibit growth of biological systems in the water tank 204 and the wick assembly 240. In a further embodiment, the water conditioner 400 maintains an equilibrium pH level of at least 10 in the water tank 204. In a further embodiment, the MgO cartridge maintains an equilibrium pH level of at least 10.5 in the water tank 204.

The wick assembly 240 can include regions that contain chemicals that can be dispensed into the water to change its characteristics. These can include changing the pH for the purpose of minimizing bacterial growth. Such chemicals include calcium oxide, calcium hydroxide, magnesium oxide, magnesium hydroxide, and sodium hydroxide. One approach is to cause precipitation of minerals using, sodium carbonate, sodium bicarbonate, calcium oxide, magnesium oxide, calcium hydroxide, magnesium hydroxide and sodium hydroxide. The wick assembly 240 can include regions that contain chemicals that can be dispensed into the water to change the solubility of minerals or heavy metals within the water. These chemicals can also include anti-microbial materials, to prevent the growth of biological materials. The wick assembly 240 can also include materials that bind minerals and prevent them from being absorbed by the wick material(s), thereby extending its life. Chelating or sequestering agents such as ethylene diamond tetra acetic acid, nitrilotriacetic acid, and diethylene thiamine penta acetic acid could be employed. Also citric acids and phosphates including poly phosphates like sodium polyphosphate could be used. These regions of chemicals can be designed below the water level, so they are continuously dispersed. The rate of dispersion can be limited by restricting the amount of water that can circulate around these regions, or by reaching a maximum saturation level, whereby more chemicals are not released. For example, polyphosphate beads such as SPER PolyPhos® Dissolving Polyphosphate Beads available from SPER Chemical Corporation could be used. The regions may be located near the top of the water level, so they only disperse when they are immersed in water. The humidifier can automatically lower the water level (via humidification) so that the amount of time these regions are immersed in water is time limited. In another embodiment, a conditioning element in the water tank 204 can be configured such that when the water is added to the water tank 204 the water will rise high enough to enter the area where the polyphosphate beads are located. An air bubble will be generated that isolates the water surrounding the polyphosphate beads from the balance of the water in the water tank 204. During use, the water level in the water tank 204 will drop and release the air bubble which will dose the polyphosphate into the water in the water tank 204. When water is added to the water tank 204 or refilled it will start the cycle over again. This improves the slow release because it limits the amount of water in contact with the polyphosphate beads. In another variation, these regions of chemicals may be above the maximum water level but located such that the process of refilling the humidifier (through the wick cartridge, for instance) causes chemicals to be eluted into the passing water.

With continued reference to FIG. 9, the wick 244′ forms the panels 332′ positioned in the chamber 300′ of the wick cartridge 382. The top cap 360′ forms the upper separators 370′ in the chamber 300′, disposed along the panels 332′, and interposed between consecutively arranged panels 332′ in the width direction of the wick cartridge 382. With this construction, the consecutively arranged panels 332′ are separated from each other across the upper separators 370′ and form air passages downstream from the air inlet aperture 272′ in the wicking direction. The panels 332′ are arranged overlapping each other in the width direction of the wick cartridge 382, and the upper separators 370′ are interposed between the consecutively arranged panels 332′ in the width direction of the wick cartridge 382.

With reference to FIG. 10, the first cartridge side wall 384 and the second cartridge side wall 392 define the air outlet passage 304′ when the second cartridge side wall 392 is in the closed position. In this manner, the first cartridge side wall 384 and the second cartridge side wall 392 are configured to selectively close over the top cap 360, fixing the top cap 360′ with the first cartridge side wall 384 and the second cartridge side wall 392. The first cartridge side wall 384, the second cartridge side wall 392, and the top cap 360′ are configured to selectively close over the wick 244′ such that the wick 244′ is at least partially compressed in the wick cartridge 382 and fluids passing through the wick cartridge 382 must pass through the wick 244′. The first cartridge side wall 384 is hinged with the second cartridge side wall 392 to selectively close over the top cap 360′ at the air outlet passage 304′. Unless otherwise stated, the wick cartridge 382 includes similar features and functions in a similar manner as the wick cartridge 242.

