Ventilation Fan Bracket Assembly for Overhead Recessed Installation
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Solution Overview
Problem
The installation of ventilation fans, particularly bathroom ventilation fans, is challenging due to their overhead location and the difficulty of working with recessed installations, which requires minimizing the outer extent of the fan assembly while reducing installation effort and time.
Innovation Solution
The use of a ventilation fan assembly with a plurality of installation assemblies, each comprising a first and second bracket that are securely engaged to sandwich the ceiling panel, allowing for easy insertion and secure attachment to the ceiling, with features like snap-fit connections and adjustable components to simplify the installation process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Volume of moving object
If ventilation fans are recessed into the ceiling, then the outer extent of the fan assembly is minimized, but the installation difficulty increases due to overhead work and limited access
Solution Approach 1:
The installation system is divided into separate modular components: a mounting bracket that attaches to the fan housing, a separate ceiling engagement mechanism with fingers that interface with ceiling joists, and intermediate connection elements. This segmentation allows each component to be optimized independently and simplifies the installation process by enabling step-by-step assembly without requiring the entire assembly to be manipulated simultaneously in the difficult overhead position.
Solution Approach 2:
The patent introduces intermediate engagement structures including fingers that interface with ceiling joists, channels that guide alignment, and detachable connection mechanisms. These intermediary elements mediate between the fan housing and the ceiling structure, providing alignment guidance, facilitating easy attachment and detachment, and enabling installation from below without requiring overhead manipulation of the entire fan assembly.
2Reliability
If traditional installation methods are used, then the fan can be securely attached to the ceiling, but the installation time and effort increase significantly
Solution Approach 1:
The mounting bracket is pre-attached to the fan housing during manufacturing, eliminating the need for installers to perform this step on-site. The ceiling engagement fingers are pre-positioned on the bracket, and alignment channels are pre-formed. These preliminary actions ensure that during installation, only the final connection to the ceiling structure is required, significantly reducing installation time while maintaining secure attachment.
Solution Approach 2:
The engagement mechanism includes self-aligning features where the fingers automatically position themselves relative to the ceiling joists through the alignment channels. The detachable connection allows the assembly to self-lock into place without requiring additional fastening operations. These self-service features reduce the skill level and time required for installation while ensuring reliable attachment.
3Volume of moving object
If the fan assembly is made compact for recessed installation, then ceiling space is optimized, but access for installation and maintenance becomes more difficult
Solution Approach 1:
The patent employs detachable and adjustable connection mechanisms that transition between compact and accessible states. The mounting bracket can be detached from the fan housing to provide access to the electrical connections and internal components. The ceiling engagement fingers can be disengaged to allow removal of the fan assembly for maintenance. This dynamic capability allows the system to maintain a compact installed form while providing full access during installation and maintenance operations.
Solution Approach 2:
The mounting bracket and engagement mechanisms are designed to nest within or adjacent to the fan housing when in the installed state, minimizing the overall outer extent. The fingers, channels, and connection elements are positioned to occupy minimal space when not in use, allowing the fan assembly to achieve a compact profile while still providing access points for installation and maintenance through strategically located openings and detachable connections.
Data Source
AI summary
An assembly includes a first bracket and a second bracket. The first bracket includes a first member that includes a plurality of fingers and a first channel between the plurality of fingers. The first channel includes a plurality of teeth. A first flange extends from the first member and includes a first engagement surface. The second bracket includes a second member and a third member spaced from the second member. A second channel is formed between the second member and the third member. A second flange extends from the second member on an opposite side of the second member from the third member. The second flange includes a second engagement surface. In an installed configuration, the first bracket is secured to the second bracket; the first engagement surface faces the second engagement surface; and the plurality of fingers are inserted into the second channel.