VENTILATION SYSTEM AND METHOD

Abstract

A ventilation assembly having a main housing and a removable cartridge assembly that can be positioned within the main assembly. The main housing can be mounted within an aperture in a wall or ceiling and, in certain examples, can be connected to ductwork and electrical wiring within the wall or ceiling. The cartridge assembly can include a retention feature that can be releasably engaged to the main housing to retain the cartridge assembly within the main housing. The cartridge assembly can include ventilation components such as the motor, fan wheel, capacitor, controller and various combinations thereof. The cartridge assembly can be removed from the main housing by disengaging the retention feature and replaced with a new cartridge assembly or modified elsewhere before being reinserted into the main housing, thereby permitting repairing or upgrading of the ventilation assembly without removing the main housing from the wall or ceiling.

Description

CLAIM OF PRIORITY

This patent application claims the benefit of priority, under 35 U.S.C. Section 119(e), to Mirko Zakula et al., U.S. Patent Application Ser. No. 61/935,781, entitled “VENTILATION SYSTEM AND METHOD,” filed on Feb. 4, 2014, each of which is hereby incorporated by reference herein in its entirety.

TECHNICAL FIELD

This document pertains generally, but not by way of limitation, to ventilation systems and related methods of installing, replacement or upgrading.

BACKGROUND

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 when rotated draw air through an inlet opening in a fan housing and creates an outward airflow through an outlet opening in the fan housing. The fan wheel is typically coupled to a motor supported within the fan housing, which rotates the fan wheel to provide ventilation for the area. In some cases, a curved fan scroll is fitted around the fan wheel to guide air the outward airflow to the outlet opening.

In certain situations, an installed exhaust fan may need to be replaced, repaired or upgraded. For example, an old exhaust fan may need to be replaced when the fan wheel or motor is inoperable or generating unacceptable vibration or noise during operation. Similarly, changing ventilation needs may require upgrading to a more powerful or quieter exhaust fan. The housing for exhaust fans is often mounted within a building structure, such as in an aperture in a wall or ceiling. The housing can be secured in the aperture by being attached to wall or ceiling joists, or by being attached to other structures in the wall or ceiling. As a result, exhaust fans can be relatively difficult and time consuming to remove and replace. In most cases, replacement typically requires removal of the old ventilation assembly from the wall and install the new ventilation assembly as well as disconnecting and reconnecting the associated ductwork. In addition, as exhaust fans are typically wired directly into the house power supply, a qualified electrician is often required to disconnect the exhaust fan from the house power supply and connect the replacement ventilation assembly to the house power supply.

OVERVIEW

The present inventors have recognized, among other things, that a problem to be solved can include repairing or replacing a ventilation assembly that has been installed in a building structure. In an example, the present subject matter can provide a solution to this problem, such as by providing a ventilation assembly having a main housing and a removable cartridge assembly receivable within the main assembly. The main housing can be mounted within an aperture in a wall or ceiling and, in certain examples, can be connected to ductwork and electrical wiring. The cartridge assembly can include a retention feature that can be releasably engaged to the main housing to retain the cartridge assembly within the main housing. The cartridge assembly can include ventilation components such as the motor, fan wheel, capacitor, controller and various combinations thereof. The cartridge assembly can be removed from the main housing by disengaging the retention feature and replaced with a new cartridge assembly or modified remotely before being reinserted into the main housing. The cartridge assembly allows repairing or upgrading of the ventilation assembly without removing the main housing from the wall or ceiling.

A ventilation assembly according to an example of the present subject matter can comprise a main housing and a cartridge assembly. The cartridge assembly can include at least a motor and a retention feature that is engagable to the main housing to substantially retain the cartridge assembly within the main housing. The retention feature can be disengaged from the main housing to remove the cartridge assembly from the main housing.

A cartridge assembly receivable within a main housing according to an example of the present subject matter can include a motor and a retention feature. The retention feature can be releasably engaged to the main housing to substantially retain the cartridge assembly within the main housing. The retention feature can be configured to be disengaged from the main housing to disengage the cartridge assembly from the main housing and remove the cartridge assembly from the main housing.

A method of mounting a ventilation assembly, according to an example of the present subject matter can include mounting a main housing within at least one of a wall aperture and a ceiling aperture. The main housing can define an inlet aperture. The method can include inserting a cartridge assembly into the main housing through the inlet aperture. The cartridge assembly can comprise a retention feature. The method can also include coupling the retention feature to the main housing to retain the cartridge assembly within the main housing to retain the cartridge assembly within the main housing. In at least one example, the method can also include disengaging the retention feature from the main housing and withdrawing the cartridge assembly from the main housing through the inlet aperture.

This overview is intended to provide an overview of subject matter of the present patent application. It is not intended to provide an exclusive or exhaustive explanation of the present subject matter. The detailed description is included to provide further information about the present patent application.

BRIEF DESCRIPTION OF THE DRAWINGS

In the drawings, which are not necessarily drawn to scale, like numerals may describe similar components in different views. Like numerals having different letter suffixes may represent different instances of similar components. The drawings illustrate generally, by way of example, but not by way of limitation, various examples discussed in the present document.

FIG. 1 is a top perspective view of an upgrade cartridge assembly according to one example of the present subject matter.

FIG. 2 is a side perspective view of an upgrade cartridge assembly according to one example of the present subject matter. FIG. 3 is a side perspective view of an upgrade cartridge assembly according to one example of the present subject matter.

FIG. 4 is a side perspective view of an upgrade cartridge assembly according to one example of the present subject matter.

FIG. 5 is a rear perspective view of an upgrade cartridge assembly according to one example of the present subject matter.

FIG. 6A is a side-rear view of an upgrade cartridge assembly scroll with grille spring holder according to one example of the present subject matter.

FIG. 6B is a side-rear close-up view of an upgrade cartridge assembly scroll with grille spring holder according to one example of the present subject matter.

