VENT FLAPPER WITH INTAKE/EXHAUST HOLES

Abstract

A vent assembly, including a vent flapper and one or more air intake openings formed within the vent flapper, wherein the air intake openings allow air to flow both in and out. The assembly may include a removable cover attachable to the vent flapper, or a tube opening and a vent flapper area, wherein the vent flapper area is at least 65 percent larger than the tube opening. The assembly may have air intake openings hexagonal. The assembly may include a tube configured to attach to one of the concentric cylinders, and the backplate may have a plurality of concentric cylinders arranged in decreasing diameter. The cylinders may be separated by dual-sided score lines and at least one of the cylinders is recessed from the backplate. The assembly may have a removable cover configured to block the openings for air intake formed within the vent flapper.

Description

INTRODUCTION

This disclosure generally relates to vents that may be used for exhausting different structures, including dryers or similar structures.

SUMMARY

A vent assembly, including a vent flapper and one or more air intake openings formed within the vent flapper, wherein the air intake openings allow air to flow both in and out. The vent assembly may include a removable cover attachable to the vent flapper, or a tube opening and a vent flapper area, wherein the vent flapper area is at least 65 percent larger than the tube opening.

The vent assembly may include the air intake openings are hexagonal. The vent assembly may include that the vent flapper area is non-circular or is substantially square. The vent assembly may include a flapper recess, formed on the vent flapper, and a flapper hinge, wherein the flapper recess substantially ensures the vent flapper rotates around the flapper hinge. The vent assembly may include a removable cover configured to block the openings for air intake formed within the vent flapper.

The vent assembly may include a tube configured to attach to one of the concentric cylinders, and the backplate may have a plurality of concentric cylinders arranged in decreasing diameter. The concentric cylinders may be separated by dual-sided score lines and at least one of the concentric cylinders is recessed from the backplate.

The above features and advantages, and other features and advantages, of the present disclosure are readily apparent from the following detailed description of some of the best modes and other embodiments for carrying out the disclosure, which is defined solely by the appended claims, when taken in connection with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1: Isometric view of hooded vent assembly.

FIG. 2: Top view of hooded vent assembly.

FIG. 3: Side view of hooded vent assembly.

FIG. 4: Front view of hooded vent assembly.

FIG. 5: Back-isometric view of hooded vent assembly.

FIG. 6: Back view of backplate used in hooded vent assembly.

FIG. 7: Side view of backplate used in hooded vent assembly.

FIG. 8: Front view of hooded vent assembly, showing section cut.

FIG. 9: Plane intersection view of hooded vent assembly.

FIG. 10: Front view of back plate, showing section cut.

FIG. 11: Plane intersection view of back plate.

FIG. 12: Isometric view of backplate with flapper assembly.

FIG. 13: Front view of backplate with flapper assembly, showing section cut.

FIG. 14: Plane intersection view of back plate with flapper assembly.

FIG. 15: Front view of hooded vent assembly, showing section cut.

FIG. 16: Plane intersection view of hooded vent assembly.

FIG. 17: Front view of flapper base.

FIG. 18: Isometric view of flapper base.

FIG. 19: Front view of flapper cover.

FIG. 20: Isometric view of flapper cover.

FIG. 21: Directional vent assembly isometric view.

FIG. 22: Directional vent assembly side view.

FIG. 23: Directional vent assembly front view.

FIG. 24: Directional vent assembly front view, showing section cut.

FIG. 25: Plane intersection view of directional vent assembly.

FIG. 26: Backplate used in directional vent assembly, rear isometric view.

FIG. 27: Backplate used in directional vent assembly, rear view.

FIG. 28: Directional vent assembly, front view for section cuts.

FIG. 29: Directional vent assembly, plane intersection view 1 taken along the upper cute line of FIG. 28.

FIG. 30: Directional vent assembly, plane intersection view 2 taken along the lower cut line of FIG. 28.

FIG. 31: Backplate and inner mesh, isometric view.

FIG. 32: Backplate and inner mesh, front view for section cut.

FIG. 33: Backplate and inner mesh, plane intersection view.

FIG. 34: Backplate and inner mesh, plane intersection view, 3-inch tube example.

FIG. 35: Backplate and inner mesh, plane intersection view, 4-inch tube modification.

FIG. 36: Backplate and inner mesh, plane intersection view, 6-inch tube modification.

FIG. 37: Exploded isometric view of a vent assembly.

FIG. 38: Vent assembly, front view.

FIG. 39: Vent assembly, plain intersection view, shown closed, along line from FIG. 38.

FIG. 40: Vent assembly, plain intersection view, shown open, along line from FIG. 38.

FIG. 41: Vent assembly, illustrating holes, isometric view.

