Ventilation fan mounting system

Abstract

An assembly for mounting an object in an opening in a structural member, the assembly comprising a housing containing the object, the housing having four walls and four corners intersecting adjacent walls, and a first groove formed in the first wall having a first end and a terminal end forming an opening in the adjacent wall, the first groove having a second end and a second groove formed in the second wall having a second end and a terminal end forming an opening in the adjacent wall, a first recess is formed in a first wall opposite the first wall, the opening being adjacent to a first corner formed by the first wall and an adjacent wall, and a second recess formed in a second wall opposite the first wall, the second recess having a first end and a terminal end forming an opening in the adjacent wall, the opening being adjacent to a second corner formed by the second wall and the adjacent wall.

Description

Background Art Technical Field

[0001] The present disclosure relates to mounting objects within structural members such as walls, ceilings, and more particularly to a ceiling or wall exhaust fan mounting device for simplified and safe installation.

[0002] Related technical description

[0003] Installing objects such as fans, lighting fixtures, controls, etc. inside a residence or business can be complicated and time consuming. In addition to the correct opening, the installer must adequately secure the object to the structural support. This requires the use of appropriate fasteners, tools, and proper technique, and often requires access to the backside of the surface of the structural member, such as through an attic to access the ceiling installation location. It is desirable to provide an enclosure and mounting system that allows the installer to install the enclosure from the inside of the room or space, thereby avoiding the need for the installer to access the backside of the structural member, such as entering an attic or crawl space to install the enclosure. Additionally, it is desirable to be able to install to the structural member without the use of fasteners or tools, facilitating connection to existing or new ductwork in confined spaces.

[0004] An outdated vent housing design is found in U.S. Patent No. 9,689,581, granted in 2017 to Broan-NuTone LLC, which discloses a vent housing having large vertical ear members extending from relative vertical corners of the housing. These ear members are almost as tall as the housing and extend well beyond one adjacent side of the housing. The method of attachment to the structure is through ear members or ear mounts. Ear mounts have several disadvantages, including the potential for subsequent sagging of the vent fan housing. The ear mounts hold the screws that secure the fan at a distance of 1 / 2 to 1 inch from the fan housing. This can cause the ear members to bend over time and can also cause sagging on the other side of the suspension. Ear member sagging occurs between the metal fan housing frame and the screw location.

[0005] Therefore, there is a need for an improved mounting system that overcomes the shortcomings of ear member mounting systems. Summary of the invention

[0006] The present disclosure relates to a ventilator fan mounting assembly that facilitates mounting an object such as a ventilator fan or exhaust fan in a rough opening in a structural member such as a wall or ceiling, provides an effective 120252.407P1 air seal to improve the efficiency of exhausting air and vapors through the ventilator fan, and presents an attractive aesthetic appearance after installation. According to one embodiment of the present disclosure, a housing assembly is provided that includes at least one channel or groove formed in opposing first and second side walls, each groove having a terminal end that leads to a corner formed by the respective first and second walls and an adjacent wall.

[0007] According to another aspect of the present disclosure, there is provided an assembly for mounting an object in an opening in a structural member, the structural member having first and second opposing surfaces. The assembly includes a housing sized and shaped to define an interior for accommodating the object and receivable within the opening in the structural member, the housing having four walls and having four corners at which adjacent walls of the four walls intersect; and a first groove formed in a first wall, the first groove having a first end and a terminal, the terminal forming an opening in an adjacent wall, the opening being adjacent to the first corner formed by the first wall and the adjacent wall; and a second groove formed in a second wall opposite to the first wall, the second groove having a first end and a terminal, the terminal forming an opening in an adjacent wall, the opening being adjacent to a second corner formed by the second wall and the adjacent wall.

[0008] According to another aspect of the present disclosure, the first and second grooves are concave and have an arcuate cross-sectional configuration.

[0009] According to another aspect of the present disclosure, a diameter of each of the first groove and the second groove gradually decreases from the first end to the terminal end, so that the first groove and the second groove have a larger diameter at the terminal end and a smaller diameter at the first end.

