Note: Descriptions are shown in the official language in which they were submitted.
CA 02592546 2007-06-20
TITLE OF THE INVENTION
VENTILATION EXHAUST FAN
FIELD OF THE INVENTION
The present invention relates to the field of ventilation exhaust fans for use
in
removing air from a bathroom or other area and venting it to an exterior
location.
BACKGROUND OF THE INVENTION
Ventilation exhaust fans are used to vent air from a given room to an exterior
location.
They are typically used in bathrooms, where saturated air from bath, shower
and sink
use can cause condensation and related problems such as mold and mildew. By
venting this saturated air, the ventilation exhaust fan can limit the amount
of
condensation formed. These ventilation fans are also useful in removing stale
air and
odors that may be present in the bathroom.
The ventilation fan is typically mounted in the ceiling between the joists,
and is
therefore limited in size by the space between the joists and between the
ceiling and
the floor above it. An air inlet in the bottom of the ventilation fan draws
air from the
room below into the fan. An exhaust duct is connected to an exhaust outlet
located
on a side of the ventilation fan. The duct directs air drawn into the air
inlet of the
ventilation fan from the bathroom (or other room where the fan is placed) to a
desired
location, typically outside.
The bathroom fans of the prior art typically have a square casing having a
top, bottom
3o and sides, with a maximum width corresponding to the distance between the
joists.
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The bottom is open, allowing the interior components to be fitted within the
casing
and forming the air inlet. A blower housing is fitted within the casing
interior and a
centrifugal fan, sometimes referred to as a blower wheel, is fitted within the
blower
housing. A motor is secured within the casing, and connects to the centrifugal
fan,
such that when it is activated, the motor acts to rotate the centrifugal fan.
A venturi
plate having an air inlet is then connected to the casing. When rotated by the
motor,
the blower wheel draws air in through the air inlet (aligned with the fan) and
forces it
radially outwards and in the direction of rotation of the wheel. Air being
forced
through the housing follows the rounded contour of the side wall of the blower
io housing until it exits through the exhaust outlet (located in the side
wall).
The ventilation exhaust fan is normally mounted into position during
construction of a
house prior to installation of the ceiling drywall. Even at this time of
relatively easy
access, the fans can be difficult to install, as the fan must be positioned on
the ceiling
joist in such a manner that the drywall can be installed in proper abutment
with the
fan.
In order to overcome this problem, U.S. Patent No. 6,802,770 teaches a fan
housing
having two series of spaced view holes formed in the back wall so that the
installer
can see the ceiling joist during installation for proper positioning of the
housing. In
addition, the housing has a pair of bend down tabs along the back wall. The
tabs are
set in such a position that when placed in abutment with the bottom of the
ceiling joist,
the correct spacing will be provided for the drywall (of common thickness).
However,
while the `770 patent makes it easier to install a ventilation fan prior to
putting the
finishing drywall into place, it is of no use when installing a replacement
fan in an
already finished ceiling.
Replacing a fan, or installing a new fan through finished ceiling dry wall is
difficult to
say the least. The installer is forced to work through a hole in the drywall
that is sized
to accommodate the fan housing. Depending on the positioning of the hole in
the
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drywall, the installer may have difficulty attaching the housing to the
ceiling joist.
Working in a tight space makes this all the more difficult.
It is therefore an object of an embodiment of the present invention to provide
a
ventilation exhaust fan that can be easily installed through finished drywall.
Other objects of the invention will be apparent from the description that
follows.
SUMMARY OF THE INVENTION
According to the present invention there is provided a ventilation exhaust fan
for
mounting in an opening in a surface. The ventilation exhaust fan comprises a
housing having a top, four sides and an open bottom. A motor and a fan are
housed
1s within the housing, the fan being rotatable by the motor. An exhaust outlet
is located
in the housing. A plurality of openings are located in the sides spaced above
the
bottom a distance corresponding to the thickness of the surface having the
opening.
A plurality of restraints are removably connectable to the housing through the
openings for mounting the housing to the surface.
According to the invention, the ventilating exhaust fan housing described
above is
mountable in the opening in the surface by first positioning the housing in
the opening
so that the bottom is in abutment with one side of the surface and then
inserting at
least two of the restraints through the openings so that a portion of each of
the
restraints is in abutment with an opposite side of the surface.
Other aspects of the invention will be appreciated by reference to the
detailed
description of the preferred embodiment and to the claims that follow.
