WALL CAP

Abstract

A wall cap includes a plate and an intake pipe extending from one side of the plate. One or more plate walls extend from the other side of the plate. The wall cap further includes an extension member that engages with the plate walls. The engagement of the extension member with the plate walls may be through the engagement of tabs (on the engagement member) with protrusions (on the plate walls). The extension member includes markings at pre-set intervals. The markings assist in allowing for the extension member to be cut to accommodate different thicknesses of the wall. The wall cap further includes a hood assembly for attachment to the extension member.

Description

TECHNICAL FIELD

The invention relates to wall caps, and in particular to wall caps for heating, ventilation, and air conditioning (HVAC) systems.

BACKGROUND

Exterior insulation and finish system (EIFS) is a type of wall cladding that is applied to a building's exterior surfaces to provide an insulated, water-resistant, finished surface. EIFS is touted to be more energy-efficient and lighter than conventional stucco material that is commonly used on exterior surfaces. Some jurisdictions have begun to recommend or require the use of EIFS as part of their building codes.

Wall caps, also known as wall cap vents, are units that are designed to vent air, moisture, and/or particulates through a wall. Wall caps may be used with walls that have EIFS applied; however, because EIFS may vary in thickness (between 2 and 12 inches thick), it may be difficult to find specific wall caps that are suitable for a particular application of EIFS.

SUMMARY

In one aspect, a wall cap comprises a plate and an intake pipe extending from one side of the plate. One or more plate walls extend from the other side of the plate. The wall cap further comprises an extension member that is adapted to engage with the plate walls. The engagement of the extension member with the plate walls may be through the engagement of tabs (on the engagement member) with protrusions (on the plate walls). The extension member comprises markings at pre-set intervals. The markings assist in allowing for the extension member to be cut to accommodate different thicknesses of the wall. The wall cap further comprises a hood assembly for attachment to the extension member.

The hood assembly comprises fastener openings adapted to receive fasteners. The extension member comprises fastener tubes extending along at least a portion of the extension member. The fastener tubes are adapted to receive the fasteners as well, allowing the hood assembly to be secured to the extension member.

In another aspect, a wall cap for installation on a wall comprises an intake pipe, a plate, one or more plate walls, an extension member, and a hood assembly. The plate comprises a pipe opening, with the intake pipe attached to the plate proximate to the pip opening. The plate is adapted to engage with the wall. The one or more plate walls extend from the plate, with the one or more plate walls defining, at least in part, a plate opening. The extension member includes first and second ends, with the extension member comprising a connector portion and a variable portion. The connector portion extends from the first end, with the connector portion comprising one or more connector portion walls extending from the first end. The one or more connector portion walls define, at least in part, a connector portion opening. The one or more connector portion walls are adapted to detachably engage with the one or more plate walls. The variable portion extends from the second end and is connected to the connector portion. The variable portion comprises one or more variable portion walls, with at least one of the one or more variable portion walls comprising a plurality of markings at pre-set intervals along at least a portion of a length of the variable portion. The hood assembly is detachably connected to the extension member proximate to the second end.

In yet another aspect, the one or more variable portion walls comprise four variable portion walls. The four variable portion walls comprise upper and lower extension walls and two lateral extension walls extending between the upper and lower extension walls.

In still yet another aspect, the lower extension wall is angled from the horizontal. The lower extension wall may be angled between 0 and 10 degrees from the horizontal. The lower extension wall may be angled approximately 5 degrees from the horizontal.

In yet another aspect, the upper extension wall is angled from the horizontal. The upper extension wall may be angled between 0 and 10 degrees from the horizontal. The upper extension wall may be angled approximately 5 degrees from the horizontal.

In a further aspect, the connection portion walls and the variable portion walls define, at least in part, a passageway within the extension member.

In still a further aspect, the plurality of markings comprises lines.

In still yet a further aspect, the lines are etched or scored onto the one or more variable portion walls.

In another aspect, the pre-set intervals are approximately 1 inch apart from each other.

In still another aspect, all of the variable portion walls comprise the plurality of markings.

In still yet another aspect, the plurality of markings extend along substantially an entire perimeter of the variable portion walls.

In another aspect, the hood assembly comprises a hood base adapted to engage with the variable portion walls.

In yet another aspect, the hood base comprise one or more base openings. The extension member comprises one or more fastener tubes aligned with the one or more base openings and extending along at least a portion of the variable portion walls. The base openings and the fastener tubes are adapted to receive one or more fasteners for securing the hood base to the variable portion walls.

In still yet another aspect, the one or more fastener tubes extend for substantially an entire length of the variable portion.