[0010] According to another aspect of the present disclosure, the housing includes a first tab extending from a distal end of the housing, the size and shape of the first tab being set to bend to bear against a first surface of the structural member; and a second tab extending from the distal end of the housing, the size and shape of the second tab being set to engage a second surface of the structural member adjacent to the opening and attach the housing to the structural member, and wherein the first and second tabs are integrally formed with at least one wall, are coplanar with the at least one wall, and are formed of a bendable material that maintains a bent shape and can be bent more than once without failure, and the thickness of the first and second tabs enables the first and second tabs to be manually bent from an original position relative to the at least one wall to an angle of at least 90 degrees.

[0011] According to another aspect of the present disclosure, there is provided an enclosure for mounting an object to a structure. The enclosure includes a plurality of walls, the plurality of walls being sized and shaped to define an interior for housing the object, and a plurality of corners at which adjacent walls of the plurality of walls intersect; and a first recess formed in a first wall, the first recess having a first end and a terminal end, the terminal end forming an opening in an adjacent wall, the opening being adjacent to a first corner formed by the first wall and the adjacent wall; and a first recess formed in a first wall ... forming an opening in an adjacent wall, the opening being adjacent to a first corner formed by the first wall and the adjacent wall; and a first recess formed in a first wall having a first end and a terminal end forming an opening in an adjacent wall, the opening being adjacent to a first corner formed by the first wall and the adjacent wall; and a first recess formed in a first wall having a first end and a terminal end forming an opening in a first wall.

[0012] A second groove is provided in a second wall opposite the first wall, the second groove having a first end and a terminal end that forms an opening in an adjacent wall, the opening being adjacent a second corner formed by the second wall and the adjacent wall.

[0013] According to yet another aspect of the present disclosure, the first and second grooves are concave and have an arcuate cross-sectional configuration.

[0014] According to yet another aspect of the present disclosure, a diameter of each of the first groove and the second groove gradually decreases from the first end to the terminal end, so that the first groove and the second groove have a larger diameter at the terminal end and a smaller diameter at the first end.

[0015] According to another aspect of the present disclosure, the housing includes a first tab extending from a distal end of the housing, the size and shape of the first tab being set to bend to bear against a first surface of the structural member, and a second tab extending from the distal end of the housing, the size and shape of the second tab being set to engage a second surface of the structural member adjacent to the opening and attach the housing to the structural member; wherein the first tab and the second tab are integrally formed with at least one wall, are coplanar with the at least one wall, and are formed of a bendable material that maintains a bent shape and can be bent more than once without failure, and the thickness of the first tab and the second tab enables the first and second tabs to be manually bent from an original position relative to the at least one wall to an angle of at least 90 degrees. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] The foregoing and other features and advantages of the present disclosure will be better understood and more clearly understood from the following detailed description when taken in conjunction with the accompanying drawings, in which:

[0017] Figure 1 is a bottom, right side, front isometric view of a ventilator fan housing having a mounting system formed in accordance with the present disclosure;

[0018] Figure 2 yes Figure 1 Bottom, left, rear axonometric view of the ventilation housing;

[0019] Figure 3 is its front view;

[0020] Figure 4 is its rear view;

[0021] Figure 5 This is its left side view;

[0022] Figure 6 This is its right side view;

[0023] Figure 7 This is its top view;

[0024] Figure 8 is its bottom plan view; and

[0025] Fig. 9 yes Figure 1 Bottom, right side, front isometric view of a ventilation fan housing attached to a structural joist using a mounting system in accordance with the present disclosure. DETAILED DESCRIPTION

[0026] In the following description, certain specific details are set forth in order to provide a thorough understanding of the various disclosed embodiments. However, one skilled in the relevant art will recognize that the embodiments may be implemented without one or more of these specific details, or with other methods, components, materials, etc. In other cases, well-known structures or components associated with the use of fans, ducts, panels, walls, ceilings, and doors, as well as frames for walls, ceilings, doors, etc., and the installation process of ceiling and wall fans are not shown or described to avoid unnecessarily obscuring the description of the embodiments.

