Patent Application
20190360501
The present subject matter relates to a ventilation fan that is mounted to a support surface, such as a ceiling in a bathroom or washroom. Specifically, the ventilation fan includes a removably coupled flange mounting system that is intended to improve the installation process and/or the sealing performance of the ventilation fan when installed in a support member, for example, the ceiling.
Ventilation fans are typically used to ventilate rooms, such as bathrooms and shower areas, in residential, commercial, and industrial structures. Existing bathroom ventilation fan assemblies are usually installed in a cutout or cavity formed in a support member, such as a ceiling or wall, during the installation process. The ventilation fan assembly, which can include various components, namely a grille assembly and a fan housing that includes a motor, a fan wheel or blower that draws air through the grille assembly and into the fan housing, and pre-installed electrical leads for connection to a power source.
During a typical installation process, the installer cuts an opening in the ceiling where the ceiling has dimensions that exceed the dimensions of the housing. As a result, the current installation process tends to leave small gaps between the fan housing and the edge of the ceiling that defines the opening (that receives the housing). It is not uncommon for a gap to be found on all sides of the housing. These gaps are problematic for a number of reasons, including that “conditioned air” from the room in which the fan assembly is installed can migrate upward and through the gap which negatively impacts energy efficiency ratings. These small gaps allow unwanted air and moisture to enter the ceiling or wall space, which can cause damage to the components of the bathroom fan ventilation system or other structures (e.g., joists) within a ceiling or wall space. Additionally, unwanted air and moisture can cause mold to develop, which can go undetected for large amounts of time.
Some existing designs for ventilation fan assemblies have attempted to address this issue by forming a hem around the lower edge of the fan housing. However, these hems do not provide a way to minimize larger gaps between the fan housing and the ceiling (or wall) at the installation location. Even when a hem is formed on the lower edge of the housing, which is typically sheet metal, the housing edge can be inadvertently deformed or displaced during installation, which leads to larger gaps, even if just localized. Thus, there is a tangible need to minimize gaps between a fan housing and a ceiling or wall material, while not compromising the installation process.
The present disclosure provides a ventilation fan assembly with a removable flange mounting system to facilitate installation of the ventilation fan in a support member. The flange mounting system may be installed on a housing of the ventilation fan assembly without the use of tools, and the mounting system is removable, again without the use of tools. The flange mounting system is intended to improve the sealing performance of the ventilation fan when installed in the ceiling or wall.
The subject flange mounting system may contain a bracket, which comprises a top flange, a U-shaped receiver that receives an extent of the lower edge of fan housing including its hem, a depending flange, a plurality of apertures that correspond to apertures on the hem of the fan housing, and a plurality of projections that extend from an interior portion of the receiver. These projections are configured to engage with the cooperatively positioned apertures of the fan housing.
The flange mounting system may attach to the lower edge or the hem of a fan housing by sliding the receiver portion into engagement with the lower edge/hem. Next, a downwardly directed connection force is applied to the bracket by the hand of the installer such that the projections are actuated or snapped into place with the aligned apertures formed in the housing hem. This engagement may secure the flange to the housing such that when the ventilation fan assembly is inserted into the cavity formed into the ceiling or wall, the flange fills and/or obstructs the gap between the housing and the ceiling opening edge, whereby this interaction prevents unwanted air and humidity from passing through the gap and entering the interior ceiling or wall space. In the event it becomes necessary, an upwardly directed disconnection force can be applied by the hand of the installer to the bracket such that the projections are disengaged from the apertures of the housing hem, which then allows for disconnection of the bracket. Accordingly, the installer can selectively apply a connection force or a disconnection force, by hand, to either couple the bracket to the housing or decouple the bracket from the housing.
Other aspects and advantages of the present disclosure will become apparent upon consideration of the following detailed description and the attached drawings wherein like numerals designate like structures throughout the specification.
The accompanying drawings, which are included to provide further understanding and are incorporated in and constitute a part of this specification, illustrate disclosed embodiments and together with the description serve to explain the principles of the disclosed embodiments. In the drawings:
In one or more implementations, not all of the depicted components in each figure may be required, and one or more implementations may include additional components not shown in a figure. Variations in the arrangement and type of the components may be made without departing from the scope of the subject disclosure. Additional components, different components, or fewer components may be utilized within the scope of the subject disclosure.
