Patent Application
20230087373
The present invention relates to an exhaust vent cap assembly, and more particularly, the present invention relates to an exhaust vent cap assembly for preventing water damage to insulated exhaust ducts and fan assembly of a ventilation system in a building.
As part of the ventilation system of a house, exhaust fans are installed in bathrooms or toilets to remove the odor and moist air to the outside of the house. Fans are usually installed in the ceiling of bathrooms to egress exhaust air. A small duct is connected to the fan and runs through space between floors or in the attic to vent air to the outside. The ducts end in the roof deck or outside walls of a building. The roof deck is prepared for installing the duct by making a round hole of the size proportional to the size of the duct either on the outer wall of the house or in the roof deck for the air to exhaust to the outside (called, penetration).
Roofer later installs a waterproof cap over the hole where the duct is attached, to waterproof the penetrations. In colder climates, the moist air running through the round duct to the outside can condensate and water will drip down to the fan assembly in the ceiling of the bathroom or where the fan is installed and cause damage. To avoid condensation issues, ducts are insulated. To ease installation, round flexible ducts with insulation around them, also known as flex ducts, are used in connecting the fans to the roof culler.
During construction of a building, the HVAC company installs the fans in the ceilings and makes a round hole in the plywood (roof deck) and attaches the duct to a piece of round steel tube and attaches the round tube to underneath the roof deck in front of the hole on the roof. The round tube is secured to the roof deck with few metal-sheet strips. The hole is open to the outside air for the rain to get into the duct.
In the normal course of construction, the HVAC personnel are the first trade to work on the house once the house is framed. The plumber and then electrician come after HVAC workers and other trades follow them. Roofers install the roof when HVAC personnel and plumbers have made the penetrations and done with their work. Therefore, the holes that HVAC personnel make on the roof are open to the atmosphere till the roofers come and install the permanent cap over the holes.
There could be a one- or two-weeks gap or even sometimes more till the holes on the roof can be covered by the permanent caps. During such time, rain or snow often comes and water travels down the open hole toward the fan and brings water inside the house, and also damages the insulation around the duct attached to the fan.
The HVAC personnel must come back and replace the ducts that were soaked with water and deemed useless. With a typical house having two-three vents through the roof, the cost of replacing the flexible duct or the insulation around the ridged duct can get expensive. Since these ducts are in the attic, workers must maneuver between the roof trusses and frame members to make the holes and attach the roof collar. This makes the work even more challenging and labor-intensive. The additional material and labor with the trip to make the repairs add to the operational expense of the HVAC Company, chipping away at their profits. This phenomenon happens repeatedly and often enough that the cost of the additional repairs becomes substantial.
Both the consumers and the industries have a desire for a solution to the aforesaid problems.
The following presents a simplified summary of one or more embodiments of the present invention in order to provide a basic understanding of such embodiments. This summary is not an extensive overview of all contemplated embodiments and is intended to neither identify key or critical elements of all embodiments nor delineate the scope of any or all embodiments. Its sole purpose is to present some concepts of one or more embodiments in a simplified form as a prelude to the more detailed description that is presented later.
The principal object of the present invention is therefore directed to an exhaust vent cap assembly for preventing damage to insulated exhaust ducts.
It is another object of the present invention that the assembly prevents labor, cost, and time for replacing the damaged ducts.
It is still another object of the present invention that the assembly prevents undesired alterations in the building for replacing the damaged insulated exhaust ducts.
It is a further object of the present invention that the assembly is easy to install.
It is yet another object of the present invention that the assembly is economic to manufacture.
In one aspect, disclosed is an exhaust vent cap assembly that can be installed in a roof deck of a building to allow onetime connection of the insulated duct to the roof from exhaust fans within the building.
