MULTI-TAP INTEGRATED DUCT ASSEMBLY APPARATUS AND METHOD

Abstract

A multi-tap integrated duct assembly apparatus and method of using the same. A unitary integrated duct assembly comprises a louver and plenum box integrated with angular blades and weep holes. The unitary integrated duct assembly further comprises the plenum box comprising a front, a rear, and a base. The base is angled such that it slants downward from the rear to the front, wherein the plenum box is physically coupled at the front to the louver. At least two inlet members coupled to an intake end of the plenum box enable passage of air flow from an internal environment to an external environment through the blades of the plenum box. In this manner, additional ducts can be coupled to the inlet members without the use of additional plenum boxes. At least one divider segregates the air flow passing through the plenum box.

Description

BACKGROUND OF THE INVENTION

The present invention relates generally to ventilation systems and methods and more specifically to ventilation systems and methods that utilize integrated duct assemblies.

Adequate ventilation is necessary for the comfort and safety of building occupants. Ventilation involves air exchange between interior and exterior of a building as well as air circulation within the building. It is a crucial factor and is subject to an important minimum legal requirement. Methods for ventilating a building may be divided into mechanical/forced and natural types.

Many mechanical type systems use some form of direct venting that provide direct access between the inside and the exterior of a building. While such ventilation systems facilitate air exchange, rodents or other pests can get past or through them into the building structure. Such ventilation systems also suffer from penetration of moisture into the building structure.

Moisture penetration is another issue associated with mechanical type systems. Such ventilation systems can allow moisture into building causing structural damage as well as mold, mildew or other such hazardous health conditions. In addition, such ventilation systems often require more space than is available in the exterior wall of a building structure.

It is within the aforementioned context that a need for the present invention has arisen. Thus, there is a need to address one or more of the foregoing disadvantages of conventional systems and methods, and the present invention meets this need.

BRIEF SUMMARY OF THE INVENTION

Various aspects of a multi-tap integrated duct assembly apparatus and method can be found in exemplary embodiments of the present invention.

In a first embodiment, a unitary multi-tap integrated duct assembly apparatus includes a louver and a plurality of weep holes. The plurality of weep holes is preferably located at a bottom position of the louver. The louver also includes one or more blades from a bottom of the louver to a top of the louver. Each blade is spaced equally spaced apart and angled downward.

The unitary integrated duct assembly further includes a plenum box having a front, a rear, and a base. The base is angled such that it slants downward from the rear to the front, wherein the plenum box is physically coupled at the front to the louver. Air flows from an external environment to an internal environment through the louver. Moisture is removed from the internal environment to the external environment through the weep holes of the plenum box.

In one embodiment, a plurality of taps or inlet members that are coupled to an intake end of the plenum box enable passage of air flow from an internal environment to an external environment through the blades of the plenum box. In this manner, additional ducts can be coupled to the inlet members with only a single plenum box. At least one divider segregates the air flow passing from the inlet members through the plenum box.

In a further embodiment, a method includes providing a louver having multiple blades from a bottom of the louver to a top of the louver, the multiple blades spaced equally apart and angled downward, the louver also including multiple weep holes at the bottom; the method providing a plenum box with an exhaust end, an intake end, and a base. The plenum box is connected at the exhaust end to the louver, where the base is angled such that it slants downward from the intake end to the exhaust end, the moisture is removed from the plenum box through the weep holes; the method uses multiple taps or inlet members coupled to the intake end of the plenum box, to pass air flow from an internal environment to an external environment through the blades of the louver; and the method installing the inlet members as a singular unit with the plenum box.

In a further embodiment, the method includes providing at least one divider extending between the intake end and the exhaust end of the plenum box, the at least one divider segregating the air flow passing through the plurality of inlet members.

An advantage of the unitary multi-tap integrated duct assembly of the present invention is that it is easily installed as a singular unit into congested and size limited exterior walls of a building structure. The unitary multi-tap integrated duct assembly also includes a weather tight seal with the building structure. The weather tight seal is enabled by application of a self-adhering membrane package to the duct assembly.

A further understanding of the nature and advantages of the present invention herein may be realized by reference to the remaining portions of the specification and the attached drawings. Further features and advantages of the present invention, as well as the structure and operation of various embodiments of the present invention, are described in detail below with respect to the accompanying drawings. In the drawings, the same reference numbers indicate identical or functionally similar elements.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 illustrates a unitary integrated duct apparatus according to an exemplary embodiment of the present invention.

FIG. 2 illustrates a cross-section of a unitary integrated duct apparatus according to an exemplary embodiment of the present invention

FIG. 3 illustrates a cross section of a vent system employing unitary integrated duct apparatus according to an exemplary embodiment of the present invention.

