Patent Application
20150226443
Ventilating exhaust fans, such as those typically installed in bathrooms, draw air from within an area and pass the exhausted air out to another location, such as through a vent in the gable or roof of a home or other building structure. Centrifugal exhaust fans typically include a rotating fan wheel having a plurality of vanes that create an outward airflow which, in turn, is directed out of an outlet opening. The fan wheel is typically coupled to a motor supported within the fan housing, and the motor drives the fan wheel, thus providing ventilation to an area. In some cases, a curved fan scroll is employed to channel air around the fan, and can be defined by a housing wall of the fan or by a separate element or structure within the fan housing.
Many typical ventilating exhaust fan assemblies currently in use include a housing positioned within a building structure, such as in an aperture in a wall or ceiling. The housing is generally secured in the aperture in a number of conventional manners, such as by being attached to wall or ceiling joists, or by being attached to other structures in the wall or ceiling. In some cases, it may be desirable to replace an exhaust fan within a building or structure. For example, an old exhaust fan may need to be replaced when broken or malfunctioning, or it may be desirable to replace an old exhaust fan with one that is more powerful, or has one or more features or characteristics different than the existing exhaust fan. However, conventional exhaust fans can be relatively difficult and time consuming to remove and replace due, in part, to conventional coupling assemblies. Typically, these assemblies require additional parts that require alignment and attachment to the housing, and offer limited ability to be configured for clearance or maneuverability within a pre-existing aperture and/or mounting to a structure in a wall or ceiling.
Some embodiments of the invention include a ventilation apparatus comprising a housing assembly including a main housing comprising a plurality of sides including at least a first side coupled to a second side and at least partially enclosing an inner region. In some embodiments, the housing assembly can include at least one fluid inlet for receiving fluid from a surrounding environment, and at least one fluid outlet positioned through the first side of the main housing. In some embodiments, the ventilation apparatus can include an exhaust fan assembly coupled to the housing assembly within the inner region. The exhaust fan assembly can comprise a scroll positioned within and coupled to the main housing, and a blower wheel positioned within the scroll and mechanically coupled to the motor and capable of generating a fluid flow within the scroll. In some embodiments, the ventilation assembly can include a configurable mounting panel coupled to at least one of the plurality of sides. The configurable mounting panel can comprise a main panel and at least one tab and at least one configurable flange coupled to the main panel and extending outwardly from the main panel. In some embodiments, the configurable mounting panel can include at least one bending region coupled between the main panel and the at least one configurable flange. Some embodiments of the invention include at least one bending region comprising at least one aperture.
In some embodiments, the ventilation apparatus further comprises a muffler including an aperture. The muffler can be positioned within and coupled to the housing assembly. In some embodiments, the muffler includes a top panel top side and a bottom side and an outer periphery region around the muffler aperture. In some embodiments, the outer periphery region comprises a substantially convex surface on the top side, and a substantially concave surface on the bottom side. Some embodiments include a muffler that includes a plurality of structural ridges coupled to the substantially concave surface in the bottom side. In some other embodiments, the muffler further includes a plurality of fastening mounts configured and arranged to be capable of coupling the muffler to the exhaust assembly and the main housing assembly.
In some embodiments, the configurable mounting panel is coupled to the second side, and in some further embodiments, the second side comprises the configurable mounting panel. Some embodiments of the invention include a ventilation assembly that includes a configurable mounting panel including at least one mounting aperture. In some further embodiments, the configurable mounting panel includes a first configurable flange and a second configurable flange. In some embodiments, the first configurable flange and the second configurable flange each comprise at least one mounting aperture. In some other embodiments, the first configurable flange and the second configurable flange each further comprise an aperture.
Some embodiments of the invention include a ventilation apparatus comprising at least one electrical box enclosure. In some embodiments, the at least one electrical box enclosure includes at least two anchoring flanges. The electrical box enclosure is secured to the housing assembly and a first anchoring flange couples with a third side of the main housing, and a second anchoring flange couples with a fourth side of the main housing.
In some embodiments, the at least one electrical box enclosure includes an electrical box cover plate. Further, some embodiments include an electrical box cover plate that is secured to the electrical box enclosure using at least one screw.
