ARTICULABLE FLANGE FOR VENTILATION FAN HOUSING

Abstract

A ventilation fan having a fan housing having an external wall defining an internal region configured to house a blower. The external wall has at least one sidewall having an upper edge defining an inlet aperture of the fan housing. A flange extends from the external wall upper edge to a flange outer edge and at least one aperture is defined at the intersection of the external wall and the flange.

Description

BACKGROUND

Conventional ventilation fans, such as those typically installed in a room of a building structure (e.g. a bathroom) can draw air from within an area of the room, through the fan and exhaust the air to another location, such as through a vent in the gable or roof of a home or other building structure. Many conventional ventilation fans include a fan housing defining an inlet aperture that is positioned within or adjacent an aperture formed in a wall or ceiling of the room from which air is to be drawn. Some installers of ventilations fans prefer that the fan housing have a flange at the inlet aperture. The flange can be used, for example, to cover any gap between the fan housing and the wall or ceiling in which the fan is installed. Other installers of ventilation fans prefer that the fan housing not have a flange at the inlet aperture. The absence of the flange can, for example, allow a cleaner look for the wall or ceiling. As a result, some ventilation fans are constructed in two different configurations so that one configuration will have a flange at the inlet aperture and a second configuration does not have a flange at the inlet aperture. This creates extras cost and logistical considerations. Therefore, a need exists for a ventilation fan that satisfies all installers with a single fan housing.

A full discussion of the features and advantages of the present disclosure is deferred to the following detailed description, which proceeds with reference to the accompanying drawings.

The description provided in the background section should not be assumed to be prior art merely because it is mentioned in or associated with the background section.

SUMMARY

A ventilation fan configured to be positioned adjacent to an aperture defined in a wall or a ceiling of a room of a building structure to ventilate the room, the ventilation fan comprising: a fan housing comprising an external wall defining an internal region configured to house a blower; the external wall having an upper edge and comprising at least one sidewall; the external wall upper edge defining an inlet aperture of the fan housing; a flange extending from the external wall upper edge to a flange outer edge; and at least one aperture defined at the intersection of the external wall and the flange. A blower can be situated in the internal region. The external wall can comprise a first sidewall, a second sidewall, a third sidewall and a fourth sidewall. A first flange can extend from an upper edge of the first sidewall, a second flange can extend from an upper edge of the second sidewall, a third flange can extend from an upper edge of the third sidewall, and a fourth flange can extend from an upper edge of the fourth sidewall. A receptacle aperture can be defined at the intersection of the external wall and the flange. The at least one aperture can leave one or more webs connecting the external wall to the flange. The at least one aperture can extend into both the external wall and the flange.

A ventilation fan configured to be positioned adjacent to an aperture defined in a wall or a ceiling of a room of a building structure to ventilate the room, the ventilation fan comprising: a fan housing comprising an external wall having an upper edge and comprising at least one sidewall; the external wall upper edge defining an inlet aperture of the fan housing; a flange extending from the external wall upper edge to a flange outer edge, the flange capable of extending from the external wall in one of a first position approximately perpendicular to the external wall and a second position approximately parallel to the external wall; and at least one aperture defined at the intersection of the external wall and the flange. A blower can be situated in the internal region. The external wall can comprise a first sidewall, a second sidewall, a third sidewall and a fourth sidewall. A first flange can extend from an upper edge of the first sidewall, a second flange can extend from an upper edge of the second sidewall, a third flange can extend from an upper edge of the third sidewall, and a fourth flange can extend from an upper edge of the fourth sidewall. A receptacle aperture can be defined at the intersection of the external wall and the flange. The at least one aperture can leave one or more webs connecting the external wall to the flange. The at least one aperture can extend into both the external wall and the flange.