FIG. 42: Vent assembly, illustrating holes, front view.

FIG. 43: Vent assembly, illustrating holes, plane intersection view, shown closed, from section line in FIG. 42.

FIG. 44: Vent assembly, illustrating holes, plane intersection view, shown open, from section line in FIG. 42.

FIG. 45: Flapper assembly, front view, with cover.

FIG. 46: Flapper assembly, side view, with cover.

FIG. 47: Flapper assembly, isometric view, with cover.

FIG. 48: Flapper assembly, top view, with cover.

FIG. 49: Flapper assembly, bottom view, with cover.

FIG. 50: Flapper, front view, without cover.

FIG. 51: Flapper, side view, without cover.

FIG. 52: Flapper, isometric view, without cover.

FIG. 53: Flapper, top view, without cover.

FIG. 54: Flapper, bottom view, without cover.

FIG. 55: Flapper cover, front view.

FIG. 56: Flapper cover, side view.

FIG. 57: Flapper cover, isometric view.

FIG. 58: Flapper cover, top view.

FIG. 59: Flapper cover, bottom view.

DETAILED DESCRIPTION

Referring to the drawings, like reference numbers correspond to like or similar components wherever possible throughout the several figures. All figures may be referred to in any section of the specification, without regard to numerical order. Note that any dimensions provided are exemplary only and non-limiting.

When used herein, the term “substantially” often refers to relationships that are ideally perfect or complete, but where manufacturing realities prevent absolute perfection. Therefore, substantially denotes typical variance from perfection. For example, if height A is substantially equal to height B, it may be preferred that the two heights are 100.0% equivalent, but manufacturing realities likely result in the distances varying from such perfection. Skilled artisans will recognize the amount of acceptable variance. For example, and without limitation, coverages, areas, or distances may generally be within 10% of perfection for substantial equivalence. Similarly, relative alignments, such as parallel or perpendicular, may generally be considered to be within 5%. When used herein, the term “approximately” often refers to relationships where skilled artisans would recognize the amount of coverage needed.

The drawings and figures presented herein are diagrams, are not to scale, and are provided purely for descriptive purposes. Thus, any specific or relative dimensions or alignments shown in the drawings are not to be construed as limiting. While the disclosure may be illustrated with respect to specific applications or industries, those skilled in the art will recognize the broader applicability of the disclosure. Those having ordinary skill in the art will recognize that terms such as “above,” “below,” “upward,” “downward,” et cetera, are used descriptively of the figures, and do not represent limitations on the scope of the disclosure, as defined by the appended claims. Any numerical designations, such as “first” or “second” are illustrative only and are not intended to limit the scope of the disclosure in any way.

Features shown in one figure may be combined with, substituted for, or modified by, features shown in any of the figures. Unless stated otherwise, no features, elements, or limitations are mutually exclusive of any other features, elements, or limitations. Furthermore, no features, elements, or limitations are absolutely required for operation. Any specific configurations shown in the figures are illustrative only and the specific configurations shown are not limiting of the claims or the description.

All numerical values of parameters (e.g., of quantities or conditions) in this specification, including the appended claims, are to be understood as being modified in all instances by the term “about,” whether or not the term actually appears before the numerical value. About indicates that the stated numerical value allows some slight imprecision (with some approach to exactness in the value; about or reasonably close to the value; nearly). If the imprecision provided by about is not otherwise understood in the art with this ordinary meaning, then about as used herein indicates at least variations that may arise from ordinary methods of measuring and using such parameters. In addition, disclosure of ranges includes disclosure of all values and further divided ranges within the entire range. Each value within a range and the endpoints of a range are hereby all disclosed as separate embodiments.

Some of the present disclosure relates to a utility vent assembly (101) consisting of, at least, a base plate (102), or backplate (102), and a face plate (117). In this instance we have, without limitation, a hooded face plate (103) and directional face plate (104), other face plate (117) designs may be used but these two styles are the most common, as will be recognized by those having ordinary skill in the art. Depending on the face plate (117) design additional components may be needed for the vent assembly (101).

The base plate (102) attaches to a wall substrate (115). The base plate (102) includes a plurality of concentric tube cylinders (112) on the side of the base plate (102) facing the wall substrate (115). The tube cylinders (112) decrease in diameter as they move towards the wall substrate (115). This is for two reasons. First, this makes the part manufacturable via injection molding. Second, for installation purposes it is ideal to cut the smallest hole possible in the wall substate (115) for a ventilation tube (116). It is important to note that it is ideal to have, at least, the largest tube cylinder (112) height does not extend past the wall substate (115).