FIG. 4 illustrates a cross section of a blade for use in according to an exemplary embodiment of the present invention.

FIG. 5A illustrates a self-adhering membrane installation process in accordance with an exemplary embodiment of the present invention.

FIG. 5B further illustrates a self-adhering membrane installation process in accordance with an exemplary embodiment of the present invention.

FIG. 5C further illustrates a self-adhering membrane installation process in accordance with an exemplary embodiment of the present invention.

FIG. 5D further illustrates a self-adhering membrane installation process in accordance with an exemplary embodiment of the present invention.

FIG. 6 illustrates a cross-section of a unitary integrated duct apparatus employing a plurality of inlet members in accordance with an exemplary embodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION

Reference will now be made in detail to the embodiments of the invention, examples of which are illustrated in the accompanying drawings. While the invention will be described in conjunction with the preferred embodiments, it will be understood that they are not intended to limit the invention to these embodiments. On the contrary, the invention is intended to cover alternatives, modifications and equivalents, which may be included within the spirit and scope of the invention as defined by the appended claims. Furthermore, in the following detailed description of the present invention, numerous specific details are set forth to provide a thorough understanding of the present invention. However, it will be obvious to one of ordinary skill in the art that the present invention may be practiced without these specific details. In other instances, well-known methods, procedures, components, and circuits have not been described in detail as to not unnecessarily obscure aspects of the present invention.

FIG. 1 illustrates a unitary integrated duct apparatus 100 according to an exemplary embodiment of the present invention.

In FIG. 1, unitary integrated duct apparatus 100 includes a louver 101 and plenum box 105 coupled to the inside of louver 101. In this embodiment, louver 101 and plenum box 105 are integrated such that the unitary integrated duct apparatus 100 is installable on an exterior wall of a building as a single assembly.

Louver 101 is itself comprised of rectangular or square-shaped frame 102 that engages a plurality of blades 104 extending from one side of the frame to the other along its front face. Each blade of the plurality of blades 104 is positioned with a downward angle such that air can pass through them without debris directly entering the building past the blades 104.

Blades 104 are also spaced at a distance to reduce external moisture from entering plenum box 105, and to allow for ventilation. Although not shown, one of ordinary skill in the art will realize that louver 101 may be any shape or configuration consistent with the spirit and scope of the present invention.

In FIG. 1, unitary integrated duct apparatus 100 further includes a J-molded frame 102 protruding from an outside of louver 101, the J-molded frame having weep holes 103 at its own bottom face. An advantage of the present invention is that weep holes 103 enable shedding of water that is driven into the unitary integrated duct apparatus 100 from external wind and/or rain. Although shedding of moisture is accomplished via weep holes 103, a person skilled in the art will realize that said shedding of moisture can be implemented via other means consistent with the spirit and scope of the present invention.

In FIG. 1, plenum box 105 is positioned such that it slants toward weeping holes 103 to enable water driven into unitary integrated duct apparatus 100 to be discharged to the exterior of the building. It is evident by the above described assembly of unitary integrated duct apparatus 100, water can be removed from the inside of plenum box 105 via weep holes 103 to the exterior of the building. Unlike conventional systems which retain water within the plenum box, causing mold and other unhealthy conditions, the present invention discharges entrained moisture to prevent unhealthy spore conditions as well as provide building stability.

Unitary integrated duct apparatus 100 further provides improvements over conventional systems as a result of being a singular assembly. Conventional systems can require adaptation of an existing plenum box in order to attach a louver.

According to one embodiment, unitary integrated duct apparatus 100 is two inches deep and can fit into an exterior wall with water tight application. The unitary integrated duct assembly of the present invention overcomes disadvantages faced by prior systems, including ineffective water tight seals. Such disadvantages are related to small sized louvers required due to space constraints and exterior wall thickness. In another embodiment, the unitary integrated duct assembly combines the space efficiency of smaller systems with the performance of larger systems.

FIG. 2 illustrates a cross-section 200 of a unitary integrated duct apparatus 100 according to an exemplary embodiment of the present invention.

In FIG. 2, unitary integrated duct apparatus 100 comprises louver 101 physically coupled to and in front of plenum box 105. J-molded frame 102 is attached to the outside of louver 101, also in front of plenum box 105. J-molded frame 102 includes a plurality of blades 104 attached along its front face.

As described with respect to FIG. 1, each blade of the plurality of blades 104 is spaced apart appropriately from the next, and positioned with a downward angle. Each blade of the plurality of blades 104 is further coupled at a front end to J-molded frame 102 and coupled at a rear end to a mesh screen 201. Mesh screen 201 prevents insects or other pests from entering into the building.