FIG. 7 is a top perspective vlew of a ventilation assembly according to one example of the present subject matter.

FIG. 8 is a bottom perspective view of a ventilation assembly according to one example of the present subject matter.

FIG. 9 is a bottom perspective view of an upgrade cartridge assembly according to one example of the present subject matter.

FIG. 10A is a side perspective view of a ventilation assembly according to one example of the present subject matter.

FIG. 10B is a close-up view of a side of a ventilation assembly according to one example of the present subject matter. FIG. 10C is a close-up top view of the ventilation assembly according to one example of the present subject matter.

FIG. 11 is a close-up view of the electrical box enclosure of a main housing according to one example of the present subject matter.

FIG. 12 is a close-up view of the electrical box cover plate according to one example of the present subject matter.

FIG. 13A is a close-up view of a duct connector assembly with a closed damper flap according to one example of the present subject matter.

FIG. 13B is a close-up view of a duct connector assembly with an open damper flap according to one example of the present subject matter.

FIG. 14A is a close-up view of a duct connector assembly installed in a main housing viewed from within the main housing according to one example of the present subject matter.

FIG. 14B is a close-up view of a duct connector assembly installed in a main housing according to one example of the present subject matter.

FIG. 14C is a close-up view of a duct connector assembly installed in a main housing according to one example of the present subject matter.

FIG. 15 shows an exploded view of a ventilation assembly according to one example of the present subject matter.

FIG. 16 shows an exploded view of ventilation assembly according to another example of the present subject matter.

FIG. 17 shows an exploded vlew of ventilation assembly according to another example of the present subject matter.

FIG. 18 shows an exploded view of ventilation exhaust fan assembly according to another example of the present subject matter.

FIG. 19 shows an exploded view of ventilation exhaust fan assembly according to another example of the present subject matter.

FIG. 20A shows a top view of a motor plate illustrating cross-sections cut lines according to one example of the present subject matter.

FIG. 20B illustrates a cross-sectional view of the motor plate of FIG. 20A through the cut line 18-18 according to one example of the present subject matter.

FIG. 20C illustrates a cross-sectional view of the motor plate of FIG. 20A through the cut line 17-17 according to one example of the present subject matter.

FIG. 20D illustrates a cross-sectional view of the motor plate of FIG. 20A through the cut line 19-19 according to one example of the present subject matter.

FIG. 20E illustrates a cross-sectional view of the motor plate of FIG. 20A through the cut line 15-15 according to one example of the present subject matter.

FIGS. 21A-21E illustrates various views of a ventilation assembly grille according to another example of the present subject matter.

DETAILED DESCRIPTION

FIGS. 7 and 15 illustrate a ventilation assembly 10 according to one example of the present subject matter. Some examples of the ventilation assembly 10 can include several components and devices that can perform various functions. In some examples, the ventilation assembly 10 can include a main housing 25, which can house the various components and devices of the ventilation assembly 10. In some examples, the ventilation assembly 10 generally can include a cartridge assembly 20, substantially housed within the main housing 25, and positioned within the main housing 25 aided by a fan cartridge locating rib 80, and coupled to the main housing 25 with a retention feature 85. In some examples, the cartridge assembly 20 generally can include a motor 30, such as a permanent split capacitor motor 30, and a motor capacitor 35. Some examples provide a fan cartridge assembly 20 that can also include a scroll 40, and a blower wheel 50 positioned substantially within the scroll 40, and mechanically coupled to the motor 30. Furthermore, in some examples, a duct connector assembly 270 can be coupled to the ventilation assembly 10. The duct connector assembly 270 can include a moveable damper flap 280 coupled with a ventilation orifice 272. In some examples, the damper flap 280 can control the backflow of a fluid into a ventilation orifice 272 and the cartridge assembly 20, and further 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.

In some examples, the ventilation assembly 10 can be used to ventilate any room, area or space. In some examples, the ventilation assembly 10 can be secured within a wall, ceiling, or other building structure in a partially, or in a fully recessed position. In some examples, 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 examples, the fluid can comprise air, or other gases, or vapor, such as water vapor. In some examples, the fluid can comprise a smoke, ash, or other particulate in addition to air or other gases.

In some examples, 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 examples of the present subject matter provide a ventilation assembly 10 that can replace a pre-existing ventilation system. In some examples, the cartridge assembly 20, can be installed as a new, or a replacement ventilation system, and in some examples, the cartridge assembly 20 can replace an existing cartridge assembly 20.

As shown in the top perspective view of FIG. 1, in some examples of the present subject matter, a cartridge assembly 20 can be provided as a compact assembly comprising a permanent split capacitor motor 30, motor mounting plate 70, nestled within a scroll 40, and coupled to a blower wheel 50. In some examples, the motor 30 can be mechanically secured to the motor mounting plate 70 using at least one motor plate bolt 75, and can be any motor 30 capable of providing sufficient rotational torque to turn the blower wheel 50. In some examples, the blower wheel 50 can be mechanically coupled to the motor 30 using a main drive bolt, (see first end 60 of the main drive bolt in FIG. 1). In some examples, when a permanent split capacitor motor 30 is used, the motor 30 can be electrically coupled to at least one permanent split capacitor 35. As shown in FIG. 1, the permanent split capacitor 35 can be secured to the scroll 40, or in some other examples, it can be secured to another component of the ventilation assembly 10. In some examples, the motor 30 is electrically coupled to a motor power harness 65 that is electrically coupled to the capacitor 35. In some other examples, the permanent split capacitor 35 can be secured to a surface of a structure of a building, adjacent to the cartridge assembly 20, and can be electrically coupled with the cartridge assembly 20 with a motor power harness 65 (not shown).