A method for installing a ventilation fan adjacent to an aperture defined in a wall or a ceiling of a room of a building structure, wherein the ventilation fan comprises a fan housing having an external wall with an upper edge and a flange extending from the external wall upper edge, at least one aperture defined at the intersection of the external wall and the flange, the method comprising the steps of: a) reorienting the flange to a position approximately parallel to the external wall. The fan housing can be inserted into the aperture defined in the wall or ceiling. The fan housing flange can comprise a first flange, a second flange a third flange and a fourth flange and step (a) can comprise reorienting the first flange to a position approximately parallel to the external wall, reorienting the second flange to a position approximately parallel to the external wall, reorienting third flange to a position approximately parallel to the external wall, and reorienting the fourth flange to a position approximately parallel to the external wall. The fan housing flange can comprise a first flange, a second flange a third flange and a fourth flange and step (a) can comprise reorienting the first flange to a position approximately parallel to the external wall. A receptacle aperture can be defined at the intersection of the external wall and the flange and the method can further comprise the step of attaching an accessory to the receptacle aperture. The external wall can define an internal region and step (a) can comprise positioning the flange outside of the internal region.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are included to provide further understanding and are incorporated in and constitute a part of this specification, illustrate disclosed embodiments and together with the description serve to explain the principles of the disclosed embodiments. In the drawings:

FIG. 1 is a perspective view of a ventilation fan of the present disclosure.

FIG. 2 is a top view of the ventilation fan of FIG. 1.

FIG. 3 is a side view of the ventilation fan of FIG. 1.

FIG. 4 is a perspective view of a portion of the fan housing of FIG. 1.

FIG. 5 is another perspective view of the fan housing of FIG. 1.

FIG. 6 is a side view of the fan housing of FIG. 1.

In one or more implementations, not all of the depicted components in each figure may be required, and one or more implementations may include additional components not shown in a figure. Variations in the arrangement and type of the components may be made without departing from the scope of the subject disclosure. Additional components, different components, or fewer components may be utilized within the scope of the subject disclosure.

DETAILED DESCRIPTION

FIG. 1 depicts one embodiment of a ventilation fan 10 in accordance with the present disclosure. The ventilation fan 10 is configured to be positioned in a room of a building structure (not depicted) to provide ventilation for the room of the building structure. For example, the ventilation fan 10 may be positioned in sidewall or a ceiling panel of the room (not shown) and aligned with an aperture defined in the sidewall or the ceiling panel to allow the ventilation fan 10 to selectively ventilate the room. The ventilation fan 10 has a fan housing 12 with an external wall structure 14 that defines an internal region 16 of the fan housing 12. A blower 18 can be located in the internal region 16 of the fan housing 12. The external wall structure 14 is configured to define an inlet aperture 20 through which air can be drawn from the room into the fan housing 12. The external wall structure 14 is also configured to define an outlet aperture 22 through which air can exit the fan housing 12. The aperture defined in the room sidewall or the room ceiling panel is optionally shaped and dimensioned to approximately comport with the fan housing inlet aperture 20 shape and dimension.

In the depicted embodiment, the external wall structure 14 of the fan housing 12 has a first sidewall 14a, a second sidewall 14b, a third sidewall 14c and a fourth sidewall 14d approximately forming a rectangle. Each of these sidewalls 14a, b, c, d defines an upper edge 24 and a lower edge 26. The depicted external wall structure 14 further has a bottom wall 14e closing one side of the rectangle formed by the four sidewalls 14a, b, c, d at the lower edge 26 of each of those four sidewalls 14a, b, c, d. In this embodiment, the inlet aperture 20 is defined by the upper edge 24 of the four sidewalls 14a, b, c, d. Although the depicted embodiment of the external wall structure 14 has four planar sidewalls 14a, b, c, d forming a rectangle, the external wall structure 14 can have any number of sidewalls and need not be planar. In one possible embodiment, the external wall structure 14 could have a single curvilinear sidewall.

The fan housing 12 can be formed of any material known to those skilled in the art capable of withstanding varying temperatures, such as, for example, any heat radiated and/or conducted from the blower 18 and/or other components while providing structural integrity to the ventilation fan 10. In some embodiments, the fan housing 12 is formed of sheet metal, but could instead be formed of a ceramic or a polymer having a relatively high melting temperature and/or glass transition temperature. The fan housing 12 can have any shape, including a box-like or cubical shape, a hemi-spherical shape, a spherical shape, a pyramidal shape, and the like. The fan housing 12 can form a base or frame for the ventilation fan 10, thereby providing points and areas of attachment for other components of the ventilation fan 10.