In FIG. 2, louver 101 is attached to a top side 204 of plenum box 105 at an upper point 202. Louver 101 is further attached to a bottom side 205 of plenum box 105 a lower point 203. The bottom side 205 of plenum box 105 is angled toward louver 101 at a downward angle 206 to enable draining of water through weep holes 103 (as in FIG. 1).

Although the plenum is box-shaped, one skilled in the art will realize that plenum box 105 may have other configurations, shapes, molds, etc. so long as such adaptations are consistent with the spirit and scope of the present invention.

According to one embodiment, the described components of unitary integrated duct apparatus 100 are manufactured using 26 gauge galvanized steel, and all seams are lapped and sealed with polyurethane sealant. Lapping and sealing of all seams creates a water tight seal to reduce moisture from being introduced into the building interior.

FIG. 3 illustrates a cross section 300 of a vent system employing unitary integrated duct apparatus 100 according to an exemplary embodiment of the present invention.

In FIG. 3, unitary integrated duct apparatus 100 is installed onto an exterior of building wall 301 such that plenum box 105 is positioned between exterior wall 301 and interior wall 302. An upper duct 212 is positioned between exterior wall 301 and interior wall 302, and is physically coupled to interior wall 302. Upper duct 212 includes a liner 213. Upper duct further includes a vent face 214 at its point of attachment with interior wall 302. Vent face 214 facilitates airflow between the exterior and interior of the building.

In FIG. 3, unitary integrated duct apparatus 100 attaches to exterior wall 301 at louver 101 by using a self-adhering sheet membrane. Self-adhering sheet membrane includes at least an upper sheet 210 and a lower sheet 211 for attaching unitary integrated duct apparatus 100 at louver 101 (as is explained further in FIG. 5).

FIG. 4 illustrates a cross section of a blade 104 for use in according to an exemplary embodiment of the present invention.

In FIG. 4, blade 104 comprises a lower blade face 401, middle blade face 402, and upper blade face 403. Upper blade face 403 is positioned above middle blade face 402 and coupled to middle blade face 402 at a first elbow 405. Upper blade face 403 and middle blade face 402 are connected at elbow 405 such than an angle 406 exists at first elbow 405. Lower blade face 403 is positioned below middle blade face 402 and coupled to middle blade face 402 at a second elbow 404. Lower blade face 401 and middle blade face 402 are connected at second elbow 404 such than an angle 407 exists at second elbow 404.

According to one embodiment, blade 104 can be constructed from a single piece of steel (e.g., 26 gauge galvanized steel). Lower blade face 401 is 0.5 inches long, middle blade face 402 is 1.458 inches in length, and upper blade face 405 is 0.5 inches long. First elbow 405 has an angle 406 of 143 degrees. Second elbow 404 has an angle 407 of 143 degrees. As can be seen from FIG. 4, blade 104 can be thought of as having a “Z” like shape. Such a shape enables ventilation and discourages the entry of moisture past the blade 104.

FIG. 5A illustrates a self-adhering sheet membrane installation process 500 in accordance with an exemplary embodiment of the present invention.

In FIG. 5A, surfaces of vent flange 510 and surrounding sub-straight 501 are cleaned and prepared. Preparation includes applying primer to the surfaces of vent flange 510 and surrounding sub-straight 501. Vent flange 510 includes an upper edge 502, side edge 503, side edge 504, and bottom edge 505. Preparation of surrounding sub-straight 501 includes area at least 6″ in each direction outside of edges 502, 503, 504, and 505 of vent flange 510.

FIG. 5B further illustrates a self-adhering sheet membrane installation process 500 in accordance with an exemplary embodiment of the present invention.

In FIG. 5B, a protective backing is removed from the back of a bottom piece 506 of a self-adhering sheet membrane. The bottom piece 506 is carefully adhered to vent flange 510. Bottom piece 506 is positioned such that it extends 6″ below the bottom edge 505 of vent flange 510. Bottom piece 506 is also positioned such that it extends 6″ beyond each of the side edges 503 and 504.

FIG. 5C further illustrates a self-adhering sheet membrane installation process 500 in accordance with an exemplary embodiment of the present invention.

In FIG. 5C, protective backing is removed from the backs of side pieces 507 and 508 of a self-adhering sheet membrane. Side piece 507 is carefully adhered to vent flange 510. Side piece 507 is positioned such that it extends 6″ to the left of side edge 504 (not shown), 6″ above top edge 502 (not shown), and 6″ below bottom edge 505 (not shown).