In this design, the tube cylinders (112) have a slightly larger diameter than the ventilation tube (116) application. This is the method that allows the largest diameter flow through the system. It is important to note that the description may also have a tube cylinder (112) diameter smaller than the ventilation tube (116), so the ventilation tube (116) installs over the tube cylinder (112). This design may slightly restrict airflow but may be used for other benefits.

Alternative configurations of the base plate (102) or the backplate (102) may include snap-in tube cylinders (112). For example, and without limitation, the largest diameter of the tube cylinders (112) is molded into the base plate (102). Then, the smaller tube cylinders (112) may be snapped into the largest cylinder. For example, and without limitation, a six-inch cylinder may be formed in of the base plate (102) and then, progressively, smaller cylinders may be attached to that larger cylinder. This means that only a single tube cylinder (112) is formed on the base plate (102), and then several snap-in cylinders are also available to snap into the larger cylinder.

The base plate (102) is designed to accept multiple ventilation tube (116) diameters. This is done by removing pieces of the base plate (102). Components may include, without limitation: flapper assembly (105), flapper base (106), flapper cover (107) or removable flapper cover (107), inner mesh (108), vent face open area (109), back plate maximum open area (110). Note that any of these structures may be referred to as, simply, the vent flapper. The vent flapper may be solid or have any shape of holes.

Once the base plate (102) exists a section where the larger tube cylinder (112) diameter transitions to the next smallest tube cylinder (112) diameter, this is called the tube base (118). On the tube base (118) exists score lines. There are concentric, opposite score lines on either surface of the tube base (118). These are called a score line—back (113) which faces the wall substrate (115) and a score line—face (114) which faces the face plate (117). This is unique because, typically, score lines are only on one surface. Depending on the installation type, it may be advantageous to use one score line over the other.

The contractor will cut along either the score line—back (113) or score line—face (114) to remove the tube base (118) and all smaller tube cylinders (112). Once removed, a plurality of tabs will be left in the opening. These tabs are called one or more tube stoppers (111). The tube stopper (111) tabs are designed to prevent the ventilation tube (116) from being over inserted into the base plate (102). Over inserting the ventilation tube (116) impedes proper airflow.

The utility vent assembly (101) described herein is a highly versatile design that is capable of accepting multiple ventilation tube (116) diameters with slight modifications on the jobsite. The versatility of the design makes it ideal for use in a wide range of ducting applications.

The vent assembly (101) also includes a unique locking system. The goal was to have the base plate outer perimeter (119) be free of any faceplate attachment design features, allowing a contractor to caulk around the base plate outer perimeter (119) if desired.

On the base plate (102) exists a locking tooth (201) or, simply, tooth (201). On the face plate (117) exists a lock receiver (202) or tooth receiver (202). This is the opposite of a typical competitor, or alternative vent assembly. By putting the lock receiver (202) on the face plate (117) extra area in the base plate (102) is created allowing for the largest sized vent assembly (101) to accept a 6″ ventilation tube (116), or even larger.

With the baseplate locking tooth (201) being less complex than the lock receiver (202) less manufacturing tooling is needed in this area. It can be molded by two methods. A first method is by using lifters in the injection molding equipment. This requires a tool movement area (203). This is an area where secondary actions in the injection molding equipment can move, allowing the tooth to form. A second method is to have a tool pass through area underneath the tooth. This allows for the tool to have a bypass shutoff, allowing the tooth to be made without secondary actions.

In summary, by positioning the lock receiver (202) on the face plate (117) and the locking tooth (201) on the base plate (102) we created a system that allows the contractor to caulk around the base plate outer perimeter (119) and minimizes the overall size of the base plate (102) to accommodate large ventilation tubes (116).

Hooded vents exist, generally, as a covered penetration into a house or building structure. These vents are often, though not always, used as a dryer exhaust vent, or other structures recognizable to those having ordinary skill in the art. A hooded vent consists of a vent backplate (603), a flapper (601), and a vent faceplate (604). The flapper (601) is a device to cover the opening into the house and is often attached to the vent backplate (603).

Exhaust air (606) comes from the dryer and exits from behind the flapper (601). In some instances, dryer vent debris (607) is present in the exhaust air. This will exit via from behind the flapper (601).

In some instances, a hooded vent is used as an air intake, often in furnace intake air applications. The installer is required to remove the flapper and insert a screen, or other wire mesh, in its place. The screen is present to prevent bugs and/or rodents from entering the penetration and passing into the wall or the interior of the structure. Note that in some cases these may also be used for dryer exhaust vent applications.

If the installer places the intake screen into the vent with the flapper (601) in a dryer exhaust vent application, a fire hazard may be created. There is no opening big enough for the dryer vent debris (607) to exit. This gets hot from dryer vent exhaust air (606), potentially creating a fire.

