Note: Descriptions are shown in the official language in which they were submitted.
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RECESSED BOX ASSEMBLY FOR A DRYER EXHAUST HOSE
TECHNICAL FIELD OF THE INVENTION
The present invention relates to the field of clothes dryer
exhaust systems. More specifically, the present invention
relates to a recessed box assembly for a dryer exhaust hose.
BACKGROUND OF THE INVENTION
Clothes dryers exhaust hot air and lint from a vent that is
typically located in a lower rear portion of the clothes dryer.
The hot air and lint is routed from the dryer vent to the
outside of a home or other building via a flexible and/or non-
flexible conduit. This conduit then runs through an opening in
the building and is terminated external to the building with an
exhaust vent adapter.
In a typical configuration, a non-flexible dryer exhaust
vent duct is routed within a wall cavity to the outside of the
home. The dryer exhaust vent is angled so that it protrudes
perpendicularly from a wall surface on the interior of the
home. A flexible dryer exhaust hose leading from the dryer
vent is then coupled to the exhaust vent duct. As such, this
flexible dryer exhaust hose resides between the dryer and the
wall surface.
The perpendicular positioning of the dryer exhaust vent
duct from the wall surface typically requires the flexible hose
to bend in at least two places to compensate for the locations
of the dryer vent on the rear of the dryer and the dryer
exhaust vent duct within a wall cavity. During installation,
this connection is initially made and the dryer is then pushed
toward the wall. The flexible dryer exhaust hose is easily
kinked, crushed between the wall and the rear of the dryer, or
otherwise damaged when pushing the dryer to the wall.
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Damage to the flexible hose can cause a restriction in air
flow from the dryer resulting in inefficient operation of the
dryer. That is, it can take longer periods of time for the
clothing to dry. Longer drying periods results in undesirable
wear on the clothes due to long tumbling time and higher
electricity expenditures. More critically, however, lint can
clog the hose in the restricted area. Lint is highly
combustible and restricted airflow causes overheating of the
exhaust environment, which can result in fire.
To avoid damaging or altering the hose during installation,
the dryer is often positioned a considerable distance from the
wall containing the exhaust conduit. For example, in order to
accommodate the bends in the flexible hose, a space of about
five inches between the dryer and wall is typically needed.
This additional distance of the dryer from the wall results in
less useable space within the laundry room and is aesthetically
displeasing.
Attempts have been made to alleviate the problems
associated with the aforementioned flexible dryer exhaust hose.
The prior art discloses recessed rectangular boxes that are
mounted in a wall. In particular, flanges around the perimeter
of the boxes are fastened to wall studs. Wallboard is then
installed over the wall studs and the flanges, and an opening
is made in the wallboard in the area of the box. Some prior
art recessed boxes further include a shoulder extending
outwardly from the periphery of the box. The shoulder abuts
the inner edges of the wall surface at the opening. The non-
flexible dryer exhaust vent duct extends into an interior space
of the box and the flexible hose is coupled to the vent duct
within the interior of the box.
Unfortunately, the use of these prior art recessed boxes
requires additional finish work to be performed to the wall
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surface following installation. The finish work can entail
caulking and/or the installation of trim board about the
periphery of the opening. Performing finish work is time
consuming, thus leading to undesirably high installation costs.
In addition, the shoulder of some prior art recessed boxes,
configured to abut the inner surface of the wall surfaces, is
of a finite height. Consequently, the shoulder cannot
accommodate wall surfaces of varying thickness, such as
wallboard, plasterboard, wood paneling, and so forth. Thus, in
some applications the shoulder may jut too far forward from the
wall surface, or may not protrude far enough to abut the entire
thickness of the inner edge. An ill fit leads to an
unprofessional appearing installation.
Further problems arise when performing remodeling work at a
later date. In particular, the installed box, trim molding,
and so forth are difficult to work around when the wall surface
is to be painted, wall papered, textured, and so forth. For
example, products such as paint, wall paper glue, and texture
material may get on the box, trim board, or caulk, thus slowing
down progress due to the additional time required for
preparation, such as masking, and for clean up. Similarly,
special care must be taken when measuring, cutting, and
aligning wall paper on the wall surface around the recessed
box. Again, the special care hampers progress, which is time
consuming, thus, frustrating for the homeowner performing such
work, or resulting in higher labor costs when an outside
company is hired to perform such work.