In some embodiments, the electrical box cover plate further comprises a lifting tab. In some embodiments, the electrical box cover plate can be at least partially opened by pivoting the plate about an edge by applying a lifting force to the lifting tab following loosening and removal of the screw.
Some embodiments of the invention include a ventilation apparatus comprising a housing assembly including at least one fluid inlet for receiving fluid from a surrounding environment and a main housing comprising at least a first side coupled to a second side comprising a configurable mounting panel. A fluid outlet is positioned through the first side of the main housing, and an exhaust fan assembly comprising a scroll is positioned within and coupled to the main housing, a blower wheel is positioned within the scroll and mechanically coupled to the motor and capable of generating a fluid flow within the scroll and fluid discharge through the fluid outlet. The configurable mounting panel can comprise a main panel, at least one tab, and at least one configurable flange coupled to and extending outwardly from the main panel. The configurable mounting panel can comprise at least one bending region comprising at least one aperture coupled between the main panel and the at least one configurable flange, and a muffler including an aperture, the muffler positioned within and coupled to the housing assembly. An electrical box enclosure can be coupled within the main housing, and a duct connector assembly can be coupled to the first side.
Before any embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways. Also, it is to be understood that the phraseology and terminology used herein is for the purpose of description and should not be regarded as limiting. The use of “including,” “comprising,” or “having” and variations thereof herein is meant to encompass the items listed thereafter and equivalents thereof as well as additional items. Unless specified or limited otherwise, the terms “mounted,” “connected,” “supported,” and “coupled” and variations thereof are used broadly and encompass both direct and indirect mountings, connections, supports, and couplings. Further, “connected” and “coupled” are not restricted to physical or mechanical connections or couplings.
The following discussion is presented to enable a person skilled in the art to make and use embodiments of the invention. Various modifications to the illustrated embodiments will be readily apparent to those skilled in the art, and the generic principles herein can be applied to other embodiments and applications without departing from embodiments of the invention. Thus, embodiments of the invention are not intended to be limited to embodiments shown, but are to be accorded the widest scope consistent with the principles and features disclosed herein. The following detailed description is to be read with reference to the figures, in which like elements in different figures have like reference numerals. The figures, which are not necessarily to scale, depict selected embodiments and are not intended to limit the scope of embodiments of the invention. Skilled artisans will recognize the examples provided herein have many useful alternatives that fall within the scope of embodiments of the invention.
In some embodiments, the ventilation assembly 10 generally can include an exhaust assembly 20, substantially housed within the housing assembly 25, and positioned within the housing assembly 25 and coupled to the main housing assembly with a conventional retention feature such as one or more conventional screws, bolts, rivets, or quick-connect tabs. As shown in
Some embodiments of the ventilation assembly 10 can include a coupled a duct connector assembly 160. In some embodiments, the duct connector assembly 160 can include a moveable damper flap 170 coupled within a ventilation orifice 180. In some embodiments, the duct connector assembly 160 coupled with the ventilation orifice 180 and including the moveable damper flap 170 can control the backflow of a fluid into housing assembly 25. For example, in some embodiments, a closed moveable damper flap 170 at least partially covering the ventilation orifice 180 can substantially impede the flow of fluid into the exhaust assembly 20 and the housing assembly 25. Further, in some embodiments, the moveable damper flap 170 can be capable of substantially controlling the flow of fluid from a space, such as a room, into the ventilation duct of a building, or structure, to an outside location.
As illustrated in
In some other embodiments, the housing assembly 25 can be formed from a polymer-based material, including, but not limited to injection molded polymers, thermo-formed polymers, thermosetting polymers, or any other suitable material. Some embodiments can include a housing assembly 25 that comprises a wood-based product, such as wood, or particle-board or wood laminate. In some other embodiments, the housing assembly 25 can comprise a ceramic or ceramic-composite based product. In some further embodiments, the housing assembly 25 can comprise a glass-fiber or other fiber-reinforced laminate material.
The housing assembly 25 can be formed into any shape, including, but not limited to, a rectangular box-like shape, an oval shape, a hemispherical shape, a spherical shape, a pyramidal shape, or any other shape. The housing assembly 25 can form a base or a similar support structure of the assembly 10. Further, in some embodiments, the housing assembly 25 can provide points and areas of attachment for other components of the system 10, as described in further detail below.