As shown in the side perspective view of a fan cartridge assembly 20 of some examples of the present subject matter in FIG. 2, the scroll 40 can be formed into any shape, but generally is shaped to provide a compact and optimal fluid flow towards the blower outlet 55 when coupled to the motor mounting plate 70. The scroll 40 can 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 allow a variety of functional components to be included into the structure of the scroll 40. For example, in some examples, as shown in FIG. 2, the cartridge assembly 20 can include at least one fan cartridge locating rib 80. The rib 80 provides centering and guidance when maneuvering the cartridge assembly 20 within a main housing 25 to form the ventilation assembly 10. In some further examples, other useful features can be provided. For example, as shown in FIG. 2, in some examples, the scroll 40 can include a retention feature 85. The retention feature 85 is also shown in more detail in FIG. 5, showing the positional relationship with respect to the capacitor 35 and the motor power harness 65. In some examples, the retention feature 85 can be integral with the scroll 40, and can be used to secure the cartridge assembly 20 into a main housing 25 of a ventilation assembly 10. In some other examples, the retention feature 85 is not integral to the scroll, but a separate component (not shown). In some examples, the retention feature 85 can be integral with the scroll 40, however the cartridge assembly 20 can be coupled with the main housing 25 using alternative methods.

In some examples, other useful features can be integral with the scroll 40. For example, as shown in FIG. 3, a screw boss 90 can be formed. In some other examples, more than one screw boss 90 can be formed. The screw boss 90 provides an anchoring feature for a fastener (not shown) to secure the scroll 40 to the motor mounting plate. In some examples, a surface of the scroll 40 can provide an anchoring point for other components of the cartridge assembly 20. For example, one or more screw holes (not shown) can provide an anchoring location for the motor capacitor 35, while at least one side of the scroll can provide a mating surface for other components. As shown in FIG. 3, other surfaces of the scroll 40 can provide a convenient location for further fan cartridge locating ribs 80.

In some examples, one or more integral features of the scroll can provide an anchoring location for at least one component of the motor power harness 65. For example, referring to FIG. 4, showing a side perspective view of a cartridge assembly 20 according to one example of the present subject matter, the motor power harness 65 can be secured with at least one feature integral to the scroll. Also shown in FIG. 4, in some examples, the motor power harness, secured to the scroll 40 can include at least one plug 67. Referring again to FIG. 5, in some examples, the one or more wires of the motor power harness 65 can be secured to the scroll using a component integral to the scroll 40. In some examples, as shown in FIG. 5, holes can be integral to the scroll to provide a guide for at least one wire of the motor power harness 65. In some examples, plastic tie-wrap can be used (as shown in FIG. 5), in addition to other methods, however in other examples, other methods can be used, such as clips, wire, wrap, or adhesive, or the like.

In other examples of the present subject matter, other useful features can be integral to the scroll 40. For example, the rear perspective view of a cartridge assembly 20 in FIG. 5 shows an anchor 100, formed within the body of the scroll. In some examples, the scroll 40 can include at least one anchor 100. In some examples, the anchor 100 can be used with a fastener (not shown), to anchor the upgrade cartridge assembly to the main housing 25. As described above, in some examples, the scroll 40 can include a retention feature 85 (also shown in FIG. 5). In some examples, the retention feature 85 can be used to secure the cartridge assembly 20 into a main housing 25 of a ventilation assembly 10. In some other examples, the retention feature 85 is not integral to the scroll, but a separate component (not shown). In some examples, the retention feature 85 can be integral with the scroll 40, however the cartridge assembly 20 can be coupled with the main housing 25 using alternative methods, for example, using at least one anchor 100. In some examples, the cartridge assembly 20 can be secured into the main housing 25 of a ventilation assembly 10 using at least one anchor 100, and at least one retention feature 85.

In some further examples of the present subject matter, other useful features can be formed integral to the scroll 40. For example, as shown in the side-rear view of a cartridge assembly 20 in FIG. 6A and FIG. 6B, the scroll features a grille spring holder 110 according to one example of the present subject matter. Referring to the exploded projection view in FIG. 15, in some examples, the grille spring holder 110 can be used with a spring 115 to conveniently secure a grille 117 to the ventilation assembly 10.

FIG. 7 is a top perspective view of a ventilation assembly 10 according to one example of the present subject matter. As discussed earlier, one or more of the examples of the cartridge assembly 20 as shown in FIGS. 1-5 can be coupled with a main housing 25 to form a ventilation assembly 10. For example, in FIG. 7, the ventilation assembly 10 is shown in perspective without the aforementioned grille 117, (shown in FIG. 15). A bottom perspective view is shown in FIG. 8, showing the bottom side of the main housing 25. In some examples, the main housing 25 can 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 examples, the main housing 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 examples, the main housing 25 can be formed from injection molded polymers, thermo-formed polymers, thermosetting polymers, or sheet metal, or any other suitable material. In some other examples, the housing can comprise a wood-based product, such as wood, or particle-board or wood laminate. In some examples, the main housing 25 can form a base or a similar support structure of the ventilation assembly 10. Furthermore, in some examples, the main housing 25 can provide points and areas of attachment for the cartridge assembly 20, or other components of the assembly 10.

In some examples, the ventilation assembly 10 can include a duct connector assembly 270, comprising a first end 274 coupled with the main housing 25, and the blower outlet 55 (not shown), and a second end 276, forming a ventilation orifice 272. In some examples, the duct connector assembly 270 is pre-installed in a building structure and the duct connector assembly is coupled with a ventilation duct of a building with the second end 276 of the duct connector assembly 270. In some examples, the main housing 25 is firstly installed in an existing cavity or aperture of a structure such as a wall or ceiling. Subsequently the duct connector assembly 270 is installed by connecting a second end 276 with a ventilation duct of a building, and a first end 274 with an aperture in the main housing 25 (not shown). Installation is completed by securing a fan cartridge assembly 20 substantially in the main housing, positioning the blower outlet 55 adjacent to the first end 274 of the duct connector assembly 270 installed adjacent to an aperture of the main housing 25.