The upper separators 370′ define curved surfaces complementary with the geometry of the wick 244′ such that the top cap 360′ conforms to the wick 244′ and restricts the air flow in the first cartridge end portion 310′ through the wick 244′. With this construction, when the wick cartridge 382 is closed over the wick 244′, air flow through the first cartridge end portion 310′ and the air outlet passage 304′ is forced to move through the wick 244′, thereby picking up additional moisture from the wick 244′ in the evaporation zone 254′ between the air inlet aperture 272′ and the top surface 282′ of the wick 244′ before exiting the wick cartridge 382.

FIG. 11 illustrates a method 402 of manufacturing an alternative embodiment of the wick assembly 240 of FIGS. 3, 4, and 6, and FIG. 12 depicts a front perspective view of the wick assembly 240 embodiment of FIG. 11. In the embodiment of FIGS. 11 and 12, like elements with the wick assembly 240 of FIGS. 3, 4, and 6 are denoted with the same reference numerals but followed by a primed suffix (′).

As shown in FIG. 11, the method includes a step 404 where the primary wick 250′ and the booster wick 252′ are cut and registered under dividers 410. The dividers 410 are pressed onto the wick 244′ with sufficient force to hold the primary wick 250′ and the booster wick 252′ together. In an embodiment, pins (not shown) are disposed through the primary wick 250′ and the booster wick 252′ for gripping and maneuvering the primary wick 250′ and the booster wick 252′ together.

The method 402 further includes a step 412 where the dividers 410 are positioned closer together, folding the primary wick 250′ and the booster wick 252′ to form the folds 330′ and the panels 332′. The method 402 further includes a step 414 where the primary wick 250′ and the booster wick 252′ are placed on a front portion 420 of a wick cartridge 422 using the dividers 410 such that the upper separators 370′ and the lower separators 372′ are interposed between and separate the panels 332′ in a width direction of the wick cartridge 422, and the dividers 410 are removed from the wick assembly 240. The folded wick 244′ can also be inserted into a back portion 424 of the wick cartridge 422 first.

The method 402 further includes a step 430 where the back portion 424 of the wick cartridge 422 is positioned over the wick 244′ and engaged with the front portion 420. While the depicted wick assembly 240 includes the front portion 420 and the back portion 424 fixed together with snaps, other interlocking features or connecting means such as ultrasonic welding or thermal welding may be implemented in addition, or alternative to the snaps without departing from the scope of the present disclosure.

As shown in FIG. 12, the front portion 420 of the wick cartridge 422 includes middle separators 432 are interposed between and separate the upper separators 370′ and the lower separators 372′ in a height direction of the wick cartridge 422. The middle separators 432 are formed from ribs that continue a surface shape of the upper separators 370′ and the lower separators 372′, where the surface shape engages the wick 244′, supporting the wick 244′ in front of the air inlet aperture 272′. Unless otherwise stated, the wick cartridge 422 includes similar features and functions in a similar manner as the wick cartridge 242′.

FIGS. 13-16 depict an alternative embodiment of the wick assembly 240 of FIGS. 3, 4, and 6, where a wick 434 includes multiple wick segments 440 stacked in a width direction of a wick cartridge 442. In the embodiment of FIGS. 13-16, like elements with the wick assembly 240 of FIGS. 3, 4, and 6 are denoted with the same reference numerals but followed by a primed suffix (′).

As shown in FIGS. 13-15, the wick segments 440 are spaced from each other to form air gaps between consecutively stacked wick segments 440, and each wick segment 440 is formed from a layer of the booster wick 252′ interposed between and separating layers of the primary wick 250′ in a laminated structure. As shown between FIGS. 14 and 15, the wick cartridge 442 is configured to receive the relatively dry, warmer air from the blower assembly 212 through the air inlet aperture 272′, through air gaps 444 between consecutively stacked wick segments 440 from the air inlet aperture 272′, and is driven into the wick segments 440.

FIG. 16 depicts a method 450 of manufacturing the wick assembly 240 depicted in FIGS. 13-15. As shown in FIG. 16, the method 450 includes a step 452 of placing booster wick 252′ portions formed from a pleated material in a fixture (not shown) and placing pairs of primary wick 250′ portions in slots defined in the pleated material of the booster wick 252′. The method 450 also includes a step 454 of compressing the pairs of primary wick 250′ portions and booster wick 252′ portions forming the wick 434 in the width direction of the wick cartridge 442 to fit the wick cartridge 442. The method 450 also includes a step 460 of sliding the wick 434 into a cartridge back 462, where blades 464 formed from a fixture 470 protrude through the cartridge back 462 and press into the pairs of the primary wick 250′ portions to define space between the pairs of the primary wick 250′ portions. The method 450 also includes a step 472 of positioning a cartridge front 474 over the wick 434 to engage the cartridge back 462, where air spacers 480 contact the blades 464 of the fixture 470. The method 450 also includes a step 482 where the fixture 470 is removed from the wick assembly 240.