[0027] Unless the context requires otherwise, throughout this specification and the claims that follow, the word "include" and variations such as "comprises" and "comprising" should be construed as having an open, inclusive meaning, i.e., "including but not limited to." The foregoing also applies to the words "including" and "having."

[0028] Throughout this specification, references to "one embodiment" or "an embodiment" mean that a particular feature, structure, or characteristic described in conjunction with the embodiment is included in at least one embodiment. Thus, the phrases "in one embodiment" or "in an embodiment" appearing in various places throughout this specification are not necessarily all referring to the same embodiment. Furthermore, in one or more embodiments, the particular features, structures, or characteristics may be combined in any suitable manner.

[0029] refer to Figure 1-8 , which shows a housing 10 formed by at least one wall 12 that defines an interior space 14. Ideally, when sold or installed, the fan housing 10 has a fan 100, a motor 102, and electrical connections (not shown) in the housing interior space 14, although this is not required. The at least one wall 12 is formed to have a square plan shape defined by four side walls 16, 18, 20, 22, and the side walls 16, 18, 20, 22 are preferably but not required to be orthogonal to adjacent side walls, and each side wall 16, 18, 20, 22 has a substantially square or rectangular shape. The end wall 24 is formed at the closed end of the housing 10, while the opposite side is an open end. For the purposes of this disclosure, the wall with reference number 16 is labeled as the first wall, and the opposite wall will be the second wall 20. The wall connecting the first wall 16 and the second wall 20 is referred to as the adjacent wall 22.

[0030] The cross-sectional configuration of the housing is square to form a square plan shape. It should be understood that the cross-sectional shape can vary from a circle to any number of sides (polygons) and other geometric shapes, such as a triangle (having three sides) or a square, and the three-dimensional housing shape can take other forms, such as a cone.

[0031] Each of the side walls 16, 18, 20, 22 has a distal end 40 on which a plurality of tabs are formed, including a central tab 32, a pair of intermediate tabs 34, and a pair of outer tabs 36, wherein the intermediate tabs 34 are on each side of the central tab 32 and adjacent to the central tab 32, and each outer tab 36 is adjacent to a corresponding intermediate tab 34. Although referred to as tabs, it should be understood that the tabs can be flanges, tabs, strips, or similar components. If desired, each tab 32, 34, 36 has an optional opening 38 for a fastener. The housing 10 is preferably constructed of a material such as aluminum or other material having similar properties, and its thickness allows the tabs to be manually bent around the support legs as described below, so that the housing 10 can be mounted to a structural member as also described below. The intermediate tabs 34 and the outer tabs 36 extend upward to terminate evenly at the distal edges 44 of their respective walls 16, 18, 20, 22.

[0032] Ideally, when initially formed, each tab 32, 24, 36 is coplanar with its corresponding wall 16, 18, 20, 22. However, the tabs 32, 24, 36 have different bendable lengths and different bend lines to limit the length of the tabs when the tabs are reset to the bent configuration. Ideally, the tabs 32, 34, 36 are formed to bend at an angle of approximately 90 degrees, orthogonal to the corresponding wall 16, 18, 20, 22 formed with them. For example, the center tab 32 has one or more elongated openings 40 formed at the intersection of the center tab 32 and the corresponding wall 16, 18, 20, 22. The size and shape of these openings 40 are designed for design choice and aesthetic considerations. The legs 42 support the tab 32 on the wall 16, 18, 20, 22 and can be bent due to manual force applied to the tab 32. The manual force is preferably the force of a human hand or a finger of a human hand. Thus, the center tab 32 can be repositioned by manually bending about the leg 42 in either direction within a range of approximately 180 degrees, and more preferably orthogonal to the respective wall 16, 18, 20, 22 toward the interior 14 or exterior of the housing 10, as will be more fully described below.

[0033] The center tab 32 extends a sufficient distance beyond the terminal or distal edge 44 of the respective wall 16, 18, 20, 22 so that when the housing 10 is placed in the rough opening, the center tab 32 extends downwardly below the outer surface of the structural member (in this case, a ceiling or wall).