Moreover, as shown in FIG. 7, illustrating a top perspective view of a ventilation assembly 10 according to one example of the present subject matter, the duct connector assembly can comprise a damper flap 280. In some examples, the ventilation assembly 10 can be operable to discharge fluid flow from a space to another location. For example, in some examples, when power is provided to the cartridge assembly 20, a motor 30, such as a permanent split capacitor motor 30, can rotate a blower wheel 50 positioned substantially within a scroll 40. Fluid flow is moved substantially towards the duct assembly, and the moveable damper flap 280 coupled with a ventilation orifice 272 will open, allowing fluid to be expelled from the ventilation assembly 10. In some examples, the damper flap 280 can control the backflow of a fluid into the ventilation orifice 272 and the cartridge assembly 20, and further 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 discussed previously, some examples of the present subject matter comprise a cartridge upgrade assembly that includes a motor mounting plate. For example, as shown in FIG. 9, a bottom perspective view of a cartridge assembly 20 shows a motor mounting plate 70 with the fan cartridge upgrade assembly 20 components mounted to the motor mounting plate 70. In some examples, the scroll 40 includes at least one screw boss 90 which provides an anchoring feature for a fastener 73 to secure the scroll 40 to the motor mounting plate 70. As shown in FIG. 9, a permanent split capacitor motor 30 is mounted on the opposite side of the motor mounting plate 70, and the second end 62 of the main drive bolt can be seen at the base of the motor 30.

As described previously, it can 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, if the fan produces excessive vibration or noise during operation. 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. By providing a ventilation assembly 10 that comprises a fan cartridge assembly 20 with certain attachment and detachment features, replacement or upgrade can be a faster and less complex task. For example, as discussed earlier, some examples of the present subject matter include a scroll 40 with a retention feature 85 (see FIG. 2 and FIG. 5). In some examples of the present subject matter, a cartridge assembly 20 is secured into a main housing 25 using at least one retention feature 85. For example referring to FIG. 10 showing a side perspective view of a ventilation assembly 10 according to one example of the present subject matter, the retention feature 85 can be seen engaged into an aperture in the main housing 25. In some examples of the present subject matter, one or more retention feature 85 can retain the cartridge assembly 20 in a main housing 25 without the use of additional tools or hardware. As discussed previously, the retention feature 85 can be an integral part of the scroll 40, or can be a separate component. FIG. 10B shows a close-up view of a side of a ventilation assembly 10 according to one example of the present subject matter, and the retention feature 85 can be seen exiting the main housing 25. FIG. 10C is a close-up top view of the ventilation assembly 10 according to one example of the present subject matter showing a retention feature 85 as an integral part of the scroll 40, engaged with the main housing 25. Some examples of the present subject matter provide a ventilation exhaust fan comprising a fan cartridge assembly 20 having at least one permanent split capacitor motor, at least one permanent split capacitor electrically coupled to the motor, a motor harness including at least one plug, and a blower wheel coupled with a scroll, coupled with the motor to generate a flow of fluid out of the fluid outlet. In some examples, the motor 30 is electrically coupled to a motor power harness 65 that is electrically coupled to the capacitor 35. In some examples, the cartridge assembly 20 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 examples, the cartridge assembly 20, can be installed as a new, or a replacement ventilation system, and in some examples, the cartridge assembly 20 can replace an existing cartridge assembly 20. Furthermore, in some examples, the main housing 25 can provide points and areas of attachment for the upgrade cartridge assembly, or other components of the assembly 10. In some examples, when the main housing 25 is installed, an electrical box enclosure 210 is positioned within the main housing to provide a source of electrical power to the capacitor 35 and motor 30. In some examples, the electrical box enclosure 210 can comprise an electrical box cover plate 200, an electrical box anchoring tab 240 to secure the electrical box cover plate 200 to the electrical box enclosure 210. The electrical box cover plate 200 can be seen in more detail in FIG. 12. As show, in some examples, electrical box attachment screw holes 230a and 230b are included and used with a fastener (not shown) to secure the electrical box cover plate 200 to the main housing 25. Furthermore, electrical box anchors 220a and 220b can be used to anchor the electrical box enclosure 210 to the main housing 25. In some examples, the electrical box enclosure 210 includes a power receptacle 250.

In some examples, when the main housing 25 is installed, an electrical box enclosure 210 is positioned within the main housing and the internal wiring of the main housing (not shown) is coupled with an electrical power supply to supply electrical power to the power receptacle 250. As described earlier, in some examples of the present subject matter, a fan cartridge assembly 20 can include a motor power harness 65 that can be secured, with at least one feature integral to the scroll. Also shown in FIG. 4, in some examples, the motor power harness, secured to the scroll 40 can include at least one plug 67.

In some examples of the present subject matter, the main housing can be pre-installed by inserting into a cavity or aperture of a structure. In some examples, following assembly and installation of at least the main housing 25, the installer can connect one or more terminals of the power receptacle 250 to an external source of electrical power. The electrical box enclosure 210 and the electrical box cover plate 200 can be fully assembled, and the power receptacle 250 can be coupled to the external power source. The installer can maneuver the cartridge assembly 20 in the main housing 25 and the plug 67 can be coupled with the power receptacle 250. In some examples, the plug 67 can be coupled with the power receptacle 250, and then the installer can maneuver the cartridge assembly 20 in the main housing 25. In some examples, once the cartridge assembly 20 has been maneuvered into the main housing 25, one or more cartridge snap retention features 85 can be used to secure the cartridge assembly 20 into a main housing 25 of a ventilation assembly 10. In some other examples, the ventilation assembly 10 can be fully assembled and installed directly into a cavity or aperture of a structure.

