Patent Grant
10323853
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. The exhaust fan is usually positioned adjacent an aperture in a wall or ceiling, and secured in a number of conventional manners, such as by being attached to wall or ceiling joists, or by being attached to another other structure in the wall or ceiling. 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 within the fan housing. During operation, most modern ventilating exhaust fans do not run silently. The noise emission and audible noise can depend on a variety of factors, including but not limited to the size and type of motor, the fan wheel and/or scroll design and the size, and shape of the ventilation inlet and outlet.
Some embodiments of the invention provide a ventilation assembly including a discharge grid. In some embodiments, the discharge grid comprises an outlet restriction, including a restriction wall with an inner surface and a first edge and a second edge. In some embodiments, the discharge grid comprises a plurality of vertical fins and horizontal fins. In some embodiments, the discharge grid includes a main wall coupled to the first edge and the inner surface. The main wall includes a first end and a second end and first and second surfaces.
In some embodiments, the plurality of vertical fins includes a first vertical fin including a top edge and a bottom edge. In some embodiments, the bottom edge of the first vertical fin is coupled to the restriction wall at the second edge and the inner surface. In some embodiments, a plurality of horizontal fins are coupled to the second surface of the main wall and the inner surface of the restriction wall and the first vertical fin. In some embodiments, at least one of the plurality of horizontal fins extends from the outlet restriction to couple with at least one other vertical fin and form at least one aperture. Some embodiments also include a base wall coupled to the second end of the main wall and the bottom edge of the first vertical fin.
Some embodiments provide a ventilation assembly including a scroll assembly. In some embodiments, the scroll assembly comprises a scroll housing including an inner scroll surface. In some further embodiments, the scroll assembly includes a scroll crescent including a first crescent end and a second crescent end. In some embodiments, the scroll crescent can include a substantially incurvated surface, and a substantially convex surface coupled to the inner scroll surface of the scroll housing. In some embodiments, the substantially convex surface is coupled to the first crescent end and the second crescent end and the substantially incurvated surface. Some embodiments include a ventilation assembly with a scroll crescent that is integrally formed with the inner scroll surface of the scroll housing. In other embodiments, the scroll crescent comprises a discrete component coupled to the inner scroll surface of the scroll housing. Some further embodiments of the ventilation assembly include a blower assembly including a motor coupled to a blower wheel.
In some embodiments of the ventilation assembly, at least a portion of at least one of the plurality of vertical fins includes a flared surface. In some other embodiments, at least a portion of at least one of the plurality of horizontal fins includes a flared surface. Some embodiments include one or more flared surface surfaces that include a flare bottom surface comprising a flare bottom length, and a flare top surface comprising a flare top length. In some embodiments, the flare top surface and flare bottom surface is at least partially curved. In some embodiments, the flare top length and flare bottom length is substantially equal, whereas in other embodiments, the flare top length and flare bottom length are unequal.
Some embodiments include a discharge grid comprising at least one coupling pin. In some embodiments, the discharge grid is configured and arranged to be coupled to the scroll by coupling the at least one coupling pin with at least one scroll pin coupling hole.
Some embodiments include a discharge grid with at least one fastener coupling hole and the scroll includes at least one scroll fastener coupling hole. In some embodiments, the discharge grid is further configured and arranged to be coupled to the scroll using at least one fastener secured through the at least one fastener coupling hole and through at least one scroll fastener coupling hole.
Some embodiments include a discharge grid that further includes a flange coupled to the main wall. In some embodiments, the flange includes a coupling edge including at least one snap tab. Some embodiments also include a base wall that includes at least one snap tab. In some embodiments, the scroll includes at least one snap slot and at least one vertical slot and at least one snap slot. In some embodiments, the discharge grid is secured to the scroll by coupling the at least one snap tab with the at least one snap slot. In other embodiments, the discharge grid is secured to the scroll by coupling the coupling edge with the vertical slot. In some further embodiments, the discharge grid is secured to the scroll by coupling the at least one snap tab with the at least one snap slot and by coupling the coupling edge with the vertical slot.
In some embodiments, the scroll crescent is positioned within the scroll so that the scroll crescent is positioned within the scroll with the first crescent end substantially 80° or more from the first wall of the inner scroll surface. In some further embodiments, the scroll crescent is positioned within the scroll so that the second crescent end is substantially 170° or less from the first wall of the inner scroll surface. In some other embodiments, the scroll crescent is positioned within the scroll so that the first crescent end is positioned substantially at 90° from the first wall of the inner scroll surface, and the second crescent end is substantially at 180° from the first wall of the inner scroll surface.
Some embodiments include a ventilation assembly where at least one of the plurality of vertical fins and at least one the plurality of horizontal fins form at least one perpendicular intersection. In some embodiments, the discharge grid is configured and arranged to guide air exiting the scroll housing in at least two different directions.