In one aspect, disclosed is an exhaust vent cap assembly comprising a tubular body, the tubular body comprising a hollow tube having a proximal end and a distal end, a flange extends around a periphery of the proximal end perpendicularly to the hollow tube, and a mouth upstanding from the proximal end of the hollow tube; and a cap configured to sealably fasten to the mouth, the cap and the mouth having a fastening mechanism, wherein an outer diameter of the cap is substantially same as an outer diameter of the mouth. The mouth and the hollow tube are integral, and the flange is mechanically attached. The flange and the hollow tube are integral, and the mouth is mechanically attached. The flange and the mouth are integral, and the hollow tube is mechanically attached. The hollow tube, the mouth, and the flange are integral. The cap and the mouth are having threads for securing the cap to the mouth, the cap is having a handle for turning the cap. The cap and the mouth are configured for snap-fitting the cap onto the mouth. The cap is having a furrow as a handle for lifting the cap. The cap and the mouth are configured for a friction fit.
In one aspect, disclosed is an exhaust vent cap assembly comprising a tubular body, the tubular body comprising a hollow tube having a proximal end and a distal end, a flange extends around a periphery of the proximal end perpendicularly to the hollow tube, and a mouth upstanding from the proximal end of the hollow tube; a cap configured to sealably fasten to the mouth, the cap and the mouth having a fastening mechanism, wherein an outer diameter of the cap is substantially same as an outer diameter of the mouth; and a duct, the duct has a proximal end and a distal end, the proximal end of the duct is coupled to the distal end of the hollow tube.
These and other objects and advantages of the embodiments herein and the summary will become readily apparent from the following detailed description taken in conjunction with the accompanying drawings.
The accompanying figures, which are incorporated herein, form part of the specification and illustrate embodiments of the present invention. Together with the description, the figures further explain the principles of the present invention and to enable a person skilled in the relevant arts to make and use the invention.
Subject matter will now be described more fully hereinafter with reference to the accompanying drawings, which form a part hereof, and which show, by way of illustration, specific exemplary embodiments. Subject matter may, however, be embodied in a variety of different forms and, therefore, covered or claimed subject matter is intended to be construed as not being limited to any exemplary embodiments set forth herein; exemplary embodiments are provided merely to be illustrative. Likewise, a reasonably broad scope for claimed or covered subject matter is intended. Among other things, for example, the subject matter may be embodied as methods, devices, components, or systems. The following detailed description is, therefore, not intended to be taken in a limiting sense.
The word “exemplary” is used herein to mean “serving as an example, instance, or illustration.” Any embodiment described herein as “exemplary” is not necessarily to be construed as preferred or advantageous over other embodiments. Likewise, the term “embodiments of the present invention” does not require that all embodiments of the invention include the discussed feature, advantage, or mode of operation.
The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of embodiments of the invention. As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises”, “comprising,”, “includes” and/or “including”, when used herein, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof.
The following detailed description includes the best currently contemplated mode or modes of carrying out exemplary embodiments of the invention. The description is not to be taken in a limiting sense but is made merely for the purpose of illustrating the general principles of the invention, since the scope of the invention will be best defined by the allowed claims of any resulting patent.
Disclosed is an exhaust vent cap assembly for a ventilation system of a building. The disclosed exhaust vent cap assembly secures the insulated exhaust ducts of the ventilation system to the roof deck or outer wall of the building. Disclosed exhaust vent cap assembly eliminates the redundant work and the extra costs associated with replacing the insulated exhaust ducts in the attic that are damaged by water and stopping water from entering the house through the exhaust fans.
Referring to
The fastening mechanism and the handle can be varied for desired water tightness.
The removable cap can have different shapes to achieve water tightness. It can be snapped onto the top of the tubular member. It can also be a shape of a lid that goes over the tube having friction fit, a cap that can be screwed onto the tubular member by fasteners, or other methods of securing the cap to the tubular member so it is not easily removed by wind. All these methods are meant to produce a waterproof assembly so water may not be able to seep inside the insulated ducts.
The duct 400 can be pushed onto the distal end of the tubular body and secured using fasteners 440 and/or a strap. A tubular body can have a protrusion 460 that further prevents the slipping of the duct over the tubular body. An instruction label will be affixed or printed on the cap for a roofer to remove before they install the permanent roof cap 470.