SiJi~lARY OF THE INVENTION
Accordingly, it is an advantage of the present invention
that an improved recessed box assembly for a dryer exhaust hose
is provided.
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It is another advantage of the present invention that a
recessed box assembly is provided that enables close placement
of a clothes dryer to a wall surface.
Yet another advantage of the present invention is that a
recessed box assembly is provided that is cost effectively
installed, while yielding an aesthetically pleasing appearance.
The above and other advantages of the present invention are
carried out in one form by a recessed box assembly for a dryer
exhaust hose. The assembly includes a box portion having
planar walls defining a box interior open at a front thereof.
The box portion has a port in one of the planar walls
configured to allow a dryer exhaust vent duct to pass through
the port into the box interior for interconnection with the
dryer exhaust hose. The planar walls include a back wall, a
top wall, a bottom wall opposing the top wall, and a pair of
opposing side walls, each extending perpendicular to and
between the top and bottom walls. At least one of the top,
bottom, and side walls has a tab extending into the box
interior. The assembly further includes a removable frame
attachable to the box portion. The frame has first and second
opposing sides, and third and fourth opposing sides, each of
the third and fourth sides extending perpendicular to and
between the first and second opposing sides. The frame furthex
has a receptacle section positioned on an outer surface of at
least one of the first, second, third, and fourth sides. The
receptacle section is configured to releasably engage with the
tab to attach the frame to the box portion.
BRIEF DESCRIPTION OF THE DRAWINGS
A more complete understanding of the present invention may
be derived by referring to the detailed description and claims
when considered in connection with the Figures, wherein like
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reference numbers refer to similar items throughout the
Figures, and:
FTG. 1 shows an exploded perspective view of a recessed box
assembly in accordance with a preferred embodiment of the
present invention;
FIG. 2 shows a side view of a frame of the box assembly of
FIG. 1;
FIG. 3 shows a perspective view of a box portion of the box
assembly of FIG. 1 installed between wall studs;
FIG. 4 shows a perspective view of a finish layer installed
over the box portion and wall studs of FIG. 3;
FIG. 5 shows a perspective view of the frame of FIG. 2
installed onto the box portion installed in a wall; and
FIG. 6 shows a perspective view of the recessed box
assembly installed in a finished wall with a dryer exhaust hose
installed therein.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows an exploded perspective view of a recessed box
assembly 20 in accordance with a preferred embodiment of the
present invention. Recessed box assembly includes a box
portion 22 and a removable frame 24 attachable to box portion
22. Box portion 22 and frame 24 of box assembly 20 may be
fabricated from a variety of materials including injection-
molded, high tensile strength plastics, metal, fiberglass,
ceramic materials, and so forth.
Box portion 22 has planar walls that define a box interior
26 open at a front. In particular, the planar walls of box
portion 22 include a back wall 28, a top wall 30, and a bottom
wall 32 opposing top wall 30. A pair of opposing side walls 34
extend perpendicular to and between top and bottom walls 30 and
32, respectively. The terms "top", "bottom", and "side" in
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CA 02508150 2005-05-24
connection with the planar walls of box portion 26 are used to
distinguish the planar walls of box portion 22 for clarity of
illustration. However, top wall 30, bottom wall 32, and side
walls 34 are of substantially equivalent lengths so that box
portion 22 may be advantageously oriented in any of a number of
desired positions. Accordingly, in any given installation,
that which is coined "top wall" herein may be a bottom wall or
side wall. Similarly, that which is coined "side wall" herein
may be a top wall or bottom wall, while that which is coined
"bottom wall" herein may be a top wall or side wall. As such,
box portion 22 is adaptable for enabling venting in any of four
lateral directions (i.e., top, bottom, right side, or left
side).