Unless otherwise stated, the wick 434 and the wick cartridge 442 respectively include similar features and function in a similar manner as the wick 244 and the wick cartridge 242.

FIG. 17 illustrates an alternative embodiment of the evaporative humidifier 200 and the wick assembly 240 of FIGS. 2-7, and FIG. 18 depicts a front perspective view of the wick assembly 240 embodiment of FIG. 17. In the embodiment of FIGS. 17 and 18, like elements with the wick assembly 240 of FIGS. 2-7 are denoted with the same reference numerals but followed by a primed suffix (′).

As shown in FIG. 17, the evaporative humidifier 200 includes a lid 484 which defines apertures 490. The apertures 490 extend through the lid 484 to allow humidified air to escape the water tank 204′ into ambient. In another embodiment, the apertures 490 may be disposed on at least one side wall 492 of the water tank 204′ and extend through the at least one side wall 492 of the water tank 204′ at a location near enough the lid 484 at a top portion 494 of the water tank 204′ to not allow for liquid water to escape. The water tank 204′ is in fluid communication with ambient via the apertures 490. The water tank 204′ further includes the air inlet aperture 272′ through which air (typically heated) from the power unit housing 202′ enters the water tank 204′. Additionally, the water tank 204′ further includes an air outlet, via the apertures 490, that is in fluid communication with ambient.

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 a user should fill the water tank 204′. The fill indicator 502 may be disposed on an inside surface or an outside surface of the side wall 492. The fill indicator 502 may be, but is not limited to, a notch, a line, or a protrusion on the side wall 492. The fill indicator 502 is located beneath the air exit 274′ to prevent water from entering into the power unit housing 202′.

The wick assembly 240 included in a plurality of similar wick assemblies disposed within the water tank 204′. With reference to FIGS. 17 and 18, the wick assembly 240 includes a wick cartridge 504 and a wick 510 disposed within the wick cartridge 504. The wick assembly 240 can also include a separator 512 that seals against an inner surface of a water tank 204′ to provide a warm or hot air zone 514 between the separator 512 and an upper level of the water in the water tank 204′ and a condensation zone 520 between the separator 512 and the lid 484. The separator 512 also ensures that all air entering the water tank 204′ passes through wicks 510 before exiting the evaporative humidifier 200, thereby humidifying the passing air.

With continued reference to FIG. 17, at least one side wall 522 in a plurality of side walls 522 forming the wick cartridge 504 may further include a protrusion 524, which can be in the form of a flange, for example, disposed at a top portion of the at least one side wall 522. In the illustrated embodiment, the protrusion 524 is disposed on an outer periphery of the plurality of side walls 522. The protrusion 524 extends outwardly away from the least one side wall 522. The top surface of the protrusion 524 may coincide with the upper surface 322′ of the wick cartridge 504.

In the illustrated embodiment, the wick cartridge 504 includes a plurality of air inlet apertures 272′ provided in the side walls 522 of the wick cartridge 504. It is to be understood that any number of side walls 522 may include any number of air inlet apertures 272′. The plurality of air inlet apertures 272′ are disposed at equal heights on the plurality of side walls 522. The width of each air inlet aperture 272′ may span a majority of the width of the respective side wall 522 through which it extends. When the wick cartridge 504 is a rectangular shape in longitudinal cross section and the wick cartridge 504 includes four side walls 522, one air inlet aperture 272′ may be provided in each side wall 522. Alternatively, when the wick cartridge 504 is a rectangular shape in longitudinal cross section and the wick cartridge 504 includes four side walls 522, one air inlet aperture 272′ may be disposed on each of two side walls 522. In an embodiment, one air inlet aperture 272′ is disposed on two parallel side walls 522.