Some embodiments of the invention include at least one mounting apparatus. For example, as shown in
In some further embodiments, the main housing 27 can be formed from several structural members at least one of which includes the mounting panel 100. For example, in some embodiments, the second side 74 comprising the mounting panel 100 can be coupled with at least one other structural member to form the main housing 27. For example, in some embodiments, a structural member comprising the first, third and fourth sides 72, 76, 78 can be formed and coupled to the second side 74 comprising the mounting panel 100. In some other embodiments, a structural member of the main housing 27 can be formed comprising the second side 74 comprising the mounting panel 100 and at least one other side (e.g., either with the first side 72 or the third side 76 or both) and then coupled to at least one other structural member to form the main housing 27.
Some embodiments of the invention include a mounting panel 100 that comprises at least one mounting flange or tab. For example, in some embodiments, the ventilation assembly 10 can include a main housing 27 that comprises at least one configurable mounting panel 100 that includes first tab 130 and a second tab 135. In some embodiments, either of the first tab 130 and the second tab 135 can be moved relative the housing 27. For example, as shown in
In some embodiments, the ventilation assembly 10 can be used to ventilate any room, area or space. Some embodiments include a ventilation assembly 10 that can be secured within or to a wall, ceiling, or other building structure in a partially, or fully recessed position. In some embodiments, the ventilation assembly 10 can be installed within an intermediate space, outside of the room, area or space, and coupled with one or more ventilation duct assemblies to provide ventilation to the room, area or space. In some other embodiments, the fluid may comprise air, or other gases, or vapor, such as water vapor. In some embodiments, the fluid may comprise a smoke, ash, or other particulate in addition to air or other gases.
In some embodiments, the ventilation assembly 10 can be installed as a new, original equipment installation in a room or building where none had previously existed, whereas some embodiments of the invention provide a ventilation assembly 10 that can replace a pre-existing ventilation system. In some embodiments, the exhaust assembly 20, can be installed as a new, or a replacement ventilation system, and in some embodiments, the exhaust assembly 20 can replace an existing exhaust assembly 20.
In some embodiments, the ventilation assembly 10 that can be secured within or to a wall, ceiling, or other building structure using at least one configuration flange portion of the configurable mounting panel 100. For example, as shown in
In some embodiments, at least one or both of the first configurable flange 140 and the second configurable flange 150 can comprise at least one aperture suitable for use as an attachment region and/or a guiding aid. For example, in some embodiments, the first configurable flange 140 can include mounting apertures 142 and aperture 144, and the second configurable flange 150 can include mounting apertures 152, and an aperture 154. In some other embodiments, the configurable flanges 140, 150 may comprise more or fewer apertures than those shown, and may include one or more apertures that comprise a different shape and/or diameter. For example,
In some instances during installation, the ventilation assembly 10 may need to be secured to one or more surfaces that are not parallel with the second side 74. In this instance, either the first configurable flange 140 or the second configurable flange 150 can be moved forward or backward by bending and reconfiguring to a new position that allows coupling with one or more surfaces of a building or other structure. As a result of this, either the first configurable flange 140 or the second configurable flange 150 can be moved to a position that is no longer parallel with the second side 74. In some embodiment, the first configurable flange 140 and the second configurable flange 150 can be moved by bending to a new position that results in both the first configurable flange 140 and the second configurable flange 150 being angled from the configurable mounting panel 100 by substantially the same amount or number of degrees. In some other embodiments, the first configurable flange 140 and the second configurable flange 150 can be moved by rotating about the configurable mounting panel 100 by different amounts, thereby resulting in the first configurable flange 140 and the second configurable flange 150 being positioned at different angles from the configurable mounting panel 100.
In some instances, different angles may be necessary to adequately secure the ventilation assembly 10 to a surface that is substantially uneven over a distance spanning the configurable mounting panel 100 from at least the first configurable flange 140 and the second configurable flange 150. Further, in order to accommodate a wide variety of geometries of cavities, walls, ceilings, joists, etc., including instances in which an attachment geometry on one side of the ventilation assembly 10 is different from the opposite side, in some embodiments, from a starting position of the first configurable flange 140 and the second configurable flange 150 being parallel with the second surface 74, either or both of the first configurable flange 140 and the second configurable flange 150 can be rotated inward (towards the main housing 27) to any angle by up to about 90°. In some further embodiments, from a starting position of the first configurable flange 140 and the second configurable flange 150 being parallel with the second surface 74, either or both of the first configurable flange 140, and the second configurable flange 150, can be rotated inward (towards the main housing 27) to any angle up to about 270°.