The detailed description set forth below is intended as a description of various implementations and is not intended to represent the only implementations in which the subject technology may be practiced. As those skilled in the art would realize, the described implementations may be modified in various different ways, all without departing from the scope of the present disclosure. Still further, modules and processes depicted may be combined, in whole or in part, and/or divided, into one or more different parts, as applicable to fit particular implementations without departing from the scope of the present disclosure. Accordingly, the drawings and description are to be regarded as illustrative in nature and not restrictive.
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The flange 34 illustratively extends from the first leg 52 away from the second leg 54. The first leg 52 is coupled to the second leg 54 by the connecting segment 56, which provides the receiver 36 with a U-shaped configuration in cross-section open on the top in the orientation of
The first leg 52 is illustratively positioned: (i) substantially perpendicular to the flange 34 and (ii) substantially parallel with the second leg 54. The first leg 52 is spaced apart from the second leg 54 to define a receiver space 59 for receiving connection with the housing 20. While the first and second legs 52,54 are shown substantially parallel to each other, in some embodiments, the first and second legs 52,54 may be oriented at angle with respect to each other, provided that angle does not hamper engagement of the receiver 36 with the lower housing edge 28.
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The depending member 46 extends from the end 60 of the second leg 54 and it is positioned such that the inner surface 62 of the depending member 46 is in contact with the outer surface 64 of the second leg 54. In this position, the depending member 46 is substantially parallel with the second leg 54. In some embodiments, the depending member 46 may be angled with respect to the second leg 54. For example, the inner angle between the depending member 46 and the second leg 54 may be approximately 45°, preferably 25°, and most preferably 15°. When installed, the depending member 46 is preferably configured to press against an outer wall 66 of the fan housing 20 to act as a biasing member to ensure proper engagement between the lower housing edge 28 and the bracket 16. This can help create an effective air seal between the fan housing 20, the removable flange mounting system 14, and the ceiling or wall.
To facilitate the coupling of the bracket 16 to the fan housing 20, the bracket 16 includes at least one projection 38 positioned within the receiver 36 of the bracket 16. These projections 38 may extend from the second leg 54 towards the first leg 52 and may be formed by bending (pressing for relief) a section of the second leg 54. In the embodiments of
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To disconnect the bracket 16, the installer applies a upwardly directed force on the bracket 16 (relative to the housing 20 in the orientation of
To begin installation of the flange mounting system 14, the user can orientated the bracket 16 such that the flanges 34 extend outwardly from the fan housing 20 (see
When the fan housing 20 is inserted into the cutout opening formed in the ceiling, the bracket 16 can fill and/or obstruct the gap G between the housing 20 and the ceiling opening edge E. This gap filling can prevent unwanted air and humidity from passing through the gap G and entering the interior ceiling or wall space. In this assembled state, the flange mounting system 14 can provide an improved seal between the ceiling (or wall) and the fan housing 20.
In the illustrative embodiment, the projections 38 are formed on the receiver 36, and more specifically, on the second leg 54, however, in some embodiments, the projections 38 may be formed on the first leg 52, and/or on the flap 30 and corresponding apertures may be formed on the first and/or second legs 52, 54 of the receiver 36.
In some embodiments, the flange mounting system 14 may be installed after the fan housing 20 is inserted into the cutout formed in the ceiling without fully removing the housing 20 from the cutout. The bracket 16 may configured with the receiver 36 formed with substantially parallel first and second legs 52, 54 that provide the receiver 36 with a substantially rectangular cross-section. At least one projection 38 may extend from the second leg 54 and is configured to engage with the apertures 32 of the corresponding flap 30. The connecting segment 56 may be coplanar with the flange 34, such that they have a continuous, planar appearance. As such, the top flange 34 extends substantially perpendicular to the receiver 36.
It is to be understood that all described elements are preferably formed from sheet metal and are bent into the shapes shown and described herein. Other materials, such as plastic may injection molded and used instead of sheet metal. In further embodiments, other materials may be used including, but not limited to, polymers, rubbers, foams, ceramics, other metals, metal alloys, or any other material known to those skilled in the art.