As mentioned above, at least one water inlet opening 302′ through which water passes to be absorbed by the wick 510 is provided in the wick cartridge 504 beneath the air inlet apertures 272′. In one embodiment, a bottom portion 530 (see FIG. 18) of the wick 510 extends through the water inlet opening 302′ and out of the chamber 300′. With reference to FIG. 18, the wick cartridge 504 may further include a plurality of lower legs 532 provided near a bottom of the wick cartridge 504 configured to create a space 534 between a lower edge 540 of the wick cartridge 504 and a base 542 of the water tank 204′ when the wick assembly 240 is received in the water tank 204′. The space 534 can coincide with the at least one water inlet opening 302′.

The wick 510 is made from a water absorbent material, or a combination of absorbent materials that can be arranged vertically (in the direction of water flow) or horizontally. In an embodiment, the wick 510 includes an absorbent fiber. In another embodiment, the wick 510 may include holes (not shown) to allow air and water vapor to pass through the wick 510. The wick 510 may have any shape, although in the illustrated embodiment the wick 510 is dimensioned to fill the chamber 300′ of the wick cartridge 504.

In use, the water tank 204′ is filled with water up to or at any location below an upper edge 544 of each of the plurality of air inlet apertures 272′ of the wick cartridge 504 and below an air inlet 500 of the water tank 204′. Accordingly, the fill indicator 502 is disposed at a position lower than a lower edge 550 of each of the plurality of air inlet apertures 272′. Also, each side wall 522 extends downwardly from the lower edge 550 of the air inlet aperture 272′ to an upper boundary of the water inlet opening 302′. Each side wall 522 also extends downwardly from the upper surface 322′ of the wick cartridge 504 to the upper edge 544 of the air inlet apertures 272′.

The separator 512 is made from an air and water impermeable material. In an embodiment, the separator 512 includes a polyurethane material. The separator 512 extends to the inside perimeter of the water tank 204′ and seals against the inner surface of a 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 so that the separator 512 is appropriately positioned in the water tank 204′. The apertures 490 (which mentioned above could also be in the side wall 522 of the water tank 204′) are positioned above the separator 512.

The separator 512 further includes at least one wick-receiving aperture 552 that extends from a top surface 554 of the separator 512 to a bottom surface 556 of the separator 512. A respective wick cartridge 504 is inserted into each wick-receiving aperture 552. Each wick-receiving aperture 552 has a similar shape as the longitudinal cross section of the wick cartridge 504. A seal (not shown) may be disposed on an inner periphery of each wick-receiving aperture 552 to prevent fluid from passing between the wick cartridge 504 and the separator 512 through the wick-receiving aperture 552. The wick cartridge 504 may be configured to extend above the top surface 554 of the separator 512. Alternatively, only the wick 510 may extend above the top surface 554 of the separator 512. The separator 512 further includes an outer seal 560 that seals against the inner surface of the water tank 204′ to separate the water tank 204′ into the warm or hot air zone 514 between the separator 512 and an upper level of the water in the water tank 204′ and the condensation zone 520 between the separator 512 and the lid 484.

In the embodiment in which the wick cartridge 504 includes the protrusion 524, the wick-receiving aperture 552 is large enough so that the side walls 522 of the wick cartridge 504 can be inserted through the wick-receiving aperture 132 but small enough so that the protrusion 524 cannot be inserted into the wick-receiving aperture 552. A bottom surface 562 of the protrusion 524 may contact the top surface 554 of the separator 512 when the wick cartridge 504 is inserted into the wick-receiving aperture 552. The separator 512 may further include a depression 564 disposed in the top surface 554 of the separator 512 around an outer periphery of the wick-receiving aperture 552. The depression 564 can receive the protrusion 524 of the wick cartridge 504. In one embodiment, the depression 564 has the same height as the protrusion 524 so that an upper surface 570 of the protrusion 524 is planar with the top surface 554 of the separator 512.

As shown in FIG. 18, the wick cartridge 504 may be provided with a wick cartridge lid 572. The wick cartridge lid 572 may be constructed separately from the side walls 522 of the wick cartridge 504. The wick cartridge lid 572 covers the wick 510 during shipment and can provide a location for branding.

With reference to FIG. 17, in using the evaporative humidifier 200, a user fills the water tank 204′ with water. In the embodiment that includes the fill indicator 502, the user fills the water tank 204′ to the fill indicator 502. The user may insert the separator 512 with the wick cartridges 504 and the wicks 510 positioned therein either before or after filling the water tank 204′ to the appropriate level with water. When the evaporative humidifier 200 is turned on, the heater 220 heats up air within the power unit housing 202. The fan 214 blows the heated air from the power unit housing 202 into the water tank 204′ through the air inlet 500.