Side piece 508 is carefully adhered to vent flange 510. Side piece 508 is positioned such that it extends 6″ to the right of side edge 503 (not shown), 6″ above top edge 502 (not shown), and 6″ below bottom edge 505 (not shown).

FIG. 5D further illustrates a self-adhering sheet membrane installation process 500 in accordance with an exemplary embodiment of the present invention.

In FIG. 5D, protective backing is removed from the backs of a top piece 509 of a self-adhering sheet membrane. Top piece 509 is carefully adhered to vent flange 510. Top piece 509 is positioned such that it extends 6″ to the right of side edge 503 (not shown), 6″ to the left of side edge 504 (not shown), and 6″ above top edge 502 (not shown).

As such, unitary integrated duct apparatus 100 (not shown in FIGS. 5A-5D) can be easily mounted to the self-adhering sheet membranes attached to vent flange 510 at louver 101. It will be appreciated that, while distances depicted and described in FIGS. 5A-5D are referred to herein as being 6″, larger or smaller distances can be utilized as appropriate.

FIG. 6 illustrates a cross-section 600 of unitary integrated duct apparatus 100 employing a plurality of inlet members 608a, 608b in accordance with an exemplary embodiment of the present invention.

In FIG. 6, unitary integrated duct apparatus 100 is installed onto an exterior of building wall 301 such that plenum box 105 is positioned between exterior wall 601 and interior wall 602. Plenum box 105 is positioned between exterior wall 601 at an exhaust end 604 and interior wall 602 at an intake end 606, and is physically coupled to interior wall 602.

Unitary integrated duct apparatus 100 comprises louver 101 physically coupled to and in front of plenum box 105 at exterior wall 601. J-molded frame 102 is attached to the outside of louver 101, also in front of plenum box 105. J-molded frame 102 includes a plurality of blades 104 attached along its front face. Blades 104 are selectively opened and closed to regulate passage of air flow.

Plenum box 105 is defined by an exhaust end 604 and an oppositely disposed intake end 606. Intake end 606 is disposed to orient towards interior wall 602. Exhaust end 604 is disposed to orient towards exterior wall 601. Exhaust end 604 is defined by an opening and a plurality of blades 104 through which air flow passes through from internal environment 610 to external environment 612.

A plurality of inlet members 608a, 608b mount to an opening at intake end 606 of plenum box 105. Inlet members 608a, 608b form a singular unit with plenum box 105. A fastener, such as a screw, may be used to inlet members 608a, 608b to intake end 606 of plenum box 105.

Inlet members 608a, 608b may have difference sizes and may be sized the same or differently. Inlet members 608a, 608b may have different sizes and dimensions. Thus, inlet members 608a, 608b may be sized differently, or have substantially the same shape and dimension. In this manner, the velocity, direction, and pressure of air flow may be regulated through selection of a particularly sized and dimensioned inlet member 608a, 608b.

Further, each inlet member 608a operates independently of the other 608b to selectively enable and restrict passage of air flow.

Inlet members 608a, 608b are configured to enable passage of air flow from the internal environment 610 to the external environment 612. Inlet members 608a, 608b enable air flow to pass through plenum box 105, and out through blades 104. In one embodiment, inlet members 608a, 608b are disposed adjacently, and in a stacked vertical arrangement, as viewed from interior wall 602. Those skilled in the art will recognize that pressure and heat can build up in the internal environment 610, and a free passage through multiple, size variable inlet members 608a, 608b may be useful.

At least one divider 614 extends between the intake end and the exhaust end of plenum box 105. The at least one divider 614 is configured to segregate the air flow passing through the plurality of inlet members 608a, 608b. In this manner, air flow enters each inlet member 608a, 608b from internal environment 610 and remains segregated while passing through plenum box 105. Then after the segregated air flow passes through plenum box 105, the air flow combines to pass through exhaust end 604 of plenum box 105 and louver 101 into external environment 612.

Thus, divider 614 allows multiple inlet members 608a, 608b i.e., exhausts, to be in communication with a single plenum box 105 and louver 101, i.e., air outlet. Segregating air flow through plenum box 105 has numerous advantageous. Those skilled in the art will recognize that tying multiple inlet members 608a, 608b to the same louver 101 and plenum box 105 is necessary when only one wooden frame stud is available for installing the louver 101 and plenum box 105 to the external wall 601. Further, tying multiple inlet members 608a, 608b to the same louver 101 and plenum box 105 is a cost effective way to minimize multiple outlets for air flow.