In another aspect, the hood assembly further comprises a curved cover extending from the hood base.

In a further aspect, the one or more connector portion walls comprises one or more tabs, and the one or more plate walls comprises one or more protrusions adapted to detachably engage with the one or more tabs.

In still a further aspect, the wall cap is constructed, at least in part, from injection-moulded plastic.

The foregoing was intended as a summary only and of only some of the aspects of the invention. It was not intended to define the limits or requirements of the invention. Other aspects of the invention will be appreciated by reference to the detailed description of the embodiments.

BRIEF DESCRIPTION OF THE DRAWINGS

The embodiments will be described by reference to the drawings thereof, in which:

FIG. 1 is a perspective view of the wall cap in accordance with one embodiment;

FIG. 2 is an exploded view of the wall cap;

FIG. 3 is another exploded view of the wall cap;

FIG. 4 is a side view of the wall cap;

FIG. 5 is a front view of the wall cap;

FIG. 6 is a top view of the wall cap;

FIG. 7 is another perspective view of the wall cap;

FIG. 8 is yet another perspective view of the wall cap, from the bottom; and

FIG. 9 is a cross-sectional view of the wall cap, as installed in a wall.

DETAILED DESCRIPTION

Referring to FIGS. 1 to 9, in accordance with one embodiment, a wall cap 10 for use with a wall 1 comprises a plate 12, with the plate 12 comprising first and second surfaces 14, 16. The plate 12 may be attached to an interior surface 2 of the wall 1 (as shown in FIG. 8). The plate 12 comprises a pipe opening 18. In some embodiments, the pipe opening 18 may be circular in shape. The wall cap 10 may further comprise an intake pipe 20 attached to the plate 12. In some embodiments, the intake pipe 20 may extend from the first surface 14 of the plate 12, with the intake pipe 20 situated generally about, or coextensive with, the pipe opening 18. The intake pipe 20 may be generally cylindrical in shape and provides a passageway for air, moisture, and/or particulates to enter into the wall cap 10 and to pass through the pipe opening 18.

The wall cap 10 further comprises one or more plate walls 22 extending from the second surface 16 of the plate 12. For example, referring to FIGS. 2 and 3, the plate walls 22 may comprise four plate walls 22 extending from the second surface 16, defining, at least in part, a generally rectangular plate opening 78. In some embodiments, the plate walls 22 are arranged around the pipe opening 18. It is understood that the number of the plate walls 22 provided and the shapes formed therewith may differ.

In some embodiments, the intake pipe 20 may extend through the plate 12 (i.e. portions of the intake pipe 20 extend from both the first and second surfaces 14, 16), as shown in FIG. 2. For example, the intake pipe 20 may be fitted within the pipe opening 18.

In some embodiments, the wall cap 10 may further comprise a damper 68 that extends, at least partially, across the pipe opening 18. The damper 68 may be hingedly attached to the second surface 16, such as through damper clips 70 located on the second surface 16. The damper 68 may be adapted to move hingedly inwards when a force (such as airflow) is exerted against the damper 68. The damper 68 is adapted to allow airflow in one direction only.

The wall cap 10 further comprises an extension member 28 that is adapted to engage with the plate walls 22. The extension member 28 comprises first and second ends 30, 32, with the extension member 28 adapted to engage with the plate walls 22 proximate to the first end 30. The extension member 28 comprises a connector portion 72 and a variable portion 74 connected to the connector portion 72. The connector portion 72 extends from the first end 30, while the variable portion 74 extends from the second end 32

The connector portion 72 comprises one or more connector portion walls 76 extending from the first end 30. For example, referring to FIG. 2, the connector portion walls 76 may comprise four connector portion walls 76 extending from the first end 30, defining, at least in part, a generally rectangular connector portion opening 80. It is understood that the number of the connector portion walls 76 provided and the shapes formed therewith may differ.

The connector portion walls 76 may be adapted to engage with the plate walls 22. In some embodiments, the perimeter of the connector portion opening 80 is slightly smaller than the perimeter of the plate opening 78 such that the connector portion walls 76 are adapted to fit within the plate walls 22.