While some implementations have been illustrated and described, numerous modifications come to mind without significantly departing from the spirit of the disclosure, and the scope of protection is only limited by the scope of the accompanying claims.
Headings and subheadings, if any, are used for convenience only and do not limit the invention. The word exemplary is used to mean serving as an example or illustration. To the extent that the term include, have, or the like is used, such term is intended to be inclusive in a manner similar to the term comprise as comprise is interpreted when employed as a transitional word in a claim. Relational terms such as first and second and the like may be used to distinguish one entity or action from another without necessarily requiring or implying any actual such relationship or order between such entities or actions.
Phrases such as an aspect, the aspect, another aspect, some aspects, one or more aspects, an implementation, the implementation, another implementation, some implementations, one or more implementations, an embodiment, the embodiment, another embodiment, some embodiments, one or more embodiments, a configuration, the configuration, another configuration, some configurations, one or more configurations, the subject technology, the disclosure, the present disclosure, other variations thereof and alike are for convenience and do not imply that a disclosure relating to such phrase(s) is essential to the subject technology or that such disclosure applies to all configurations of the subject technology. A disclosure relating to such phrase(s) may apply to all configurations, or one or more configurations. A disclosure relating to such phrase(s) may provide one or more examples. A phrase such as an aspect or some aspects may refer to one or more aspects and vice versa, and this applies similarly to other foregoing phrases.
The disclosed systems and methods are well adapted to attain the ends and advantages mentioned as well as those that are inherent therein. The particular implementations disclosed above are illustrative only, as the teachings of the present disclosure may be modified and practiced in different but equivalent manners apparent to those skilled in the art having the benefit of the teachings herein. Furthermore, no limitations are intended to the details of construction or design herein shown, other than as described in the claims below. It is therefore evident that the particular illustrative implementations disclosed above may be altered, combined, or modified and all such variations are considered within the scope of the present disclosure. The systems and methods illustratively disclosed herein may suitably be practiced in the absence of any element that is not specifically disclosed herein and/or any optional element disclosed herein. While compositions and methods are described in terms of “comprising,” “containing,” or “including” various components or steps, the compositions and methods can also “consist essentially of” or “consist of” the various components and steps. All numbers and ranges disclosed above may vary by some amount. Whenever a numerical range with a lower limit and an upper limit is disclosed, any number and any included range falling within the range are specifically disclosed. In particular, every range of values (of the form, “from about a to about b,” or, equivalently, “from approximately a to b,” or, equivalently, “from approximately a-b”) disclosed herein is to be understood to set forth every number and range encompassed within the broader range of values. Also, the terms in the claims have their plain, ordinary meaning unless otherwise explicitly and clearly defined by the patentee. Moreover, the indefinite articles “a” or “an,” as used in the claims, are defined herein to mean one or more than one of the element that it introduces. If there is any conflict in the usages of a word or term in this specification and one or more patent or other documents that may be incorporated herein by reference, the definitions that are consistent with this specification should be adopted.
A phrase “at least one of” preceding a series of items, with the terms “and” or “or” to separate any of the items, modifies the list as a whole, rather than each member of the list. The phrase “at least one of” does not require selection of at least one item; rather, the phrase allows a meaning that includes at least one of any one of the items, and/or at least one of any combination of the items, and/or at least one of each of the items. By way of example, each of the phrases “at least one of A, B, and C” or “at least one of A, B, or C” refers to only A, only B, or only C; any combination of A, B, and C; and/or at least one of each of A, B, and C.
It is understood that the specific order or hierarchy of steps, operations, or processes disclosed is an illustration of exemplary approaches. Unless explicitly stated otherwise, it is understood that the specific order or hierarchy of steps, operations, or processes may be performed in different order. Some of the steps, operations, or processes may be performed simultaneously. The accompanying method claims, if any, present elements of the various steps, operations or processes in a sample order, and are not meant to be limited to the specific order or hierarchy presented. These may be performed in serial, linearly, in parallel or in different order. It should be understood that the described instructions, operations, and systems can generally be integrated together in a single software/hardware product or packaged into multiple software/hardware products.