Flanges 36 extend from at least one of top wall 30, bottom
wall 32, and side walls 34 for fastening to wall studs,
discussed below. In a preferred embodiment, flanges 36 extend
from each of top, bottom, and side walls 30, 32, and 34,
respectively, so that box portion 22 can be installed in any of
a number of orientations, discussed below.
Box portion 22 includes knockouts 38 desirably located in
back wall 28, top wall 30, bottom wall 32, and side walls 34.
Knockouts 38 may be readily removed by punching, hammering, or
cutting to enable passage of a conduits, for example, a gas
pipe (not shown) for a gas heated dryer into box interior 26.
In addition, box portion 22 includes a port 42, shown in top
wall 30, for allowing dryer exhaust vent duct 40 to pass into
box interior 26.
Box portion 22 further includes tabs 44 extending from at
least one of top wall 30, bottom wall 32, and side walls 34 and
into box interior 26. Tabs 44 are configured to engage with
receptacle sections 46 (see FIG. 2) on frame 24. In a
preferred embodiment, tabs 44 extend from each of top, bottom,
and side walls 30, 32, and 34, respectively, into box interior
CA 02508150 2005-05-24
26 to facilitate an interconnection of box portion 22 with
removable frame 24 in a desired orientation.
Removable frame 24 includes a first side 48 and a second
side 50 opposing first side 48. In addition, frame 24 includes
a third side 52 and a fourth side 54 opposing third side 52.
Third and fourth sides 52 and 54, respectively, extend
perpendicular to and between first and second sides 48 and 50,
respectively.
Referring to FIG. 2 in connection with FIG. 1, FIG. 2 shows
a side view of frame 24 of box assembly 20. First, second,
third, and fourth sides 48, 50, 52, and 54 have forward facing
edges 56 substantially aligned in a single plane and
collectively defining a frame periphery. An outer trim element
58 extends perpendicularly from first, second, third, and
fourth sides 48, 50, 52, and 54, respectively, and forms a
single contiguous element about the frame periphery. Outer
trim element 58 has an inside return portion 60 along an outer
edge of element 58.
Receptacle sections 46 are positioned on an outer surface
62 of at least one of first, second, third, and fourth sides
48, 50, 52, and 54. In a preferred embodiment, receptacle
sections 46 extend from outer surface 62 of each of first,
second, third, and fourth sides 48, 50, 52, and 54,
respectively, to facilitate releasable engagement with tabs 44
on box portion 22 in a desired orientation.
Receptacle sections 46 are generally configured as a ridges
64. When frame 24 is mounted onto box portion 22, first,
second, third, and fourth sides 48, 50, 52, and 54 of frame 24
slide into box interior 26 so that ridges 64 slide against tabs
44. Thus, ridges 64 provide frictional engagement with tabs 44
for ready installation and removal of frame 24 onto box portion
22 as desired.
Referring to FIGS. 3-5, FIG. 3 shows a perspective view of
box portion 22 of box assembly 20 (FIG. 1) installed between
wall studs 66. FIG. 4 shows a perspective view of a finish
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layer 68 installed over box portion 22 and wall studs 66, and
FIG. 5 shows a perspective view of frame 24 of box assembly 20
attached to box portion 22 installed in a wall 70.
Accordingly, FIGs. 3-5 show the progression of an installation
of recessed box assembly 20. As shown in FIGS. 3-5, box
portion 22 is oriented such that port 42 (~''IG. 1) faces
upwardly to accommodate the vertically rising dryer exhaust
vent duct 40. However, box portion 22 may be reoriented in the
appropriate direction if duct 40 is horizontally oriented.
Box portion 22 is sized such that flanges 36 rest against
and can be fastened to wall studs 66. Far example, box portion
22 of top, bottom, and side walls 30, 32, and 34 has exterior
dimensions that are less than sixteen inches in height and
width so that box portion can fit between wall studs 66 on
sixteen inch centers. For example, with box portion 22 having
outside dimensions of approximately fourteen inches, flanges 36
can be made to extend far enough to fasten onto wall studs 66
on twenty-four inch centers. In an alternative preferred
embodiment, separately attachable tabs can be coupled to and
extend from flanges 36 to be subsequently attached to wall
studs on twenty-four inch centers.