To remedy this problem, one or more flapper intake holes (602) were added to the flapper (601). Note that the flapper intake holes (602) may also be referred to as air intake openings. The flapper intake holes (602) in this design are hexagonal, but the flapper intake holes (602) are not limited to this design and could be, without limitation, circles, squares, slots, or other shapes recognizable to those having ordinary skill in the art. The flapper intake holes (602)—shown schematically in FIGS. 5, 17-18, 41-42, and 51-54—are designed to maximize open surface area and minimize intake air (605) velocity.

The flapper (601) with one or more flapper intake holes (602) allows for intake air (605) to come through the flapper intake holes (602). If the flapper (601) with flapper intake holes (602) is installed in a dryer vent application fire hazards are eliminated. In the instance that dryer vent debris (607) clogs the flapper intake hole (602) the flapper can simply open as designed, allowing exhaust air (606) to flow underneath and outward.

In the event the vent is being used as an exhaust vent, it may not be ideal to have flapper intake holes (602). This is because hot or cold ambient air can travel inside the vent, when it is not being used, potentially causing thermal losses in the house. A vent assembly (615) comes with a flapper cover (608) to assist with this issue. The flapper cover (608) has a flapper cover attachment feature (609) allowing it to attach to the flapper (601) creating a flapper assembly (614). The flapper assembly (614) functions as a typical flapper (601) without flapper intake holes (602). The installer can simply remove the flapper cover (608) to utilize the flapper intake holes (602) in an air intake application. If the flapper cover (608) is lost, the vent will still be functional. Note that the flapper cover (608) may block the flapper intake holes (602).

Components may include, without limitation, a flapper hinge (610), a tube opening (612), and a flapper recess (613). The flapper recess (613) substantially ensures the vent flapper rotates around the flapper hinge (610). The tube opening (612) may be smaller than the vent flapper area, such that are is allowed to flow in, or out, through the tube opening (612), and the vent flapper area may be 50% to 95% larger than the tube opening (612).

Claims

1. A vent assembly, comprising: a vent flapper; andone or more air intake openings formed within the vent flapper, wherein the air intake openings allow air to flow both in and out.

2. The vent assembly of claim 1, further comprising: a removable cover attachable to the vent flapper.

3. The vent assembly of claim 2, further comprising: a tube opening; anda vent flapper area, wherein the vent flapper area is at least 65 percent larger than the tube opening.

4. The vent assembly of claim 3, wherein the air intake openings are hexagonal.

5. The vent assembly of claim 4, wherein the vent flapper area is non-circular.

6. The vent assembly of claim 5, wherein the vent flapper area is substantially square.

7. The vent assembly of claim 6, further comprising: a flapper recess, formed on the vent flapper; anda flapper hinge, wherein the flapper recess substantially ensures the vent flapper rotates around the flapper hinge.

8. The vent assembly of claim 7, further comprising: a cover configured to block the air intake openings formed within the vent flapper.

9. The vent assembly of claim 3, wherein the vent flapper area is at least 80 percent larger than the tube opening.

10. The vent assembly of claim 9, further comprising: a removable cover configured to block the air intake openings formed within the vent flapper.

11. A vent assembly, comprising: a vent flapper;one or more air intake openings formed within the vent flapper, wherein the air intake openings allow air to flow both in and out; anda removable cover configured to block the air intake openings formed within the vent flapper.

12. The vent assembly of claim 11, further comprising: a backplate having plurality of concentric cylinders arranged in decreasing diameter, wherein the concentric cylinders are separated by score lines and at least one of the concentric cylinders is recessed from the backplate;a ventilation tube configured to attach to one of the concentric cylinders; andone or more tube stoppers to prevent the ventilation tube from being over inserted.

13. The vent assembly of claim 12, further comprising: a face plate;a tooth formed on one of the backplate and the face plate; anda tooth receiver formed on the other of the backplate and the face plate.

14. The vent assembly of claim 13, wherein: the tooth is formed on the backplate, andthe tooth receiver is formed on the face plate.

15. The vent assembly of claim 14, wherein the score lines are dual-sided score lines.

16. A vent assembly, comprising: a vent flapper;one or more air intake openings formed within the vent flapper, wherein the air intake openings allow air to flow both in and out;a backplate having a plurality of concentric cylinders arranged in an order of decreasing diameter; anda tube configured to attach to one of the concentric cylinders, the concentric cylinders are separated by dual-sided score lines and at least one of the concentric cylinders is recessed from the backplate;a face plate;a tooth formed on the backplate; anda tooth receiver formed on the face plate.

17. The vent assembly of claim 16, further comprising: a removable cover configured to block the air intake openings formed within the vent flapper.