In one aspect, a term coupled or the like may refer to being directly coupled. In another aspect, a term coupled or the like may refer to being indirectly coupled. Terms such as top, bottom, front, rear, side, horizontal, vertical, and the like refer to an arbitrary frame of reference, rather than to the ordinary gravitational frame of reference. Thus, such a term may extend upwardly, downwardly, diagonally, or horizontally in a gravitational frame of reference.
The disclosure is provided to enable any person skilled in the art to practice the various aspects described herein. In some instances, well-known structures and components are shown in block diagram form in order to avoid obscuring the concepts of the subject technology. The disclosure provides various examples of the subject technology, and the subject technology is not limited to these examples. Various modifications to these aspects will be readily apparent to those skilled in the art, and the principles described herein may be applied to other aspects.
All structural and functional equivalents to the elements of the various aspects described throughout the disclosure that are known or later come to be known to those of ordinary skill in the art are expressly incorporated herein by reference and are intended to be encompassed by the claims. Moreover, nothing disclosed herein is intended to be dedicated to the public regardless of whether such disclosure is explicitly recited in the claims. No claim element is to be construed under the provisions of 35 U.S.C. § 112, sixth paragraph, unless the element is expressly recited using the phrase “means for” or, in the case of a method claim, the element is recited using the phrase “step for”.
The title, background, brief description of the drawings, abstract, and drawings are hereby incorporated into the disclosure and are provided as illustrative examples of the disclosure, not as restrictive descriptions. It is submitted with the understanding that they will not be used to limit the scope or meaning of the claims. In addition, in the detailed description, it can be seen that the description provides illustrative examples and the various features are grouped together in various implementations for the purpose of streamlining the disclosure. The method of disclosure is not to be interpreted as reflecting an intention that the claimed subject matter requires more features than are expressly recited in each claim. Rather, as the claims reflect, inventive subject matter lies in less than all features of a single disclosed configuration or operation. The claims are hereby incorporated into the detailed description, with each claim standing on its own as a separately claimed subject matter.
The claims are not intended to be limited to the aspects described herein, but are to be accorded the full scope consistent with the language claims and to encompass all legal equivalents. Notwithstanding, none of the claims are intended to embrace subject matter that fails to satisfy the requirements of the applicable patent law, nor should they be interpreted in such a way.
All references, including publications, patent applications, and patents, cited herein are hereby incorporated by reference to the same extent as if each reference were individually and specifically indicated to be incorporated by reference and were set forth in its entirety herein.
The use of the terms “a” and “an” and “the” and “said” and similar references in the context of describing the invention (especially in the context of the following claims) are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. An element proceeded by “a,” “an,” “the,” or “said” does not, without further constraints, preclude the existence of additional same elements. Recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range, unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., “such as”) provided herein, is intended merely to better illuminate the disclosure and does not pose a limitation on the scope of the disclosure unless otherwise claimed. No language in the specification should be construed as indicating any non-claimed element as essential to the practice of the disclosure. Numerous modifications to the present disclosure will be apparent to those skilled in the art in view of the foregoing description. Preferred embodiments of this disclosure are described herein, including the best mode known to the inventors for carrying out the disclosure. It should be understood that the illustrated embodiments are exemplary only, and should not be taken as limiting the scope of the disclosure.
While certain aspects and implementations of the disclosure have been described, these have been presented by way of example only, and are not intended to limit the scope of the disclosure. Indeed, the novel methods and systems described herein may be embodied in a variety of other forms without departing from the spirit thereof. The accompanying claims and their equivalents are intended to cover such forms or modifications as would fall within the scope and spirit of the disclosure.
This patent application claims the benefit of priority under 35 U.S.C. § 119(e) of U.S. Provisional Application No. 62/675,566, filed on May 23, 2018, entitled “Bathroom Ventilation Fan with a Flange Mounting System,” the contents of which are hereby incorporated by reference in their entirety, including but without limitation, those aspects of devices, systems, and methods for ventilation and mounting of ventilation components.
| Number | Date | Country | |
|---|---|---|---|
| 62675566 | May 2018 | US |