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BRIEF DESCRIPTION OF THE DRAWINGS
These and other features of the invention will become more apparent from the
following description in which reference is made to the appended drawings and
wherein:
Fig. 1 is an exploded perspective view of a preferred embodiment of a
ventilating exhaust fan;
Fig. 2 is a perspective view of the fan housing shown in Fig. 1;
Fig. 3 is a detailed view of a portion of a wall of the housing shown in Fig.
2
taken at the line 3-3;
is Fig. 4 is a sectional view of a portion of a wall of the housing shown in
Fig. 2
shown mounted to a portion of drywall using the preferred embodiment of a
clip;
Fig. 5 is a sectional view of a portion of a wall of the housing shown in Fig.
2
shown mounted to a portion of drywall using an alternative embodiment of a
clip;
Fig. 6 is a sectional view of a portion of a wall of the housing shown in Fig.
2
shown mounted to a portion of drywall using a further alternative embodiment
of a clip;
Fig. 7 is a perspective view of an alternative embodiment of a ventilation
exhaust fan housing;
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Fig. 8 is a sectional view of a portion of a wall of the housing shown in Fig.
7
shown mounted to a portion of drywall using a further alternative embodiment
of a clip; and
Fig. 9 is a perspective view of the clip shown in Fig. 8.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
io The preferred embodiment of a ventilation exhaust fan 10 is shown in Fig.
1. As
shown in Fig. 1, the ventilation exhaust fan 10 has a housing 12 having a top
surface
14, four sides 16 and an open bottom 18. The open bottom 18 is bordered by
flanges
28 extending outwards from each of the sides, substantially perpendicular
thereto.
An exhaust outlet 14 is defined in one of the sides to which outlet fitting 2
is
attachable. Outlet fitting 2 connects to an exhaust duct (not shown) for
venting to an
exterior location.
A blower housing 26 is mountable within the interior of housing 12. A motor 22
and a
fan 24 are fitted within the blower housing. A cover plate 8 attachable to the
blower
housing has an inlet opening through which air is drawn in to the blower
housing
when the fan is in operation. Motor 22 is connected to the fan, and when it is
activated, the motor acts to rotate the fan, thereby acting to draw air
through the air
inlet opening into the blower housing where it is then forced out the exhaust
outlet 14
and outlet fitting 2 to the exhaust duct to be vented to an exterior location.
A hinged
door 4 allows air to flow out of the exhaust outlet 14 through the outlet
fitting to the
exhaust duct while preventing outside air from passing back through the blower
housing 26 and into the room when the fan is shut off.
Electrical connection 7 is adapted for connection to a source of electrical
power and is
contained within power box 5.
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The ventilating exhaust fan 10 is adapted for easy installation where a
ceiling drywall
or other surface is already in place, either through an existing opening in
the surface
or a new opening. According to a preferred embodiment of the invention, the
housing
has a plurality of openings 30 for connection to ceiling drywall by way of
restraints,
such as clips 20 shown in Fig. 1 and Fig. 4. As best viewed in Fig. 3, the
opening 30
is preferably in the form of an inverted "T" shaped slot having a vertical
slot 32 and a
horizontal slot 34. The horizontal slots 34 of openings 30 are positioned a
suitable
distance from the flanges 28 to accommodate common ceiling surface
thicknesses.
Clips 20 are formed of a solid material such as plastic or metal with
sufficient strength
and rigidity to support the ventilating exhaust fan on the ceiling drywall
when installed
in the ceiling. Preferably, the clips 20 are elongated planar members having a
first
portion 21 sized to fit through horizontal slot 34, a second portion 23
substantially
perpendicular to first portion 21, and a third portion 25 substantially
parallel to first
portion 21. Preferably first portion 21 terminates in an upwardly angled
portion 27. It
is contemplated that a screw or other connector could be used to attach clip
20 in
place on housing 12.
When installing the exhaust fan 10, after the ducting and electrical
connections are
completed as known in the art, the housing 12 is inserted into an opening in a
ceiling,
connected to the already installed components, and mounted in place. Once the
housing is in place the remaining components, including the motor and fan, are
mounted into the housing 12 and connected as necessary.
Using the easy-install system of the present invention, when the housing 12 is
inserted into an opening in a surface for mounting, it is positioned so that
the bottom,
in this case flanges 28, are in abutment with the ceiling drywall 36 as shown
in Fig. 4.