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 and fall within the scope of embodiments of the invention.
In some embodiments, the ventilation assembly 10 can be used to ventilate any room, area or space. In some embodiments, the ventilation assembly 10 can be secured within 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 extract a fluid from 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 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 assembly 10, can be installed as a new, or a replacement ventilation system, and in some embodiments, the assembly 10 can replace an existing assembly 10.
Some embodiments of the ventilation assembly 10 can include several components and devices that can perform various functions. In some embodiments, the ventilation assembly 10 can include a housing 20, which can house the various components and devices of the ventilation assembly 10. For example, in some embodiments the ventilation assembly 10 can generally include the blower assembly 15 as shown in
In some embodiments, the ventilation assembly 10 includes a duct connector assembly 58 (shown in
In some embodiments, the scroll 30 can be formed into any shape, but generally is shaped to provide a substantially laminar fluid flow towards a discharge outlet 35. In one embodiment, the discharge outlet can be defined at least partially by a first wall 35a and a second wall 35b opposing the first wall 35a. In some embodiments, the first and second opposing walls 35a, 35b can extend from a top 35d of the discharge outlet 35 to a bottom 35c of the discharge outlet 35. The scroll 30 may be formed from any material that is readily shaped, including, but not limited to, polymers, polymer-composites, metal, ceramic, or wood, or paper-based composite or laminate. Furthermore, the use of injection-molded or thermo-formed polymeric materials conveniently allows a variety of functional or aesthetic components to be included into the structure of the scroll 30. In some embodiments, one or more functional or aesthetic components can be integrally formed within the scroll 30 using one or more thermoplastic polymers and injection-molding technology, thermo-molding or other molding technology. In other embodiments, one or more thermosetting polymer precursors may be used with a thermo-molding or other molding technology.
In some other embodiments, the use of injection-molded or thermo-formed polymeric materials conveniently allows a variety of functional or aesthetic components to be included and formed as discrete components, and then attached to the scroll 30 using adhesive, fasteners, thermo-molding or other melt-attachment process. In some embodiments, one or more functional and/or aesthetic components can be formed and then later attached to the scroll 30 using one or more thermoplastic polymers and injection-molding technology, thermo-molding or other molding technology. In other embodiments, one or more thermosetting polymer precursors may be used with a thermo-molding or other molding technology to form a component and then later attached to the scroll 30. In some other embodiments, the scroll 30 may utilize a combination of integrally formed and discrete components attached to the scroll 30.
In some embodiments, the main housing 20 may be formed into any shape, included but limited to, a rectangular box-like shape, an oval shape, a hemispherical shape, a spherical shape, a pyramidal shape, or any other shape. In some embodiments the main housing 20 is formed from a sheet metal, including, but not limited to an aluminum-based metal, a steel or iron-based metal, a zinc-based metal, or a nickel and tin-based metal. In some other embodiments, the main housing 20 may be formed from injection molded polymers, thermo-formed polymers, thermosetting polymers, or sheet metal, or any other suitable material. In some other embodiments, the housing 20 may comprises a wood-based product, such as wood, or particle-board or wood laminate. In some other embodiments, the housing 20 can form a base or a similar support structure of the ventilation assembly 10.
Some embodiments can include at least one component suitable for modifiying a flow of fluid within the scroll assembly 25. In some embodiments, this can include the addition of at least one component that can reduce noise creation with the main housing 20. For example, some embodiments include at least one noise reduction feature 65, 300, 305. For example, some embodiments of the scroll assembly 25 include a discharge grid 65. For example, as shown in the various perspective views of a scroll assembly according to one embodiment in the
In some embodiments the discharge grid 65 can include one or more structures designed to at least partially obstruct fluid flow. For example, in some embodiments, the discharge grid 65 can include an outlet restriction 67. In some embodiments, the outlet restriction 67 can be integrally formed with the discharge grid 65, and in other embodiments, the the outlet restriction 67 can be formed as a discrete component and assembled with the discharge grid 65.