[0034] The middle tab 34 is formed by two longitudinally elongated openings 46, 48 of equal length on each side of the middle tab 34. An elongated opening 40 is formed below the middle tab 34 to form two support legs 42, the size and shape of the support legs 42 being set to yield to the manual force applied to the middle tab 34 and bend upward and exceed an angle of 90 degrees, such as about 180 degrees in either direction (limited by the bend margin). In this way, the tab 34 can be reset to any angle from 0 degrees to about 180 degrees or -180 degrees relative to the wall 22, including preferably 90 degrees or right angles. When reset, the length of the middle tab 34 is determined by the distance of the corresponding opening 40 from the distal edge 44 of the corresponding wall 16, 18, 20, 22.

[0035] The outer tab 36 is formed by two longitudinal openings 50, 52 of equal length on either side. The longitudinal opening 48 is longer than the adjacent longitudinal opening 50 and connects the longitudinal openings 50 with a stepped bottom edge 54. Thus, the outer tab 36 is supported by two legs 42, as are the other tabs, and the two legs are separated by the elongated opening 40. The legs 42 bend near the elongated opening 40, as are the legs of the other tabs 32, 34. However, due to the length of the longitudinal openings 50, 52, the outer tab 36 is longer than the middle tab 34, and when a force is applied to the tab 36 and the legs 42 bend in either direction, this forms a larger tab 36. Like the center tab 32 and the middle tab 34, the outer tab 36 can be bent approximately 180 degrees in either direction relative to the corresponding wall 16, 18, 20, 22 (taking into account the bending allowance). In this design, the outer tabs 36 have a width of approximately 1 / 2 inch when bent about the legs 42, and the middle tabs 34 have a width of approximately 5 / 8 inch when bent about their supporting legs 42.

[0036] As shown, the duct opening 60 is formed in one of the walls (in this case, the longer wall 20) and adjacent to one edge of the wall 20. The opening can be round or square, although nearly any geometric or irregular shape can be used as desired. On opposite sides of the ventilation duct opening 60 are two L-shaped guides 62, each having a leg 64 spaced from the wall 20 to form a connection for a ventilation duct connector 68 (such as Fig. 9 shown) and grooves or tracks for pipes (not shown).

[0037] The housing includes a plurality of corners 91 where two of the plurality of walls 16, 18, 20, 22 intersect. A pair of first grooves 92 are provided in the first wall 16, and each of the first grooves 92 has a first end 94 and a terminal end 96, the terminal end forming an opening in the adjacent wall 22, the opening being adjacent to the corner 91 formed by the first wall 16 and the adjacent wall 22. A second pair of grooves 92 are formed in the second wall 20 opposite to the first wall 16, and each of the second pair of grooves 92 has a first end 94 and a terminal end 96, the terminal end forming an opening in the adjacent wall 22, the opening being adjacent to the second corner 91 formed by the second wall 20 and the adjacent wall 22.

[0038] Ideally, the first and second pairs of grooves 92 are concave and have an arcuate cross-sectional configuration. Preferably, the diameter of each groove 92 tapers from the terminal 96 to the first end 94, so that each groove 92 has a larger diameter at the terminal 96 and a smaller diameter at the first end 94.

[0039] Installation Process

[0040] like Fig. 9 As shown, if the sheet rock is to be installed before it is placed on the ceiling or wall, the following steps are used. In this example, it is assumed that 5 / 8 inch sheet rock will be attached to the ceiling joist 90. To place the sheet rock, the two center tabs 34 are bent outward, i.e., away from the interior 14 of the housing 10. Ideally, the center tabs are bent at 90 degrees or perpendicular to the adjacent wall 22.