Clips 20 are inserted through openings 30 so that first portion 21 sits above
and in
abutment with drywall 36, second portion 23 is in abutment with that portion
of wall 16
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below horizontal slot 34, and third portion 25 is in abutment with the
underside of
flange 28. Upwardly angled portion 27 makes it easier to clear the edge of
drywall 36
when inserting the clip 20 through horizontal slot 34. The clips 20 transfer
the weight
of the exhaust fan 10 to the drywall 36, thereby supporting it in the ceiling.
Should a
user wish to remove the exhaust fan housing, they need simply use a
screwdriver or
like instrument to pry out the clips. The clips could also be used with a
housing with
sides terminating in an open bottom with no flanges, as third portion 25 is in
abutment
with the bottom side of surface 36, with a portion of surface 36 being
sandwiched
between first portion 21 and third portion 25.
It is contemplated that different models of ventilating exhaust fan can be
adapted for
different thicknesses of drywall, by simply varying the distance of the
horizontal slot
34 from the flange 28. Alternatively, different clips can be used for
different sized
drywall as shown in Fig. 5. In Fig. 5, the clip has a first portion 31
terminating in an
upwardly angled portion 27, a second portion 33 and a third portion 35. A
stepped
portion 39 raises the level of the first portion 31 above the level of
horizontal slot 34
so that the clip sits flush when the clip is forced all the way into place.
A further alternative restraint is shown in Fig. 6. Clip 50 has a vertical
portion 52 and
a horizontal portion 54 substantially perpendicular thereto. Horizontal
portion 54
terminates in an upwardly angled portion 57. When installing the housing in an
opening in the ceiling, clip 50 is inserted through opening 30 such that
horizontal
portion 54 is fitted through horizontal slot 34 above drywall 36. Vertical
portion 52 is
connected to vertical slot 32 by way of a screw 40 or like connecter. Having a
vertical
slot allows for varied placement of the screw 40 depending on the alignment of
the
vertical portion 52.
A further alternative embodiment is shown in Figs. 7 through 9, where the
plurality of
openings 65 in the side walls 66 of the housing 60 are small circular openings
through
which restraints 64 may be inserted to support the housing 60 on the drywall
36. The
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restraint 64 is preferably a solid, pre-formed wire or plastic cylindrical
element
dimensioned to fit within opening 65. Preferably restraints 64 are
substantially u-
shaped with a first portion 61, second portion 63 and third portion 65.
It is also contemplated that other shapes and sizes of openings and restraints
could
be used, provided that they involve the insertion of a plurality of restraints
through a
plurality of openings in the housing to support the housing and ventilating
exhaust fan
on the ceiling drywall within which it is mounted. Similarly, multiple
openings to
accommodate different sized drywall could be included on each side of the
housing.
io For example, each side could have two openings per side to accommodate 'h
inch
drywall and another two opening per side to accommodate 5/8 inch drywall, two
of the
most common sizes. Other sizes could also be provided for.
Preferably the housing 12 is also equipped with the standard parts and
fittings for
is mounting within a ceiling as known in the art. For example, the housing
could be
connected directly to a joist by way of screw or like connection passing
through a
defined opening in the housing as known in the art. Referring to Fig. 1, a
screw can
be inserted through opening 19 to fasten the housing 12 to a ceiling joist.
20 The easy-install housing of the present invention can be installed using
the following
method. The housing is inserted into an opening in a surface such as a ceiling
until
the bottom (flanges 28) is in abutment with one side of the surface having the
opening
within which it is being mounted. Any connections required to be made for the
functionality of the exhaust fan are completed. Holding the housing in
position, at
25 least two restraints are inserted through openings in the housing in order
to connect
the housing to the ceiling drywall. Any further connections are then made in
order to
complete the functionality of the exhaust fan, including connecting a
decorative fan
grill (not shown) for safety and aesthetics.
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While the exhaust fan has been described being mounted in a surface in a
ceiling, it
is also contemplated that it could be mounted in a wall or other surface, the
housing
being adaptable to such variations by way of it being mounted to the surface
itself by
way of the restraints and corresponding openings in the housing. Similarly,
while the
surface being described has been referred to as drywall, it could also be
mounted in
an opening in any other surface, such as wood or particle board, having a
suitable
thickness.
It will be appreciated by those skilled in the art that the preferred and
alternative
io embodiments have been described in some detail but that certain
modifications may
be practiced without departing from the principles of the invention.
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