Also shown in FIG. 6 are the lower inlet member 608b having a height of about 7″, and an upper inlet 608a having a height of about 4″. The size of inlet member 608a, 608b may indicate the function thereof. For example, a 7″ inlet member 608a may include a kitchen hood exhaust. A 3″ inlet member 608b may include a fryer exhaust. However, inlet members 608a, 608b may be used for various types of exhausts typically installed in an interior wall 602, including, without limitation, a dryer exhaust, an air conditioner exhaust, a bathroom exhaust, a greenhouse exhaust, and a factory exhaust.

In other embodiments, the size and dimension of inlet members 608a, 608b is indicative of the type of interior wall 602. For example, a 7″ inlet member 608a is installed in a 2×6 interior wall. A 3″ inlet member 608b is installed in a 2×4 interior wall.

It is significant to note that, even when employing inlet members 608a, 608b, the unitary integrated duct apparatus 100 attaches to exterior wall 601 at louver 101 through use of the self-adhering sheet membrane (as explained above in FIG. 5). In one alternative embodiment, an interior mesh screen (not shown) is positioned across inlet members 608a, 608b to prevent passage of pests from internal environment 610 to the plenum box.

While the above is a complete description of exemplary specific embodiments of the invention, additional embodiments are also possible. Thus, the above description should not be taken as limiting the scope of the invention, which is defined by the appended claims along with their full scope of equivalents.

Claims

1. A multi-tap integrated duct assembly comprising:

a louver comprising a plurality of blades from a bottom of the louver to a top of the louver, the plurality of blades spaced equally apart and angled downward;

the louver further comprising a plurality of weep holes at the bottom;

a plenum box comprising an exhaust end, an intake end, and a base;

wherein the plenum box is coupled at the exhaust end to the louver;

wherein the base is angled such that it slants downward from the intake end to the exhaust end;

wherein moisture is removed from the plenum box through the plurality of weep holes;

a plurality of inlet members, the plurality of inlet members coupled at the intake end of the plenum box, the plurality of inlet members configured to enable passage of air flow from an internal environment to an external environment through the plurality of blades of the louver; and

wherein the plurality of inlet members are installable as a singular unit with the plenum box.

2. The multi-tap integrated duct assembly of claim 1, further including at least one divider extending between the intake end and the exhaust end of the plenum box, the at least one divider configured to segregate the air flow passing through the plurality of inlet members.

3. The multi-tap integrated duct assembly of claim 2, wherein the air flow flowing from the internal environment into the plurality of inlet members is segregated by the divider through the plenum box.

4. The multi-tap integrated duct assembly of claim 3, wherein the air flow passing through each inlet member combines at the exhaust end of the plenum box.

5. The multi-tap integrated duct assembly of claim 1, wherein the plurality of inlet members have different sizes and dimensions.

6. The multi-tap integrated duct assembly of claim 1, wherein the plurality of blades are spaced equally apart and angled downward.

7. The multi-tap integrated duct assembly of claim 1, wherein each blade of the plurality of blades has a substantially flat, irregular shape.

8. The multi-tap integrated duct assembly of claim 1, wherein the unitary integrated duct assembly is installed using a self-adhering sheet membrane.

9. A method comprising:

providing a louver comprising a plurality of blades from a bottom of the louver to a top of the louver, the plurality of blades spaced equally apart and angled downward, the louver further comprising a plurality of weep holes at the bottom;

providing a plenum box comprising an exhaust end, an intake end, and a base, wherein the plenum box is coupled at the exhaust end to the louver, wherein the base is angled such that it slants downward from the intake end to the exhaust end, wherein moisture is removed from the plenum box through the plurality of weep holes;

using a plurality of inlet members coupled to the intake end of the plenum box, to pass air flow from an internal environment to an external environment through the plurality of blades of the louver; and

installing the plurality of inlet members as a singular unit with the plenum box.

10. The method of claim 9 further including at least one divider extending between the intake end and the exhaust end of the plenum box, the at least one divider configured to segregate the air flow passing through the plurality of inlet members.

11. The method of claim 10, wherein the air flow flowing from the internal environment into the plurality of inlet members is segregated by the divider through the plenum box.

12. The method of claim 9, wherein the air flow passing through each inlet member combines at the exhaust end of the plenum box.

13. The method of claim 9, wherein the plurality of inlet members have different sizes and dimensions.

14. The method of claim 9, wherein the plurality of blades are spaced equally apart and angled downward.

15. The method of claim 9, wherein each blade of the plurality of blades has a substantially flat, irregular shape.

16. The method of claim 9, wherein the unitary integrated duct assembly is installed using a self-adhering sheet membrane.