In some embodiments, one or more of the connector portion walls 76 may comprise one or more tabs 36 proximate to the first end 30. The tabs 36 may flare outwards and are adapted to engage with one or more protrusions 38 located on one or more of the plate walls 22. For example, when the extension member 28 is placed proximate to the plate walls 22 and pushed against the plate walls 22, the contact by the tabs 36 against the protrusions 38 may cause the tabs 36 to be deflected inwards. As further force is applied against the plate walls 22, the tabs 36 may move along the protrusions 38. Once the tabs 36 move past the protrusion 38, the tabs 36 may revert back to their original configuration, which may engage the tabs 36 against the protrusions 38 and secure the extension member 28 in place with respect to the plate walls 22. It may be possible to remove the extension member 28 from the plate walls 22 by manually depressing the tabs 36 (such that they are no longer engaged against the protrusions 38) and pulling the extension member 28 away from the plate walls 22.

The variable portion 74 comprises one or more variable portion walls 82. In some embodiments, the variable portion walls 82 comprise upper and lower extension walls 40, 42 and two lateral extension walls 44 extending between the upper and lower extension walls 40, 42 (as shown in FIGS. 2 and 3). However, it is understood that in some embodiments, the variable portion walls 82 may comprise a single variable portion wall 82 that has a substantially circular or round cross-section.

When the extension member 28 is engaged with the plate walls 22, one or both of the upper and lower extension walls 40, 42 may not be oriented horizontally but are sloped. When the extension member 28 is engaged with the plate walls 22, the lower extension wall 42 may sloped away from horizontal, at an angle A (as shown in FIG. 4). In some embodiments, the angle A may be between 0 degrees and 10 degrees. In other embodiments, the angle A may be approximately 5 degrees.

The upper extension wall 40 may also be sloped away from horizontal. In some embodiments, the upper extension wall 40 and the lower extension wall 42 are substantially parallel to each other. The sloping of the lower extension wall 42 may assist in allowing any moisture that collects on the lower extension wall 42 to run out (i.e. from the first end 30 towards the second end 32.

The connection portion walls 76 and the variable portion walls 82 define, at least in part, a passageway 60 within the extension member 28 through which air, moisture, and/or particulates may move from the first end 30 to the second end 32.

The variable portion 74 may further comprise a plurality of markings 46 along one or more of the variable portion walls 82. In some embodiments, the markings 46 may comprise a plurality of lines that are spaced apart from each other, with each of the lines extending along at least a portion of the perimeter of the variable portion walls 82. In other embodiments, the markings 46 may be lines extending along substantially an entire perimeter of the variable portion walls 82. The markings 46 may be arranged at pre-set intervals to provide an indicator of where the extension member 28 may be cut in order to accommodate a particular width of the wall 1. For example, referring to FIG. 7, the markings 46 may be cut lines that are arranged in one-inch intervals. However, it is understood that other distance intervals are also possible. In some embodiments, the markings 46 may extend across all of the variable portion walls 82 (e.g. the upper and lower extension walls 40, 42 and the lateral extension walls 44). In other embodiments, only some of the variable portion walls 82 may comprise the markings 46.

The markings 46 may be formed using ink or other suitable printing methods. In some embodiments, the markings 46 may also be etched or scored onto the variable portion walls 82 (e.g. onto a surface of the variable portion walls 82). The etching and/or scoring of the markings 46 may assist in the cutting of the variable portion walls 82.

The markings 46 allow the wall cap 10 to be used with a wall 1 regardless of the thickness of the wall 1. Once the thickness of the wall 1 is determined, an appropriate length of the variable portion 74 may be determined. The variable portion 74 can then be cut using the markings 46 as a guide. Alternatively, if the markings 46 comprise scored or etched lines, the scoring or etching may make it easier to cut the variable portion 74 at or proximate to the closest one of the markings 46 that would result in the variable portion 74 being of the appropriate length.

The wall cap 10 further comprises a hood assembly 48 that is adapted to detachably engage with the extension member 28 proximate to the second end 32. The hood assembly 48 may be located substantially on an exterior surface 3 of the wall 1 when the wall cap 10 is installed onto the wall 1. The hood assembly 48 comprises a hood base 50 that is adapted to engage with the variable portion walls 82 of the extension member 28. The hood base 50 may comprise one or more base openings 52 that are adapted to receive fasteners 54 for securing the hood assembly 48 to the extension member 28. The extension member 28 may comprise one or more fastener tubes 56 formed along one or more of the connector portion walls 76 and extending from the second end 32 for at least a portion of the length of the variable portion 74. In some embodiments, the fastener tubes 56 may extend for substantially an entire length of the variable portion 74. This would allow at least a portion of the fastener tubes 56 to be present, regardless of whether a portion of the extension member 28 has been cut. The fasteners 54 may comprise screws, pins, or the like.