[0041] Next, the metal fan housing 10 is placed on the floor joists or trusses 90 and pushed upward until the two bent tabs 34 bear against the 2 inch bottom of the joists or trusses 90 and the adjacent walls 22 press against the sides of the joists or trusses 90. The housing 10 is held in place and wood screws are secured into the second ends 96 of the grooves 92 through the adjacent walls 22 and into the trusses or joists 90. Although there are two grooves 92 on the first wall 16 and two grooves 92 on the second wall 20 of the fan housing 10, it should be understood that more or less than two grooves 92 may be formed in the housing. Similarly, not all of the grooves 92 need to be used in the grooves 92 on the housing 10.

[0042] Installation using only tabs may also be performed as disclosed in applicant's prior US Pat. No. 11,015,822, which is hereby incorporated by reference in its entirety, as described below.

[0043] In short, a rough opening is formed in a structural member (here, a ceiling) into which the fan and the fan housing in which the fan resides will be mounted. The structural member can be a ceiling, wall, soffit, or other structural member of a residential or commercial building. Generally, these structural members are constructed of sheet rock or other interior wall or ceiling materials with a typical thickness of 1 / 2 inch or 5 / 8 inch. The rough opening can be created for a new installation, or it can be an existing rough opening after an old fan has been removed. In either case, preparations are made for installing the fan 100 and housing 10 of the present disclosure by sizing the rough opening to the correct size for the housing 10.

[0044] After the rough opening is prepared, the fan 100 and the housing 10 in which the fan is located are slid into the rough opening. The duct connector 68 is either already installed on the housing 10 as described above, or it can be installed by aligning the notch with the upper L-shaped leg 62 and then sliding the duct connector 68 downward until it hits a stop extending from the wall 20. The duct connector 68 can be installed before or after the housing 10 is placed through the rough opening. The duct connector 68 is then coupled to the duct (not shown) by sliding the open end of the duct over the nozzle portion of the connector 68.

[0045] Then, when the thickness of the structural member or sheet rock is 5 / 8 inch, the installer repositions all of the middle tabs 34 to an orientation of approximately 90 degrees to the corresponding wall 16, 18, 20, 22. Alternatively, when the structural member has a thickness of approximately 1 / 2 inch, the installer repositions the outer side tabs 36 to an orientation of approximately 90 degrees to the corresponding wall 16, 18, 20, 22. In either case, the tab 34 or 36 is repositioned in an outward direction, away from the interior space 14 of the housing 10.

[0046] The housing 10 can now be placed over the rough opening and will be supported on the top or attic side of the ceiling by the respective middle tabs 34 or outer tabs 36. In this example, the outer tabs 36 are used due to the thickness of the ceiling material 120252.407P1. Next, the installer will reposition the center tab 32 outward, away from the interior 14 of the housing 10, to bear against the bottom or room side of the ceiling, thereby sandwiching the ceiling sheet rock between the center tab 32 and the respective middle tab 34 or outer tab 36, as the case may be.

[0047] A key feature associated with the enclosure design is that this installation can always be done from the room side, with no screws or lofting required. Again, this is particularly useful in situations where tools are sometimes unavailable. The tabs can be repositioned or bent more than once, ideally two, three or more times, without failure due to fatigue, to facilitate removal and reinstallation as needed.

[0048] As will be readily appreciated from the foregoing, this design allows the installer to place the fan housing 10 upwardly in the rough opening and remove it to access the ductwork and electrical connections. Preferably, eight intermediate or outer tabs 34, 36 hold the housing 10 in the opening from the attic or interior wall side, and the center tab 32 is used to secure it to the sheetrock on the room side. However, it should be appreciated that more or less than eight intermediate or outer tabs may be used as desired.

[0049] The electrical connections are oriented toward the room side so they can be connected from the room side. Another unique feature is the sheetrock grab with tabs. The notches on the duct connector allow for a slide-in installation of the duct connector 68 and room side electrical for a true combined "room side" installation or retrofit. This design and method is ideal for new construction where access to studs and attics is possible. This level of ease of room side installation is unprecedented.

[0050] Another unique feature of this design is that the plastic has two notches so the installer does not need to lift the plastic too high to begin installation on the four metal tracks. This feature allows for shallow opening installations.

[0051] The weight of the fan body and the pinching of the metal tabs are sufficient to overcome the low vibration of the fan.