In some embodiments, at least the first configurable flange 140 or the second configurable flange 150 can include features to facilitate rotation on the configurable mounting panel 100. In some embodiments, the mounting panel 100 can include bending regions of reduced thickness within a region of the main panel 105 coupled to the first configurable flange 140 and the second configurable flange 150. For example, in some embodiments, material forming the mounting panel 100 can comprise a reduced thickness and/or reduce tensile strength in a bending region 140a adjacent to the first configurable flange 140, or within a bending region 150a adjacent to the second configurable flange 150. In some embodiments, when either of the regions 140a 150a comprises a reduce thickness and/or reduced tensile strength, the adjacent first configurable flange 140 and the second configurable flange 150 can be moved (i.e., rotated) about the mounting panel 100 with a lower force, thereby facilitating ease of movement of the flanges 140, 150 by a user. In some further embodiments, the regions 140a and/or 150a can include one or more apertures. For example, in some embodiments the bending region 140a can include a plurality of bending slots 156 and the bending region 150a can include a plurality of bending slots 158 (shown in
Some embodiments can also include other flange structures. For example, in some embodiments, the housing assembly 25 can comprise a main housing 27 that includes a mounting flange 120. In some embodiments, the mounting flange 120 can facilitate coupling the ventilation assembly 10 to a surface (e.g., a ceiling, wall or joist).
The assembly 10 can generally include electrical connections and various wiring components to support powering of one or more components of the assembly 10 including the motor 30. For example, in some embodiments, the housing assembly 25 can include at least one electrical box enclosure 200. The electrical box enclosure 200 can serve to house various wiring and electrical components, and can serve to route power into the ventilation assembly 10, and to provide a power supply point for coupling various components of the assembly 10, including the motor 30.
In some embodiments, an electrical box enclosure 200 can provide a source of electrical power to the motor 30 and any conventional capacitor. For example, some embodiments of the invention can include an electrical box enclosure 200 coupled with the main housing 27. In some embodiments, when the housing assembly 25 is manufactured or installed, an electrical box enclosure 200 can positioned and coupled to an inner region 29 of a main housing 27. In some embodiments, the electrical box enclosure 200 can positioned and coupled to an inner region 29 of a main housing 27 by coupling to at least the third side 76, the fourth side 78, or both. For example,
In some embodiments, the electrical box enclosure 200 can comprise an electrical box cover plate 210. In some embodiments, the electrical box enclosure 200 can include a cover plate 210 that can be moved, and/or pivoted, and/or rotated to provide access to the inside of the electrical box enclosure 200. In some embodiments, the electrical box enclosure 200 can comprise a swing-action type electrical box cover plate 210 including a fastening screw 210b and a lifting tab 240. In some embodiments, the electrical box cover plate 210 can be pivoted about an edge 210a following loosening and removal of the screw 210b, and raising of the cover plate 210 by applying a lifting force to the lifting tab 240.
In some embodiments, the electrical box enclosure 200 includes a power receptacle 230a, 230b. In some embodiments, power can be fed into the electrical box enclosure 200 through at least one wiring aperture 250 (shown in
As described earlier, in some embodiments, fluid can enter the assembly 10 and flow through the scroll 40 after entering the ventilation inlet 60 through a muffler 85 (shown for example in in
In some embodiments, the dimensions of the housing assembly 25 enable the fully assembled ventilation assembly 10 to be maneuvered and installed within a standard 2′×4′ wall structure. In some embodiments, the ventilation assembly 10 can be installed as a new, original equipment installation in a room or building where none had previously existed, whereas some embodiments of the invention provide a ventilation assembly 10 that can replace a pre-existing ventilation system. In some embodiments, the ventilation assembly 10 can be installed as a new ventilation assembly 10 or as a replacement of an older and/or previously existing ventilation apparatus. For example, in some embodiments, an installer can maneuver the ventilation assembly 10 directly into a cavity or aperture of a structure where no ventilation apparatus had previously existed, or to replace an existing ventilation apparatus that has been previously removed from the cavity or aperture of a structure.