The fastener tubes 56 may be located on an exterior of the connector portion walls 76. For example, in the embodiment shown in FIGS. 1 to 9, the fastener tubes 56 are located on the exterior of the lateral extension walls 44. The fastener tubes 56 are adapted to receive the fasteners 54 so as to allow the hood assembly 48 to be secured to the extension member 28. The fastener tubes 56 may be aligned with the base openings 52 in order to allow for the fasteners 54 to engage both the base openings 52 and the fastener tubes 56.

The hood assembly 48 further comprises a curved cover 58 extending from the hood base 50. The cover 58 is adapted to direct airflow received from the extension member 28 substantially downward. The hood assembly 48 may further comprise two side walls 62 extending between the cover 58 and the hood base 50. The hood base 50, the side walls 62, and the cover 58 define, at least in part, a hood opening 64 that allows for air, moisture, and/or particulates to exit from the wall cap 10. The hood assembly 48 may further comprise a grill 66 that extends, at least partially, across the hood opening 64. The grill 66 may prevent large objects from entering into the wall cap 10.

The wall cap 10 may be used with walls 1 that include EIFS. Regardless of the thickness of the EIFS, the extension member 28 may be cut to accommodate the thickness of the EIFS.

In some embodiments, the wall cap 10 may be constructed, at least in part, from injection-moulded plastic.

It will be appreciated by those skilled in the art that the preferred embodiment has been described in some detail but that certain modifications may be practiced without departing from the principles of the invention.

Claims

1. A wall cap for installation on a wall, the wall cap comprising: an intake pipe;a plate comprising a pipe opening, the intake pipe attached to the plate proximate to the pip opening, wherein the plate is adapted to engage with the wall;one or more plate walls extending from the plate, the one or more plate walls defining, at least in part, a plate opening;an extension member with first and second ends, the extension member comprising: a connector portion extending from the first end, the connector portion comprising one or more connector portion walls extending from the first end, the one or more connector portion walls defining, at least in part, a connector portion opening, wherein the one or more connector portion walls are adapted to detachably engage with the one or more plate walls; anda variable portion extending from the second end and connected to the connector portion, the variable portion comprising one or more variable portion walls, wherein at least one of the one or more variable portion walls comprises a plurality of markings at pre-set intervals along at least a portion of a length of the variable portion; anda hood assembly detachably connected to the extension member proximate to the second end.

2. The wall cap of claim 1, wherein the one or more variable portion walls comprise four variable portion walls, wherein the four variable portion walls comprise upper and lower extension walls and two lateral extension walls extending between the upper and lower extension walls.

3. The wall cap of claim 2, wherein the lower extension wall is angled from the horizontal.

4. The wall cap of claim 3, wherein the lower extension wall is angled between 0 and 10 degrees from the horizontal.

5. The wall cap of claim 4, wherein the lower extension wall is angled approximately 5 degrees from the horizontal.

6. The wall cap of claim 2, wherein the upper extension wall is angled from the horizontal.

7. The wall cap of claim 6, wherein the upper extension wall is angled between 0 and 10 degrees from the horizontal.

8. The wall cap of claim 7, wherein the upper extension wall is angled approximately 5 degrees from the horizontal.

9. The wall cap of claim 1, wherein the connection portion walls and the variable portion walls define, at least in part, a passageway within the extension member.

10. The wall cap of claim 1, wherein the plurality of markings comprises lines.

11. The wall cap of claim 10, wherein the lines are etched or scored onto the one or more variable portion walls.

12. The wall cap of claim 1, wherein the pre-set intervals are approximately 1 inch apart from each other.

13. The wall cap of claim 1, wherein all of the variable portion walls comprise the plurality of markings.

14. The wall cap of claim 1, wherein the plurality of markings extend along substantially an entire perimeter of the variable portion walls.

15. The wall cap of claim 1, wherein the hood assembly comprises a hood base adapted to engage with the variable portion walls.

16. The wall cap of claim 15, wherein the hood base comprise one or more base openings, wherein the extension member comprises one or more fastener tubes aligned with the one or more base openings and extending along at least a portion of the variable portion walls, and wherein the base openings and the fastener tubes are adapted to receive one or more fasteners for securing the hood base to the variable portion walls.

17. The wall cap of claim 16, wherein the one or more fastener tubes extend for substantially an entire length of the variable portion.

18. The wall cap of claim 17, wherein the hood assembly further comprises a curved cover extending from the hood base.

19. The wall cap of claim 1, wherein the one or more connector portion walls comprises one or more tabs, and wherein the one or more plate walls comprises one or more protrusions adapted to detachably engage with the one or more tabs.

20. The wall cap of claim 1, wherein the wall cap is constructed, at least in part, from injection-moulded plastic.