Alternatively, a fourteen inch outside dimension box
portion 22 may have flanges 36 that can accommodate wall stud
spacings of up to twenty-four inch centers with lengthwise
joints every one or two inches. Accordingly, flanges 35 can be
cut or snapped at the joints to remove a portion of flanges 36
in order to accommodate wall stud spacings that are between
sixteen and twenty-four inches. In yet another alternative
embodiment, box portion 22 of top, bottom, and side walls 30,
32, and 34 may exhibit outside dimensions that are
approximately twenty-two inches to fit within twenty-four inch
wall spacings.
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As shown, when box portion 22 is mounted between wall studs
66, dryer exhaust vent duct 40 directed between walls studs 66
is passed through port 42 (FIG. 1) into box interior 26. Box
portion 22 is configured for mounting below finish layer 68 of
wall 70. As such, following attachment of box portion 22 to
wall studs 66, finish layer 68 is hung over wall studs 66 and
box portion 22, thus covering flanges 36. Finish layer 68 may
be drywall material, wood paneling, and the like, which is
coupled by nailing, stapling, and/or gluing finish layer 69 to
wall studs 66 in a conventional manner. Finish layer 68 may
have a pre-cut opening sized to match the open front of box
portion 22.
Once finish layer 68 is hung, finish layer 68 may be
textured, painted, wall-papered or otherwise finished as
desired by the homeowner to create the finished appearance of
wall 70. Once work is completed on wall 70, frame 24 is simply
snapped onto box portion 22 such that ridges 64 of frame 24
engage tabs 44 of box portion 24. Thereafter, should any
remodeling work be required, frame 24 can be snapped off of box
portion 22 for repainting, wall-papering, and so forth.
The snap-on fit of frame 24 removes the need for caulking
around box portion 22 andlor hanging trim molding on the finish
layer surrounding box portion 22, thus simplifying the
installation of recessed box assembly 20 relative to prior art
devices. Furthermore, the width of ridges 64 (FIG. 2)
accommodates various widths of finish layer 68 so that first,
second, third, and fourth sides 48, 50, 52, and 54,
respectively (FIG. 1), can be held at varying depths within box
interior 26. Accordingly, when frame 24 snaps onto box portion
22, outer trim element 58 of frame 24 fits generally flush
against wall 70, regardless of the thickness of finish layer
68.
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CA 02508150 2005-05-24
FIG. 6 shows a perspective view of recessed box assembly 20
installed in wall 70 with a dryer exhaust hose 72 installed
therein. As shown, frame 24 of assembly 20 resides against
wall 70 above a baseboard 74. Although, assembly 20 is shown
as being mounted above baseboard 74, it should be apparent that
an assembly 20 such that a bottom edge of frame 24 contacts the
floor, thereby eliminating the need for baseboard 74 at that
location.
FIG. 6 further shows a clothes dryer 76 from which dryer
exhaust hose 72 extends. During installation, hose 72 is
coupled to dryer exhaust duct 40 tFIG. 3) within box interior
26. Thereafter, dryer 76 is pushed toward wall 70. Recessed
box assembly 20 enables the interconnection of hose 72 with
dryer exhaust duct 40 (FIG. 5) within the wall cavity instead
of external to the wall surface. Accordingly, dryer 76 can be
placed in relatively close proximity to wall 70 with reduced
probability of kinking, bending, or otherwise damaging hose 72.
In summary, the present invention teaches of an improved
recessed box assembly for a dryer exhaust hose. The recessed
box assembly enables close placement of a clothes dryer to a
wall surface. In addition, the box assembly having
substantially equal length sides allows box assembly to adapt
to venting in any of four directions. Moreover, installation
of a box portion beneath the wallboard, followed by the snap-on
fit of a frame after the wallboard is hung, results in a cost
effective installation that is aesthetically pleasing in
appearance. Furthermore, the frame can be readily removed to
perform later finish work to the wall, such as, painting,
texturing, and wall-papering.
Although the preferred embodiments of the invention have
been illustrated and described in detail, it will be readily
apparent to those skilled in the art that various modifications
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may be made therein without departing from the spirit of the
invention or from the scope of the appended claims.
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