As discussed earlier, in some examples of the present subject matter, the ventilation assembly 10 can include a duct connector assembly 270, comprising a first end 274 coupled with the main housing 25, and the blower outlet 55, and a second end 276, forming a ventilation orifice 272. In some examples, the main housing 25 is firstly installed in an existing cavity or aperture of a structure such as a wall or ceiling. Subsequently, the duct connector assembly 270 is installed by connecting a second end 276 with a ventilation duct of a building, and a first end 274 with an aperture in the main housing 25 (not shown). Installation is completed by securing a fan cartridge assembly 20 substantially in the main housing, positioning the blower outlet 55 adjacent to the first end 274 of the duct connector assembly 270 installed adjacent to an aperture of the main housing 25. In some examples, the duct connector assembly 270 is pre-installed in a building structure and not pre-installed in the main housing 25 of a ventilation assembly 10. As shown in FIG. 13A and FIG. 13B, in some examples, the duct connector assembly 270 can comprise damper flap 280 that is rotatable within the duct connector assembly 270, and in some examples, can further include a duct snap mounting assembly 290. In some examples, the ventilation assembly 10 can be fully assembled and include a duct connector assembly 270 including a duct snap mounting assembly 290. As shown in FIG. 14A, one example showing a close-up view of a duct connector 270 assembly installed in a main housing 25 viewed from within the main housing 25, with the duct snap mounting assembly 290 forcibly securing the duct connector assembly 270 to the main housing 25. FIG. 14B and FIG. 14C show the outside view of the fully assembled ventilation assembly 10. FIG. 14B is a close-up view of a duct connector assembly installed in a main housing according to one example of the present subject matter, and shows a duct connector tab 295 coupled with the main housing 25 when the duct connector assembly 270 is fully installed in the main housing 25. FIG. 14C is a close-up view of a duct connector assembly installed in a main housing according to one example of the present subject matter showing a portion of the duct snap mounting assembly 290 extending outside of an aperture in the main housing 25 as the assembly 290 forcibly secures the duct connector assembly 270 to the main housing 25.

FIG. 15 shows an exploded view of a ventilation assembly 10 according to one example of the present subject matter. Referring to the exploded projection view showing the grille spring holder 110, (shown previously for example in the side-rear view of a fan cartridge assembly 20 in FIG. 6A and FIG. 6B), once the ventilation assembly installation has been completed, a spring 115 can be used to conveniently secure a grille 117 to the ventilation assembly 10. In some other examples, the grille 117 can be secured to the ventilation assembly 10 with more than one spring 115 and more than one grille spring holder 110. In some other examples, the grille 117 can be secured to the ventilation assembly 10 by some other component, such as a clip, a wire, a wrap, or adhesive, or the like. In some examples, the grille 117 can be formed from injection molded polymers, thermo-formed polymers, thermosetting polymers, or sheet metal, or any other suitable material.

Some examples of the present subject matter provide a ventilation assembly 11 comprising alternative examples of the upgrade cartridge assembly 22. For example, FIGS. 16 and 17 show exploded views of ventilation exhaust fan assembly 11 according to another example of the present subject matter, and FIGS. 18 and 19 show exploded views of the upgrade cartridge assembly 22 according to another example of the present subject matter. In this instance, the upgrade cartridge assembly 22 can include a motor bracket that is an integral part of the motor plate 71. As used herein, “integral” means a single, substantially homogenous piece of material manufactured in one step.

Moreover, the assembly 22 can be provided to a customer so that there is no need to assemble the blower. This is different from the cartridge assembly 20 described earlier, and illustrated in FIGS. 3-5, and 9. In some examples, the ventilation assembly 10 generally can include an upgrade cartridge assembly 22, substantially housed within the main housing 25, and positioned within the main housing 25. Furthermore, in some examples, the main housing 25 can provide points and areas of attachment for the cartridge assembly 20, or other components of the assembly 11.

In some examples, the upgrade cartridge assembly 22 generally can include a motor 30, such as a permanent split capacitor motor 30, and a motor capacitor 35. Some examples provide a ventilation assembly 11 that can also include a scroll portion 41 that can be integral with the housing 25, and a blower wheel 50 mechanically coupled to the motor 30.

In some examples, the ventilation assembly 11 can be operable to discharge fluid flow from a space to another location. For example, in some examples, when power is provided to the upgrade cartridge assembly 22, the motor 30 can rotate the blower wheel 50 positioned substantially within the scroll portion 41 of the housing 25. Fluid can be moved substantially towards the outlet 27. A duct assembly (such as the duct assembly 270 with moveable damper flap 280) can be coupled to the outlet 27, and the flap 280 can open, allowing fluid to be expelled from the ventilation assembly 11. In some examples, the damper flap 280 can at least partially control the backflow of a fluid into the upgrade cartridge assembly 22, and can further 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. FIG. 20A shows a top view of a motor plate 71 illustrating cross-sections cut lines according to one example of the present subject matter. As described earlier, a motor bracket can form an integral part of the motor plate 71. Moreover, the plate forms a deep inlet venturi that can straighten air as it flows into the wheel 50, and can allow the use of a wider blower wheel 50. Cross-sectional views of the plate 71 enable the geometry of the plate to be visualized in more detail. For example, FIGS. 20B-20E include views of the motor plate 71 of the upgrade cartridge assembly 22. FIG. 20B illustrates a cross-sectional view of the motor plate 71 of FIG. 20A through the cut line 18-18, and FIG. 20C illustrates a cross-sectional view of the motor plate 71 of FIG. 20A through the cut line 17-17 according to one example of the present subject matter. Further, FIG. 20D illustrates a cross-sectional view of the motor plate 71 of FIG. 20A through the cut line 19-19, and FIG. 20E illustrates a cross-sectional view of the motor plate 71 of FIG. 20A through the cut line 15-15 according to one example of the present subject matter. As illustrated, the motor plate 71 includes a cross-member positioned substantially centrally across the fluid flow inlet aperture. The motor plate 71 functions similarly to a conventional motor bracket to support the motor 30. However, the cross-member includes a bracket region that is inwardly raised and therefore can enable an attached motor 30 to be moved closer to the blower wheel 50.