In the depicted embodiment, the blower 18 is a centrifugal fan type blower configured to move air from the fan housing inlet 20 to the fan housing outlet 22 to provide ventilation to the room. However, other types of blower assemblies can be used to move air through the fan housing.

A flange 50 extends from the upper edge 24 of each of the four sidewalls 14a, b, c, d of the external wall 14 in the depicted embodiment. In particular, a first flange 50a extends from the upper edge 24 of the first sidewall 14a, a second flange 50b extends from the upper edge 24 of the second sidewall 14b, a third flange 50c extends from the upper edge 24 of the third sidewall 14c and a fourth flange 50d extends from the upper edge 24 of the fourth sidewall 15d. In other embodiments less than all of the flanges 50a, b, c, d extend from the corresponding sidewalls 14a, b, c, d. In one embodiment, a single flange 50 extends from one of the sidewalls 14a, b, c, d but none of the other sidewalls 14a, b, c, d (e.g. the first flange 50a extends from first sidewall 14a, but no flanges extend from the second sidewall 14b, the third sidewall 14c or the fourth sidewall 14d). In the depicted embodiment, the flanges 50a, b, c, d extend along the entire length of the upper edge 24 of the sidewalls 14a, b, c, d. However, other embodiments are also contemplated in which the flanges 50a, b, c, d do not extend the entire length of the sidewalls 14a, b, d, c. In the depicted embodiment, each of the flanges 50 extend along approximately the entire length of the sidewall upper edges 24. In alternative embodiments, one or more of the flanges may extend along less than the entire length of the sidewall upper edges 24. In other embodiments, a plurality of discrete flanges can extend along the upper edge 24 of one or more sidewalls 14a, b, c, d.

FIGS. 1-5 depict all of the flanges 50 in a first configuration extending approximately perpendicular to the external wall structure 14 from which they extend. More specifically, FIGS. 1-5 depict each of the flanges 50 a, b, c, d extending approximately perpendicular from sidewalls 14a, b, c, d respectively. This first configuration allows for the flanges 50 to extend laterally of the fan housing 12 after installation so that the flanges 50 can cover and hide any gaps between fan housing external wall structure 14 and the ceiling or wall panel into which the fan housing 12 is installed. In addition to covering gaps between the fan housing 12 and the ceiling or wall panel, the flanges 50 can also facilitate attachment of other portions of the ventilation fan 10. For example, the flanges 50 can provide base to which a ventilation grille (not shown) can mount. In one embodiment, the flanges 50 can define receptacle apertures, such as receptacle apertures 52 depicted in flanges 50a, c. The receptacle apertures can receive a receptacle to which the ventilation grille can mount. Alternatively, the ventilation grille can comprise magnets that attract to any one or more of the flanges 50 when the flanges 50 are comprised of a material to facilitate magnetic attraction. In another embodiment, the receptacle apertures 52 can facilitate mounting of other portions of the ventilation fan such as sensors, lighting, etc.

FIG. 6 depicts three of the four flanges 50 in a second configuration extending approximately parallel to, and alongside the external wall structure 14 to which they connect. In particular, FIG. 6 depicts flanges 50 a, b, c extending approximately parallel to the sidewalls 14a, b, c from which the respectively extend. Any one or more of the flanges 50 can be in the second position. For example, all four flanges 50a, b, c, d can be in the second position. This second position allows for installation of the fan housing 12 in a wall or ceiling without one or more of the flanges 50a, b, c, d extending laterally of the fan housing 12 for those instances in which an installer does not want one or more of the flanges 50 extending laterally.

A plurality of apertures 54 are defined at the intersection of the external wall structure 14 and the flanges 50 such that the apertures 54 are defined partially in the external wall structure 14 and partially in the flanges 50. In an alternative embodiment, the apertures 54 are not through apertures as shown, but are an area of reduced thickness compared to the surrounding material to weaken the structural integrity of those areas of reduced thickness. The apertures 54 leave a plurality of webs 56 connecting the external wall structure 14 to the flanges 50. In the depicted embodiment, the apertures 54 are defined at the intersection of each of the flanges 50a, b, c, d and their respective sidewalls 14a, b, c, d. In alternative embodiments, the apertures 54 are defined at the intersection one or more of the flanges 50 and respective sidewalls 14, but less than all of the flanges 50 and respective sidewalls 14.