Alternatively, this disclosed exhaust vent cap assembly can also be attached to one end of the exhaust duct in a factory for ease of installation in the field. All the installer has to do is to make a hole in the roof deck, as usual, insert the device through the hole and screw the flange with a few fasteners underneath the roof deck and connect the other end to the exhaust fan. Roofers can remove the removable cap later without the chance of water entering the house or damaging the duct insulation.
The different components of the disclosed exhaust vent cap assembly can be made of different materials, such as virgin or recycled plastics, sheet metal, metal casting, PVC, or any material that is commonly used.
Referring to
The above embodiments describe the assembly for use in roof vents, however, the disclosed assembly can also be adapted for vents in the wall. Vents can be provided on the walls of a building, in particular, multistory buildings, such as multi-family dwellings, offices, or commercial places. Currently, the exhaust vents that are inside the building envelope for bathroom fans, dryers, or other equipment that need exhaust vents to outside are commonly placed in the band boards, exterior walls, attic gable ends, or roof area. Typically, a hole for the vent is drilled in the perimeter of the house and through the band board. Band boards are usually a wood product that covers the ends of the floor joists. The hole for the vent can also be made in the exterior sheeting or bandboard. The disclosed exhaust vent assembly can be adapted for such wall vent holes. Advantage of the disclosed vent assembly in the side mount applications is that it can be installed from inside the house instead of outside as it is currently done. Thus, making installation of the vent assembly much easier.
For installation, the tubular body can be inserted into the vent hole. The duct 1240 extending from the vent of the room’s exhaust system can be coupled to the tubular body of the disclosed assembly and the cap can be secured. Alternatively, the cap can be pre-secured to the mouth. In another implementation, the duct can be a part of the disclosed assembly, wherein the duct, the tubular body, and the cap can be pre-assembled i.e., the cap is secured to the mouth and the duct is secured to the tubular body. The free end of the duct can be coupled to the fan 1250. The cap is accessible from outside of the wall and can be removed later and a permanent cap can be placed over the vent hole. The disclosed assembly with or without the duct can be installed from inside of the wall. Perhaps, installing from inside can be safer avoiding the need for climbing tall ladders thus addressing the fall or injury concerns using tall ladders or complications associated with installation from outside. Moreover, installing from inside the wall can be easier and quicker. A tie strap 1270 can secure the duct mounted over the tubular body.
For Installation, a hole can be drilled in an exterior sheeting of a structure from the inside. Then the tubular body with the cap secured to the mouth can be inserted from the inside and the flange of the tubular body can be secured using multiple fasteners, such as screws. The flexible duct may already be attached to the tubular body or can be attached to the tubular body. The free end of the duct can be extended to the fan of the ventilation system. The removable and disposable cap of the disclosed exhaust vent assembly can seal the vent hole preventing ingress of dust and water. Upon finishing the exterior of the wall (structure), the cap of the disclosed exhaust vent assembly can be removed, and a permanent cap of choice can be installed. The temporary cap can be designed in several ways as shown in
Referring to
In one implementation, the length of the tubular body can be made of different sizes to allow for various thicknesses in the framing structures. The length of the tubular body and its diameter is of sufficient size to allow ease of use. This invention is designed to fit various sizes of flexible or rigid ducts in the market, such as 4", 6", 8", 10", or any other conceivable size. Rigid ducts are typically made of sheet metal and flexible ducts with plastic tubes with wire reinforcement having outer insulation and some are made of aluminum.
While the foregoing written description of the invention enables one of ordinary skill to make and use what is considered presently to be the best mode thereof, those of ordinary skill will understand and appreciate the existence of variations, combinations, and equivalents of the specific embodiment, method, and examples herein. The invention should therefore not be limited by the above-described embodiment, method, and examples, but by all embodiments and methods within the scope and spirit of the invention as claimed.
This application is a continuation-in-part of a U.S. Pat. Application Ser. No. 17/316,414, filed on May 10, 2021, which claims priority from a U.S. provisional Pat. Application serial number 63/146,944, filed on Feb. 08, 2021, both of which are incorporated herein by reference in its entirety.
| Number | Date | Country | |
|---|---|---|---|
| Parent | 17316414 | May 2021 | US |
| Child | 18070164 | US |