In some examples, the inwardly raised bracket region can include motor mounting apertures and a motor drive shaft aperture. Further, some examples of the cross-member can include flared portions at each end coupled to the inner rim of the inlet aperture. In some examples, the cross-member can include a plurality of substantially smooth and contoured surfaces. For example, the flared regions as coupled to the inner rim of the inlet aperture can be substantially smooth and contoured, and the transition regions extending to the bracket regions can be substantially smooth and contoured. The smooth and contoured regions can reduce the operating noise of the ventilation assembly 11 by providing more laminar flow over the motor plate and into the blower wheel 50.

In some examples, the cross-member including the inwardly raised bracket region can be generally inwardly angled so as to be generally positioned closer to the blower wheel 50. In fact in some examples, the upper surface of the cross-member can be positioned in substantially the same plane as the upper surface of the outer region of the motor plate 71, and the lower surface of the cross-member can be positioned in substantially the same plane as the lower surface of the outer region of the motor plate 71 (i.e., substantially all of the bracket region is positioned between a region defined between the upper and lower surfaces of the outer region of the motor 71.

Some examples of the ventilation assembly 11 include a coupled grille. For example, as shown in the exploded views of FIGS. 16 and 17, the ventilation exhaust fan assembly 11 can include a grille 118. Further, FIGS. 21A-21E illustrate various views of a ventilation assembly grille 118 according to another example of the present subject matter. In some examples, following installation, a spring can be used to conveniently secure the grille 118 to the ventilation assembly 11. In some other examples, the grille 118 can be secured to the ventilation assembly 11 with more than one spring 115, and more than one grille spring holder. In some other examples, the grille 118 can be secured to the ventilation assembly 11 by some other component, such as a clip, a wire, a wrap, or adhesive, or the like. The grille 118 can be formed from materials as outlined above for the grille 117 including injection molded polymers, thermo-formed polymers, thermosetting polymers, or sheet metal, or any other suitable material.

It will be appreciated by those skilled in the art that while the present subject matter has been described above in connection with particular examples and examples, the present subject matter is not necessarily so limited, and that numerous other examples, examples, uses, modifications and departures from the examples, examples and uses are intended to be encompassed by the preceding description.

VARIOUS NOTES & EXAMPLES

Example 1 can include subject matter, such as a ventilation assembly 10 can include a main housing 25 and a cartridge assembly 20 that can be substantially housed within the main housing 25. The cartridge assembly 20 can include a motor 30 and a retention feature 85 that can be coupled to the main housing 25 to releasably retain the cartridge assembly 20 within the main housing 25. The cartridge assembly 20 can be disengaged from the retention feature 85 such that the motor 30 can be removed from the main housing 25.

Example 2, the ventilation assembly 10 according to Example 1, wherein the cartridge assembly 20 optionally further includes a blower wheel 50 mechanically coupled to the motor 30 such that the motor 30 is operable to rotate the blower wheel 50 to generate an outflow.

Example 3, the ventilation assembly 10 according to Example 2, wherein the cartridge assembly 20 optionally further includes a scroll 40 positioned over the blower wheel 50 to direct the outflow through an blower outlet 55 in the main housing 25.

Example 4, the ventilation assembly 10 according to Example 3, wherein the retention feature 85 is integral to the scroll 40.

Example 5, the ventilation assembly 10 according to any one or more of Examples 1 to 4, wherein the cartridge assembly 20 includes a split capacitor 35.

Example 6, the ventilation assembly 10 according to Example 5, wherein the cartridge assembly 20 includes a motor power harness 65. The motor 30 and split capacitor 35 are mounted to the motor power harness 65.

Example 7, the ventilation assembly 10 according to Example 6, wherein the scroll 40 provides an anchoring location for coupling the motor power harness 65 to the scroll 40.

Example 8, the ventilation assembly 10 according to any one or more of Examples 3 to 7, wherein the scroll 40 provides an anchor 100 for receiving at least one fastener to mount the cartridge assembly 20 to the main housing 25.

Example 9, the ventilation assembly 10 according to any one or more of Examples 3 to 8 further including a motor mounting plate 70 for receiving the cartridge upgrades assembly 20.

Example 10, the ventilation assembly 10 according to Example 9, the scroll 40 further including at least one screw boss 90 for receiving at least one fastener 73 to secure the scroll 40 to the motor mounting plate 70.

Example 11, the ventilation assembly 10 according to Example 10, wherein the motor 30 is mounted to the motor mounting plate 70 opposite the scroll 40.

Example 12, the ventilation assembly 10 according to any one or more of Examples 1 to 3, wherein the main housing 25 optionally further includes at least one fan cartridge locating rib 80 being engagable to the cartridge assembly 20 to position the cartridge assembly 20 within the main housing 25.

Example 13, the ventilation assembly 10 according to any one or more of Examples 3 to 12 further including a grille 117 and a spring 115 for coupling the grille 117 to the cartridge assembly 20.

Example 14, the ventilation assembly 10 according to Example 13, wherein the scroll 40 includes a grille spring holder 110 being engagable to the spring 115 to couple the grille 117 to the scroll 40.

Example 15, the ventilation assembly 10 according to any one or more of Examples 1 to 14, further includes a duct connector assembly 270 including a first end 274 coupled to the main housing 25 and a second end 276. The second end 276 connectable to a ventilation duct.

Example 16, the ventilation assembly 10 according to Example 15 further including a duct connector assembly 270 defining a ventilation orifice 272 between the first end 274 and the second end 276.