[0052] It should be appreciated that various aspects of the housing 10 and ventilation duct connector 68, both individually and in combination, provide an aesthetic appearance that transcends any functionality associated therewith. Non-limiting examples include radius of curvature, symmetry and balance, use of geometric shapes not dictated by function, and the like.

[0053] Furthermore, by utilizing these two features together, the grooves and tabs can be combined for mounting the housing 10. Thus, the installer will have multiple options for mounting the housing 10.

[0054] The various embodiments described above can be combined to provide additional embodiments. These and other changes can be made to the embodiments in light of the detailed description above. In general, in the following claims, the terms used should not be interpreted as limiting the claims to the specific embodiments disclosed in the specification and claims, but should be interpreted to include all possible embodiments and these claims.

[0055] The claims are therefore not limited by this disclosure.

Claims

1. An assembly for mounting an object in an opening in a structural member, the structural member having a first surface and a second surface opposed to each other, the assembly comprising: an enclosure sized and shaped to define an interior for housing the object and receivable within the opening in the structural member, the enclosure having four walls and having four corners at which adjacent walls of the four walls intersect; as well as a first groove formed in the first wall, the first groove having a first end and a terminal end, the terminal end forming an opening in the adjacent wall, the opening being adjacent to a first corner formed by the first wall and the adjacent wall; and a second groove formed in a second wall opposite to the first wall, the second groove having a first end and a terminal end, the terminal end forming an opening in the adjacent wall, the opening being adjacent to a second corner formed by the second wall and the adjacent wall.

2. The assembly of claim 1, wherein the first and second grooves are concave and have an arcuate cross-sectional configuration.

3. The assembly of claim 2, wherein a diameter of each of the first groove and the second groove tapers from the first end to the terminal end such that the first groove and the second groove have a larger diameter at the terminal end and a smaller diameter at the first end.

4. The assembly of claim 3, wherein the housing comprises: a first tab extending from a distal end of the housing, the first tab being sized and shaped to flex to bear against the first surface of the structural member; as well as a second tab extending from the distal end of the housing, the second tab being sized and shaped to engage the second surface of the structural member adjacent the opening and attach the housing to the structural member; The first and second protrusions are integrally formed with at least one wall, are coplanar with the at least one wall, and are formed of a bendable material that maintains a bent shape and can be bent more than once without failure, and the thickness of the first and second protrusions is 120252.407P1 The first and second tabs are enabled to be manually bent from an original position to an angle of at least 90 degrees relative to the at least one wall.

5. A housing for mounting an object to a structure having a first surface and an opposing second surface, the housing comprising: a plurality of walls sized and shaped to define an interior for receiving the object, and a plurality of corners at which adjacent walls of the plurality of walls intersect; as well as a first groove formed in the first wall, the first groove having a first end and a terminal end, the terminal end forming an opening in the adjacent wall, the opening being adjacent to a first corner formed by the first wall and the adjacent wall; and a second groove formed in a second wall opposite to the first wall, the second groove having a first end and a terminal end, the terminal end forming an opening in the adjacent wall, the opening being adjacent to a second corner formed by the second wall and the adjacent wall.

6. The housing of claim 5, wherein the first and second grooves are concave and have an arcuate cross-sectional configuration.

7. The housing according to claim 6, wherein a diameter of each of the first and second grooves gradually decreases from the first end to the terminal end, so that the first and second grooves have a larger diameter at the terminal end and a smaller diameter at the first end.

8. The housing according to claim 7, wherein the housing comprises: a first tab extending from a distal end of the housing, the first tab being sized and shaped to flex to bear against the first surface of the structure; as well as a second tab extending from the distal end of the housing, the second tab being sized and shaped to engage the second surface of the structure adjacent the opening and attach the housing to the structure; The first and second tabs are integrally formed with at least one wall, are coplanar with the at least one wall, and are formed of a bendable material that maintains a bent shape and can be bent more than once without failure, and the thickness of the first and second tabs enables the first and second tabs to be manually bent from an original position relative to the at least one wall to an angle of at least 90 degrees.

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