Flush-Mount Fan Grille with Planar Integration Flange
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Solution Overview
Problem
Conventional exhaust fan grilles protrude from the wall, creating focal points and not seamlessly integrating with modern architectural designs, which seek a minimalist and flush installation.
Innovation Solution
A flush-mounted, in-ceiling exhaust fan grille with a planar integration flange and through holes for secure attachment to the wall board, combined with a light module and insert configuration that allows for air flow while maintaining a seamless appearance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If conventional exhaust fan grilles are used, then the fan can be installed in the ceiling, but the grille protrudes from the wall creating focal points and not seamlessly integrating with modern architectural designs
Solution Approach 1:
The grille transitions from a protruding three-dimensional structure to a flush-mounted planar structure that integrates with the ceiling surface. The integration flange is designed to be coplanar with the ceiling surface, eliminating the protrusion and creating a seamless appearance that blends with modern architectural designs.
Solution Approach 2:
The grille is divided into separate functional components: an integration flange for mounting to the ceiling, an insert for structural support, and a light module for illumination. This segmentation allows each component to be optimized independently while achieving the overall goal of flush mounting and aesthetic integration.
2Shape
If the grille is designed to blend seamlessly into the ceiling, then the minimalist aesthetic is achieved, but the air flow path must be maintained
Solution Approach 1:
The grille design incorporates localized openings and apertures in specific positions to maintain air flow paths while maintaining an otherwise flush and minimalist appearance. The light module is positioned to allow air passage through openings between the light module and insert, ensuring ventilation efficiency is not compromised by the aesthetic design.
3Shape
If the integration flange is permanently attached to wall board with joint compound, then the through holes are concealed and seamless appearance is achieved, but the installation process becomes more complex
Solution Approach 1:
The integration flange is pre-formed with through holes and mounting features before installation. The joint compound is applied in advance to conceal the through holes, creating a seamless appearance. This preliminary preparation simplifies the overall installation process by pre-resolving the conflict between accessibility and aesthetics.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution provides a modern, minimalist aesthetic by blending the grille seamlessly into the ceiling, concealing the fan's industrial look while ensuring effective air ventilation and easy serviceability.
Implementation Method 1
At least one spring may be attached to the insert on a first end and attached to the fan housing on a second end, wherein the at least one spring applies a force drawing the insert towards the fan housing
Implementation Method 2
An exhaust fan may be provided to draw air into the fan housing through the opening between the light module and the insert to be exhausted for proper ventilation
Implementation Method 3
The planar integration flange may be permanently attached to a wall board with a joint compound, also called wall board compound, thereby concealing the through holes along the perimeter
Data Source
AI summary
A flush-mounted, in-ceiling exhaust fan grille for attachment to an exhaust fan housing includes a planar integration flange forming a perimeter of the grille. The integration flange includes a plurality of through holes along the perimeter. An insert may be configured for insertion within the perimeter of the integration flange. A light module may be configured to join within a central portion of the insert while maintaining an opening between an entirety of the light module and the insert. At least one spring may be attached to the insert on a first end and attached to the fan housing on a second end, wherein the at least one spring applies a force drawing the insert towards the fan housing. An exhaust fan may be provided to draw air into the fan housing through the opening between the light module and the insert to be exhausted for proper ventilation.