The apertures 54, where present, reduce the total amount of material at the intersection of the external sidewall 14 and the flanges 50. As a result, only the webs 56 connect those flanges 50 to their respective sidewalls 14. This reduced material allows for the flanges 50 to be readily moved from the first configuration (i.e. approximately perpendicular to the sidewalls 14) to the second configuration (i.e. approximately parallel to the sidewalls 14), or anywhere in between those two configurations, and back again. Because the apertures 54 are located precisely at the intersection of the sidewalls 14 and the flanges 50, the bend of the webs 56 is precisely at the intersection of the external sidewall 14 and the flanges 50. As a result, the second position locates the flanges 50 immediately adjacent to the sidewalls 14, even where the flanges 50 meet the sidewall 14, as show, for example, in FIG. 6. This configuration provides a tight, clean bend that prevents unnecessary bulging of the webs 56 or flanges 50 beyond the external sidewall 14 and allows for a clean insertion of the fan housing 12 into a wall or ceiling aperture. The flanges 50 can be moved between the first and second configurations multiple times without losing this tight, clean bend. In one embodiment, one or more of the flanges 50 may be wider (in the direction extending from the sidewall 14a, b, c, d) than necessary to cover gaps between the fan housing 12 and the ceiling or wall panel in order to provide an installer with greater leverage to bend the flanges 50 from the first or second positions.

In one embodiment, all of the apertures 54 are the same length as each other and all of the webs 56 are the same length as each other. In another embodiment, the apertures 54 are approximately twice the length of the webs 56 creating a 2:1 ratio of aperture: web. In a further embodiment, the length of the apertures 54 is approximately 0.5 inches and the length of the webs is approximately 0.25 inches. In other embodiments, some of the apertures 54 can vary in length compared to others of the apertures 54, which necessarily varies the length of the webs 56.

Additional apertures such as receptacle apertures 58 may optionally be defined in at the intersection of one or more of the sidewalls 14 and the flanges 50 to allow for mounting of accessories (as discussed above). In the depicted embodiment, two receptacle apertures 58 are defined at the intersection of sidewalls 14a, c and their respective flanges 50a, c. The receptacle apertures 58 may work along or in conjunction with the receptacle apertures 52 in the flanges 50. Any combination of apertures 54 and receptacle apertures 58 may be defined at the intersection of the external wall structure 14 and the flanges 50 so long as the remaining webs 56 provide the flanges 50 with sufficient structural integrity.

In one embodiment, one or more of the flanges 50 may optionally define clearance notches 60 at the outer edge 62 of the flanges 50 to ensure that the flanges 50 do not encounter any protrusions on the fan housing 12 that would prevent the flanges 50 from folding parallel to the fan housing sidewalls 14. In the depicted embodiment, flanges 50b, d define clearance notches 60.

In one embodiment, the fan housing 12 can be provided to customers with the flanges 50a, b, c, d in the first configuration perpendicular to the sidewalls 12a, b, c, d. The customer may then install the fan housing 12 as-is. Alternatively, the customer may bend one or more of the flanges 50a, b, c, d into the second configuration parallel to the sidewalls 12a, b, c, d, or to some point between the first and second configurations, and then install the fan housing 12.

In another embodiment, the fan housing 12 can be provided to customers with the flanges 50a, b, c, d in the second configuration parallel to the sidewalls 12a, b, c, d. The customer may then install the fan housing 12 as-is. Alternatively, the customer may bend one or more of the flanges 50a, b, c, d into the first configuration perpendicular to the sidewalls 12a, b, c, d, or to some point between the first and second configurations, and then install the fan housing 12.

The various components and features described above can be combined in a variety of ways, to provide other non-illustrated embodiments within the scope of the disclosure. As such, it is to be understood that the disclosure is not limited in its application to the details of construction and parts illustrated in the accompanying drawings and described hereinabove. The disclosure is capable of other embodiments and of being practiced in various ways. It is also to be understood that the phraseology or terminology used herein is for the purpose of description and not limitation.

Although the present disclosure has been described in the foregoing description by way of illustrative embodiments thereof, these embodiments can be modified at will, without departing from the spirit, scope, and nature of the subject disclosed.