Example 17, the ventilation assembly 10 according to Example 16 further includes a damper flap 280 positioned within the ventilation orifice 272 and movable between an open position to permit flow of fluid through the ventilation orifice 272 and a closed position to restrict flow of fluid through the ventilation orifice 272.

Example 18, the subject matter of any one of Examples 1 to 17 can optionally include a method comprising: providing a main housing 25 having an inlet aperture; mounting the main housing 25 within at least one of a wall aperture and a ceiling aperture; inserting a cartridge assembly 20 including a retention feature 85 through the inlet aperture to position the cartridge assembly 20 within the main housing 25; coupling the retention feature 85 to the main housing 25 to retain the cartridge assembly 20 within the main housing 25.

Example 19, the method of Example 18 further including disengaging the retention feature 85 from the main housing 25; and withdrawing the cartridge assembly 20 from the main housing 25 through the inlet aperture.

Example 20, the method of any one or more of Example 18 to 19, wherein the cartridge assembly 20 optionally further includes a blower wheel 50 mechanically coupled to the motor 30 such that the motor 30 is operable to rotate the blower wheel 50 to generate an outflow.

Example 21, the method of any one or more of Example 20, wherein the cartridge assembly 20 optionally further includes a scroll 40 positioned over the blower wheel 50 to direct the outflow through a blower outlet 55 in the main housing 25.

Example 22, the method of any one or more of Example 21, wherein the retention feature 85 is integral to the scroll 40.

Example 23, the method of any one or more of Examples 18 to 22, wherein the cartridge assembly 20 further includes a split capacitor 35.

Example 24, the method according to Example 23, wherein the cartridge assembly 20 includes a motor power harness 65. The motor 30 and split capacitor 35 are mounted to the motor power harness 65.

Example 25, the method according to Example 23, wherein the scroll 40 provides an anchoring location for coupling the motor power harness 65 to the scroll 40.

Example 27, the method according to any one or more of Examples 20 to 25 further including inserting at least one fastener to an anchor 100 of the scroll 40 to mount the cartridge assembly 20 to the main housing 25.

Example 28, the method according to Example 27, inserting at least one fastener 73 into at least one screw boss 90 of the scroll 40 to secure the scroll 40 to the motor mounting plate 70.

Example 29, the method according to claim 28 further including mounting the motor 30 to the motor mounting plate 70 opposite the scroll 40.

Example 30, the method according to any one or more of Examples 18 to 21 further including engaging the cartridge assembly 20 with at least one fan cartridge locating rib 80 to align the cartridge assembly 20 within the main housing 25.

Examples 31, the method according to any one or more of Examples 23 to 30, providing a grille 117 and a spring 115 for coupling the grille 117 to the cartridge assembly 20.

Example 32, the method according to Example 31, wherein the scroll 40 includes a grille spring holder 110 being engagable to the spring 115 to couple the grille 117 to the scroll 40.

Example 33, the method according to any one or more of Examples 18 to 32 further including providing a duct connector assembly 270 including a first end 274 coupled to the main housing 25 and a second end 276. The method also including connecting the second end 276 to a ventilation duct.

Example 34, the method according to claim 33 further including providing a duct connector assembly 270 defining a ventilation orifice 272 between the first end 274 and the second end 276.

Example 35, the method according to Example 34 further including providing a damper flap 280 positioned within the ventilation orifice 272; moving the damper flap 280 between an open position to permit flow of fluid through the ventilation orifice 272 and a closed position to restrict flow of fluid through the ventilation orifice 272.

Each of these non-limiting examples can stand on its own, or can be combined in any permutation or combination with any one or more of the other examples.

The above detailed description includes references to the accompanying drawings, which form a part of the detailed description. The drawings show, by way of illustration, specific examples in which the present subject matter can be practiced. These examples are also referred to herein as “examples.” Such examples can include elements in addition to those shown or described. However, the present inventors also contemplate examples in which only those elements shown or described are provided. Moreover, the present inventors also contemplate examples using any combination or permutation of those elements shown or described (or one or more aspects thereof), either with respect to a particular example (or one or more aspects thereof), or with respect to other examples (or one or more aspects thereof) shown or described herein.

In the event of inconsistent usages between this document and any documents so incorporated by reference, the usage in this document controls.

In this document, the terms “a” or “an” are used, as is common in patent documents, to include one or more than one, independent of any other instances or usages of “at least one” or “one or more.” In this document, the term “or” is used to refer to a nonexclusive or, such that “A or B” includes “A but not B,” “B but not A,” and “A and B,” unless otherwise indicated. In this document, the terms “including” and “in which” are used as the plain-English equivalents of the respective terms “comprising” and “wherein.” Also, in the following claims, the terms “including” and “comprising” are open-ended, that is, a system, device, article, composition, formulation, or process that includes elements in addition to those listed after such a term in a claim are still deemed to fall within the scope of that claim. Moreover, in the following claims, the terms “first,” “second,” and “third,” etc. are used merely as labels, and are not intended to impose numerical requirements on their objects.

Method examples described herein can be machine or computer-implemented at least in part. Some examples can include a computer-readable medium or machine-readable medium encoded with instructions operable to configure an electronic device to perform methods as described in the above examples. An implementation of such methods can include code, such as microcode, assembly language code, a higher-level language code, or the like. Such code can include computer readable instructions for performing various methods. The code may form portions of computer program products. Further, in an example, the code can be tangibly stored on one or more volatile, non-transitory, or non-volatile tangible computer-readable media, such as during execution or at other times. Examples of these tangible computer-readable media can include, but are not limited to, hard disks, removable magnetic disks, removable optical disks (e.g., compact disks and digital video disks), magnetic cassettes, memory cards or sticks, random access memories (RAMs), read only memories (ROMs), and the like.