FIG. 19 illustrates an alternative embodiment of the wick cartridge 504 of FIGS. 17 and 18 where the water inlet is defined by a water permeable material. In the embodiment of FIG. 19, like elements with the wick cartridge 504 of FIGS. 17 and 18 are denoted with the same reference numerals but followed by a primed suffix (′).

As shown in FIG. 19, the second cartridge end portion 314′ of the wick cartridge 504 is formed from a water permeable material that covers the bottom portion 530 (See FIG. 18) of the wick 510. The water permeable material of the wick cartridge 504 is porous, where pores formed therein define a plurality of water inlet openings 302′ through which water permeates.

The plurality of water inlet openings 302′ allow fluids to pass through the wick cartridge 504 and into the chamber 300′ while the water permeable material of the wick cartridge 504 guides fluid flow through the wick 510 from the water inlet openings 302′ toward the air inlet apertures 272′ and the air outlet passage 304′. As such, the water inlet openings 302′ formed in the water permeable material of the wick cartridge 504 function in a similar manner as the water inlet opening 302 to introduce water from the water tank 204 into the chamber 300.

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

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

A wick assembly for an evaporative humidifier has been described above in particularity. Modifications and alterations will occur to those upon reading and understanding the preceding detailed description. The invention, however, is not limited to only the embodiments described above. It will be appreciated that various features of the above-disclosed embodiments and other features and functions, or alternatives or varieties thereof, may be desirably combined into many other different systems or applications. Also that 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

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

a wick made from a water absorbent material; and

a wick cartridge defining a chamber from an external environment outside the wick cartridge, wherein the wick is located in the chamber and the wick cartridge defines:

a water inlet configured for passing water into the chamber from the external environment;

an air inlet aperture configured for passing air into the chamber from the external environment; and

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

wherein the air inlet aperture is positioned between the water inlet and the air outlet passage in a wicking direction through the wick from the water inlet toward the air outlet passage.

2. The wick assembly of claim 1, wherein the wick cartridge is made from plastic, metal, or another material or material combination that obstructs or largely obstructs air.

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

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

the air outlet passage is positioned downstream from the water inlet opening in the wicking direction and the air inlet aperture when in the use condition.

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

5. The wick assembly of claim 1, further comprising a seal or a seal interface disposed on the wick cartridge around the air inlet aperture, and configured for sealing the air inlet aperture in fluid communication with a duct for receiving air into the chamber.

6. The wick assembly of claim 1, wherein the wick cartridge includes walls along the wick downstream from the air inlet aperture to constrain air to move through the wick.

7. The wick assembly of claim 6, wherein the wick is folded to form internal walls positioned in the wick cartridge, wherein the internal walls are arranged overlapping each other in a width direction of the wick cartridge, and are oriented parallel to the wicking direction from the air inlet aperture toward the air outlet passage, and separators are positioned between consecutively arranged internal walls in the width direction of the wick cartridge.

8. The wick assembly of claim 6, wherein the wick cartridge includes a first cartridge side wall that defines the air inlet aperture, and includes a second cartridge side wall that forms a side of the wick cartridge opposite the first cartridge side wall, and

wherein at least one of the first cartridge side wall and the second cartridge side wall define the air outlet passage.

9. The wick assembly of claim 1, wherein the wick cartridge includes walls that compress the wick in the chamber such that fluids passing through the chamber from the water inlet and the air inlet aperture pass through the wick.

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

11. The wick assembly of claim 10, wherein the mineral collector is a mineral pad, and the wick assembly further comprises a holder connected with the wick cartridge for retaining the mineral pad on the wick adjacent the air outlet passage.

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

13. The wick assembly of claim 1, wherein the wick includes a primary wick and a booster wick in contact with at least one side of the primary wick, the booster wick having a lower air permeability than the primary wick.

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

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

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

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

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

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

providing a wick cartridge that defines a chamber, a water inlet, an air inlet aperture, and an air outlet passage; and

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

20. The method of claim 19, further comprising positioning a mineral collector in contact with a first wick end portion of the wick adjacent to the air outlet passage.

21-26. (canceled)