As shown in
Some embodiments include a scroll gasket 28. In some embodiments, one or more scroll gaskets 28 can be applied to the scroll housing 31 to at least partially surround the discharge outlet 35 as shown in
In some embodiments, as fluid flows within the scroll 30 and approaches the outlet 35, the outlet restriction 67 can at least partially impede the flow of fluid within the scroll 30. Some embodiments include an outlet restriction 67 with a restriction wall (130 in
Some embodiments of the invention include a discharge grid 65 including an outlet restriction 67 that includes a main wall 150, including a first end 150a, a second end 150b, and several surfaces including a first surface 150c, and a second surface 150d. In some embodiments, the outlet restriction 67 includes a restriction wall 130. In some embodiments, the restriction wall 130 includes a first wall 135 coupled to a second wall 140. In some embodiments, the second wall 140 is further coupled to the main wall 150. A base wall 170 is coupled to the main wall 150 and the restriction wall 130 in some embodiments. In some embodiments, the base wall includes a first end 170a, a second end 170b, a top base edge 170c, and a bottom base edge 170d. In some embodiments, the first end 170a is coupled with the second end 150b at the second surface 150d, and the bottom base edge 170d is coupled with the restriction wall 130. In some further embodiments, the second end 170b of the base wall 170 is coupled to a first vertical fin 80. As depicted, for example, in
In some embodiments, as fluid flows within the scroll 30 and approaches the outlet 35, the outlet restriction 67 can at least partially substantially block the flow of fluid within the scroll 30. In some embodiments, the outlet restriction wall 67 can extend inward from the discharge outlet 35 of the scroll 30 toward the blower wheel 50 as depicted, for example, in
Some embodiments can include other features designed to change, or otherwise guide the flow of fluid within the scroll 30. In some embodiments, one or more structures can be included in the scroll 30 to change the flow of a fluid prior to contact with the discharge grid 65. For example,
As shown in
In some embodiments, the scroll crescent 300, 305 is positioned within the scroll 30 so that the first crescent end 320 and the second crescent end 325 are substantially within a quadrant 350 at least partially diagonally opposite a discharge out 35 of the scroll 30. For example, as shown in
In some embodiments, the scroll crescent 300, 305 may be formed from any material that can be readily shaped, including, but not limited to, polymers, polymer-composites, metal, ceramic, or wood, or paper-based composite or laminate, or metals. In some embodiments, the use of injection-molded or thermo-formed polymeric materials conveniently allows the scroll crescent 300 to be integrally formed with the scroll housing 31. In other embodiments, one or more thermosetting polymer precursors may be used with a thermo-molding or other molding technology of the scroll housing 31 with scroll crescent 300. In some further embodiments, the scroll crescent 305 can be formed as a discrete component and then later attached to the scroll 30. Some embodiments include a scroll crescent 305 formed from substantially the same material as the scroll housing 31. In some embodiments, the scroll crescent 305 may be formed from polymers, polymer-composites, metal, ceramic, or wood, or paper-based composite or laminate, or metals. In some embodiments, the scroll crescent 305 can be injection-molded or thermo-formed, thermo-molding or otherwise formed separately from the formation of the scroll 30, and later secured to the inner scroll surface 44 of the scroll housing 31.
As shown in
Some embodiments can include some other features designed to change, or otherwise guide the flow of fluid within the scroll 30. For example, in some embodiments, one or more structures can be included in the scroll 30 to change the flow of a fluid during exit from the scroll 30 through the discharge outlet 35. In some embodiments, these features can reduce the noise emitted by the ventilation assembly 10 as it leaves the scroll 30 either alone, or in combination with the other features within the scroll 30, such as the scroll crescent 300, 305.
In some embodiments, as fluid flows within the scroll 30 and approaches the outlet 35, one or more fins 70, 80, 90, 100 of the discharge grid 65 can at least partially straighten the air and just prior to discharge from the scroll 30 through the outlet 35. For example, as detailed in
As described earlier, in some embodiments of the invention, a base wall 170 is coupled to the main wall 150 and the restriction wall 130. In some embodiments, the first end 170a of the base wall 170 is coupled with the second end 150b at the second surface 150d of the main wall 150, and the bottom base edge 170d is coupled with the restriction wall 130. Some embodiments include the first vertical fin 80 which includes a first end 82a and a second end 82b. In some further embodiments, the second end 170b of the base wall 170 is also coupled to the first vertical fin 80 second end 82b.
Some embodiments include a plurality of horizontal fins 90, 100. As shown in
In some embodiments, the first horizontal fin 90 can include a first end 95, a second end 97, a top edge 94 and a bottom edge 92. In some embodiments, the second end 97 can be coupled to the second surface 150d of the main wall 150. In some further embodiments, the bottom edge 92 can be coupled to the inner surface 130a of the restriction wall 130. In some further embodiments, the first horizontal fin 90 can couple with the first vertical fin 80. In some further embodiments, the first horizontal fin 90 can couple with a second vertical fin 70. In other embodiments, the first horizontal fin 90 can couple with at least one other vertical fin (not shown). Some embodiments can include additional horizontal fins. For example, some embodiments include a second horizontal fin 100.