Headings and subheadings, if any, are used for convenience only and do not limit the invention. The word exemplary is used to mean serving as an example or illustration. To the extent that the term include, have, or the like is used, such term is intended to be inclusive in a manner similar to the term comprise as comprise is interpreted when employed as a transitional word in a claim. Relational terms such as first and second and the like may be used to distinguish one entity or action from another without necessarily requiring or implying any actual such relationship or order between such entities or actions.

Phrases such as an aspect, the aspect, another aspect, some aspects, one or more aspects, an implementation, the implementation, another implementation, some implementations, one or more implementations, an embodiment, the embodiment, another embodiment, some embodiments, one or more embodiments, a configuration, the configuration, another configuration, some configurations, one or more configurations, the subject technology, the disclosure, the present disclosure, other variations thereof and alike are for convenience and do not imply that a disclosure relating to such phrase(s) is essential to the subject technology or that such disclosure applies to all configurations of the subject technology. A disclosure relating to such phrase(s) may apply to all configurations, or one or more configurations. A disclosure relating to such phrase(s) may provide one or more examples. A phrase such as an aspect or some aspects may refer to one or more aspects and vice versa, and this applies similarly to other foregoing phrases.

All numbers and ranges disclosed above may vary by some amount. Whenever a numerical range with a lower limit and an upper limit is disclosed, any number and any included range falling within the range are specifically disclosed. In particular, every range of values (of the form, “from about a to about b,” or, equivalently, “from approximately a to b,” or, equivalently, “from approximately a-b”) disclosed herein is to be understood to set forth every number and range encompassed within the broader range of values. In addition, the terms in the claims have their plain, ordinary meaning unless otherwise explicitly and clearly defined by the patentee. Moreover, the indefinite articles “a” or “an,” as used in the claims, are defined herein to mean one or more than one of the element that it introduces. If there is any conflict in the usages of a word or term in this specification and one or more patent or other documents that may be incorporated herein by reference, the definitions that are consistent with this specification should be adopted.

A phrase “at least one of” preceding a series of items, with the terms “and” or “or” to separate any of the items, modifies the list as a whole, rather than each member of the list. The phrase “at least one of” does not require selection of at least one item; rather, the phrase allows a meaning that includes at least one of any one of the items, and/or at least one of any combination of the items, and/or at least one of each of the items. By way of example, each of the phrases “at least one of A, B, and C” or “at least one of A, B, or C” refers to only A, only B, or only C; any combination of A, B, and C; and/or at least one of each of A, B, and C.

In one aspect, a term coupled or the like may refer to being directly coupled. In another aspect, a term coupled or the like may refer to being indirectly coupled. Terms such as top, bottom, front, rear, side, horizontal, vertical, and the like refer to an arbitrary frame of reference, rather than to the ordinary gravitational frame of reference. Thus, such a term may extend upwardly, downwardly, diagonally, or horizontally in a gravitational frame of reference.

The title, background, brief description of the drawings, abstract, and drawings are hereby incorporated into the disclosure and are provided as illustrative examples of the disclosure, not as restrictive descriptions. It is submitted with the understanding that they will not be used to limit the scope or meaning of the claims. In addition, in the detailed description, it can be seen that the description provides illustrative examples and the various features are grouped together in various implementations for the purpose of streamlining the disclosure. The method of disclosure is not to be interpreted as reflecting an intention that the claimed subject matter requires more features than are expressly recited in each claim. Rather, as the claims reflect, inventive subject matter lies in less than all features of a single disclosed configuration or operation. The claims are hereby incorporated into the detailed description, with each claim standing on its own as a separately claimed subject matter.

The use of the terms “a” and “an” and “the” and “said” and similar references in the context of describing the invention (especially in the context of the following claims) are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. An element proceeded by “a,” “an,” “the,” or “said” does not, without further constraints, preclude the existence of additional same elements. Recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range, unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., “such as”) provided herein, is intended merely to better illuminate the disclosure and does not pose a limitation on the scope of the disclosure unless otherwise claimed. No language in the specification should be construed as indicating any non-claimed element as essential to the practice of the disclosure.