The above description is intended to be illustrative, and not restrictive. For example, the above-described examples (or one or more aspects thereof) may be used in combination with each other. Other examples can be used, such as by one of ordinary skill in the art upon reviewing the above description. The Abstract is provided to comply with 37 C.F.R. §1.72(b), to allow the reader to quickly ascertain the nature of the technical disclosure. It is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims. Also, in the above Detailed Description, various features may be grouped together to streamline the disclosure. This should not be interpreted as intending that an unclaimed disclosed feature is essential to any claim. Rather, inventive subject matter may lie in less than all features of a particular disclosed example. Thus, the following claims are hereby incorporated into the Detailed Description as examples or examples, with each claim standing on its own as a separate example, and it is contemplated that such examples can be combined with each other in various combinations or permutations. The scope of the present subject matter should be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled.

Claims

1. A ventilation assembly, comprising:

a main housing; and

a cartridge assembly comprising a motor and a retention feature, the retention feature being engagable to the main housing to substantially retain the cartridge assembly within the main housing;

wherein the retention feature is disengagable from the main housing to remove the cartridge assembly from the main housing.

2. The ventilation assembly in claim 1, the cartridge assembly further comprising a blower wheel mechanically coupled to the motor, wherein the motor is operable to rotate the blower wheel to generate an outflow from the main housing.

3. The ventilation assembly of claim 2, the cartridge assembly further comprising a scroll positioned over the blower wheel to direct the outflow through a blower outlet in the main housing.

4. The ventilation assembly of claim 3, wherein the retention feature is integral to the scroll.

5. The ventilation assembly of claim 1, the cartridge assembly further comprising a split capacitor.

6. The ventilation assembly of claim 5, the cartridge assembly further comprising a motor power harness;

wherein the motor and split capacitor are mounted to the motor power harness.

7. The ventilation assembly of claim 6, the scroll further comprising an anchoring location for coupling the motor harness to the scroll.

8. The ventilation assembly of claim 3, the scroll further comprising an anchor for receiving at least one fastener to mount the cartridge assembly to the main housing.

9. The ventilation assembly of claim 3, further comprising a motor mounting plate for receiving the cartridge upgrade assembly.

10. The ventilation assembly of claim 9, the scroll further comprising at least one screw boss for receiving at least one fastener to secure the scroll to the motor mounting plate.

11. The ventilation assembly of claim 10, wherein the motor is mounted to the motor mounting plate opposite the scroll.

12. The ventilation assembly of claim 3, further comprising a grille and a spring for coupling the grille to the cartridge assembly.

13. The ventilation assembly of claim 12, the scroll further comprising a grille spring holder engagable to the spring to couple the grille to the scroll.

14. The ventilation assembly of claim 1, wherein the main housing further includes at least one fan cartridge locating rib engagable to the cartridge assembly to position the cartridge assembly within the main housing.

15. The ventilation assembly of claim 1, further comprising a duct connector assembly comprising a first end coupled to the main housing and a second end, wherein the second end is connectable to a ventilation duct.

16. The ventilation assembly of claim 15, further comprising a duct connector assembly defining a ventilation orifice between the first end and the second end.

17. The ventilation assembly of claim 16, further comprising a damper flap positioned within the ventilation orifice, the damper flap being movable between an open position to permit flow of fluid through the ventilation orifice and a closed position to restrict flow of fluid through the ventilation orifice.

18. A cartridge assembly receivable within a main housing, comprising:

a motor; and

a retention feature, the retention feature being engagable to the main housing to substantially retain the cartridge assembly within the main housing;

wherein the retention feature is configured to be disengaged from the main housing to disengage the cartridge assembly from the main housing and remove the cartridge assembly from the main housing.

19. The cartridge assembly in claim 18, further comprising a blower wheel mechanically coupled to the motor, wherein the motor is operable to rotate the blower wheel to generate an outflow from the main housing.

20. The cartridge ventilation assembly of claim 19, further comprising a scroll positioned over the blower wheel to direct the outflow through a blower outlet in the main housing.

21. The cartridge assembly of claim 20, wherein the retention feature is integral to the scroll.

22. The cartridge assembly of claim 18, the cartridge assembly further comprising a split capacitor.

23. The cartridge assembly of claim 22, the cartridge assembly further comprising a motor power harness;

wherein the motor and split capacitor are mounted to the motor power harness.

24. The cartridge assembly of claim 23, the scroll further comprising an anchoring location for coupling the motor harness to the scroll.

25. The cartridge assembly of claim 20, the scroll further comprising an anchor for receiving at least one fastener to mount the cartridge assembly to the main housing.

26. The cartridge assembly of claim 20, further comprising a grille and a spring for coupling the grille to the cartridge assembly.

27. The cartridge assembly of claim 26, the scroll further comprising a grille spring holder engagable to the spring to couple the grille to the scroll.

28. A method for mounting a ventilation assembly, comprising:

mounting a main housing within at least one of a wall aperture and a ceiling aperture, the main housing defining an inlet aperture;

inserting the cartridge assembly into the main housing through the inlet aperture, the cartridge assembly comprising a retention feature; and

coupling the retention feature to the main housing to retain the cartridge assembly within the main housing to retain the cartridge assembly within the main housing.

29. The method of claim 28, further comprising:

disengaging the retention feature from the main housing; and

withdrawing the cartridge assembly from the main housing through the inlet aperture.

30. The method of claim 28, wherein the cartridge assembly in positioned within the main housing prior to mounting the main housing within the at least one of a wall aperture and a ceiling aperture.

31. The method of claim 28, wherein the cartridge assembly the cartridge assembly further comprises a scroll positioned over the blower wheel to direct the outflow through a blower outlet in the main housing.

32. The method of claim 28, further comprising:

mounting the motor and a split capacitor to a motor power harness; and

coupling the motor power harness to the scroll such that the motor is opposite the scroll.