In some embodiments, the second horizontal fin 100 can include a first end 105, a second end 107, a top edge 104 and a bottom edge 102. In some embodiments, the second end 107 can be coupled to the second surface 150d of the main wall 150. In some further embodiments, the bottom edge 102 can be coupled to the inner surface 130a of the restriction wall 130. In some further embodiments, the second horizontal fin 100 can couple with the first vertical fin 80. In some further embodiments, the second horizontal fin 100 can couple with a second vertical fin 70. In other embodiments, the horizontal fin 100 can couple with at least one other vertical fin (not shown).
As described and shown in
Some embodiments include further features designed to change, or otherwise guide the flow of fluid within the scroll 30. For example, in some embodiments, one or more structures can be included in the scroll 30 to change the flow of a fluid during exit from the scroll 30 through the discharge outlet 35. For example, as shown in
Some embodiments include further features designed to change, or otherwise guide the flow of fluid within the scroll 30. For example, as shown in
Some embodiments include further features designed to change, or otherwise guide the flow of fluid within the scroll 30. For example, in some embodiments, one or more structures can be included in the scroll 30 to change the flow of a fluid during exit from the scroll 30 through the discharge outlet 35. For example, as shown in
Some embodiments include further features designed to change, or otherwise guide the flow of fluid within the scroll 30. For example, in some embodiments, one or more structures can be included in the scroll 30 to change the flow of a fluid during exit from the scroll 30 through the discharge outlet 35. For example, as shown in
In some embodiments as shown in
As described earlier, in some embodiments, the discharge grid 65 can be formed as a discrete component and assembled with the scroll 30 by coupling to the scroll housing 31. Some embodiments include one or more features to enable coupling of the discharge grid 65 with the housing 31. For example,
Some embodiments include additional features for coupling the discharge grid 65 with the scroll 30. For example, referring to
As shown in
In some embodiments, the ventilation assembly 10 can be operable to discharge fluid from a space to another location. For example, in some embodiments, when power is provided to the blower assembly 15, a motor 52 can rotate a blower wheel 50 positioned substantially within the scroll 30. In some embodiments of the invention as described and illustrated, fluid flow is moved substantially towards the duct connector assembly 58. In some embodiments, the moveable damper flap 60 coupled with a ventilation orifice 62 will open, allowing fluid to be expelled from the ventilation assembly 10. In some embodiments, the damper flap 60 can control the backflow of a fluid into the ventilation orifice 62 and the blower assembly 15.
In some embodiments, the ventilation orifice 62 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. Furthermore, the duct connector assembly 58 is further capable of substantially controlling the flow of fluid from a space into the ventilation of a duct of a building when the motor 52 is unpowered. For example in some embodiments, the moveable damper flap 60 can at least partially seal, or provide a substantially sealed ventilation orifice 62. In some embodiments, when the motor 52 is unpowered, the damper flap 60 can at least partially prevent, or substantially prevent, a flow of fluid into the blower assembly 15 when the atmospheric pressure outside the ventilation assembly 10 (i.e. within a vent or duct of a home or other building structure to which the duct connector assembly 58 is fluidly coupled) is higher than the pressure within the space to be ventilated.
Some embodiments provide a ventilation assembly 10 that can be installed as a new, original equipment installation in a room or building where none had previously existed. In some other embodiments, the ventilation assembly 10 can replace a pre-existing ventilation system. In some further embodiments, the blower assembly 15 can be installed as a new, or a replacement ventilation system, and in some embodiments, the assembly 15 can replace an existing assembly 15. In some embodiments, the assembly 15 can be installed in a pre-existing cavity or housing 20 in a room or building in order to substantially reduce the level of noise emitted from the ventilation assembly 10 during operation. In some embodiments, the inclusion of either the discharge grid 65, or the scroll crescent 300, 305, or both within the ventilation assembly 10 as illustrated in
In some embodiments, the ventilation assembly 10 including discharge grid 65 and scroll crescent 300,305 as described earlier and illustrated in various embodiments shown at least in
As described, some embodiments can include at least one component suitable for modifying a flow of fluid within the scroll assembly 25, which in some embodiments can include the addition of at least one component that can reduce noise creation with the main housing 20. By applying computer aided fluid dynamic calculations, it is possible to visualize the fluid velocity profile of a fluid within the ventilation assembly 10. For example,
The plot of a fluid dynamic simulation 500 in
It will be appreciated by those skilled in the art that while the invention has been described above in connection with particular embodiments and examples, the invention is not necessarily so limited, and that numerous other embodiments, examples, uses, modifications and departures from the embodiments, examples and uses are intended to be encompassed by the claims attached hereto. The entire disclosure of each patent and publication cited herein is incorporated by reference, as if each such patent or publication were individually incorporated by reference herein. Various features and advantages of the invention are set forth in the following claims.
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| 20150038070 A1 | Feb 2015 | US |