Numerous modifications to the present disclosure will be apparent to those skilled in the art in view of the foregoing description. Preferred embodiments of this disclosure are described herein, including the best mode known to the inventors for carrying out the disclosure. It should be understood that the illustrated embodiments are exemplary only, and should not be taken as limiting the scope of the disclosure.

Claims

1. A ventilation fan configured to be positioned adjacent to an aperture defined in a wall or a ceiling of a room of a building structure to ventilate the room, the ventilation fan comprising:

a fan housing comprising an external wall defining an internal region configured to house a blower;

the external wall having an upper edge and comprising at least one sidewall;

the external wall upper edge defining an inlet aperture of the fan housing;

a flange extending from the external wall upper edge to a flange outer edge and extending along the entire length of the upper edge; and

at least one aperture defined at the intersection of the external wall and the flange, wherein the at least one aperture extends into both the at least one sidewall and the flange.

2. The ventilation fan of claim 1, further comprising a blower situated in the internal region.

3. The ventilation fan of claim 1, the external wall comprises a first sidewall, a second sidewall, a third sidewall and a fourth sidewall.

4. The ventilation fan of claim 3, the flange extends from an upper edge of the first sidewall, a second flange extends from an upper edge of the second sidewall, a third flange extends from an upper edge of the third sidewall, and a fourth flange extends from an upper edge of the fourth sidewall.

5. The ventilation fan of claim 1, further defining a receptacle aperture at the intersection of the external wall and the flange.

6. The ventilation fan of claim 1, the at least one aperture leaves one or more webs connecting the external wall to the flange.

7. (canceled)

8. A ventilation fan configured to be positioned adjacent to an aperture defined in a wall or a ceiling of a room of a building structure to ventilate the room, the ventilation fan comprising:

a fan housing comprising an external wall having an upper edge and comprising at least one sidewall;

the external wall upper edge defining an inlet aperture of the fan housing;

a flange extending from the external wall upper edge to a flange outer edge and extending along the entire length of the upper edge, the flange capable of extending from the external wall in one of a first position approximately perpendicular to the external wall and a second position approximately parallel to the external wall; and

at least one aperture defined at the intersection of the external wall and the flange, wherein the at least one aperture extends into both the at least one sidewall and the flange.

9. The ventilation fan of claim 8, further comprising a blower situated in the internal region.

10. The ventilation fan of claim 8, the external wall comprises a first sidewall, a second sidewall, a third sidewall and a fourth sidewall.

11. The ventilation fan of claim 10, the flange extends from an upper edge of the first sidewall, a second flange extends from an upper edge of the second sidewall, a third flange extends from an upper edge of the third sidewall, and a fourth flange extends from an upper edge of the fourth sidewall.

12. The ventilation fan of claim 8, further defining a receptacle aperture at the intersection of the external wall and the flange.

13. The ventilation fan of claim 8, the at least one aperture leaves one or more webs connecting the external wall to the flange.

14. (canceled)

15. A method for installing a ventilation fan adjacent to an aperture defined in a wall or a ceiling of a room of a building structure, wherein the ventilation fan comprises a fan housing having an external wall with an upper edge and a flange extending from the external wall upper edge, at least one aperture defined at the intersection of the external wall and the flange, the method comprising the steps of:

a) reorienting the flange to a position approximately parallel to the external wall.

16. The method of claim 15, inserting the fan housing into the aperture defined in the wall or ceiling.

17. The method of claim 15, wherein the fan housing flange comprises a first flange, a second flange a third flange and a fourth flange and step (a) comprises reorienting the first flange to a position approximately parallel to the external wall, reorienting the second flange to a position approximately parallel to the external wall, reorienting third flange to a position approximately parallel to the external wall, and reorienting the fourth flange to a position approximately parallel to the external wall.

18. The method of claim 15, wherein the fan housing flange comprises a first flange, a second flange a third flange and a fourth flange and step (a) comprises reorienting the first flange to a position approximately parallel to the external wall.

19. The method of claim 15, wherein a receptacle aperture is defined at the intersection of the external wall and the flange and the method further comprises the step of attaching an accessory to the receptacle aperture.

20. The method of claim 15, wherein the external wall defines an internal region and step (a) comprises positioning the flange outside of the internal region.