VENTILATION FAN

Description

BACKGROUND

The present disclosure relates to ventilation fans, and particularly to ventilation fans configured to be mounted to a building to ventilate at least one room of the building. More particularly, the present disclosure relates to a ventilation fan including a blower wheel and a partition plate configured to maximize performance and efficiency of the blower wheel.

Additional features of the present disclosure will become apparent to those skilled in the art upon consideration of illustrative embodiments exemplifying certain modes of carrying out the disclosure as presently perceived.

SUMMARY

A ventilation fan comprising a fan housing defining an interior space, an inlet and an outlet; a fan wheel configured to be located in the interior space, the fan wheel comprising a hub and a fan blade extending from the hub to a fan blade distal end; a plate configured to be located between the fan wheel and the fan housing inlet, the plate having a sump defining a plate inlet and a plate peripheral portion, wherein the sump is configured to extend away from the plate peripheral portion toward the fan housing inlet such that the plate inlet is spaced from the plate peripheral portion to define a gap; wherein the flan blade distal end is configured to be located in the gap. The fan wheel can further comprise a support ring extending from the fan blade distal end and the support ring is located in the gap. The fan wheel can comprise a plurality of fan blades extending from the hub and a support ring extends from each of the plurality of fan blades. The sump can comprise a shank extending from the plate peripheral portion to define the gap. The sump can comprise a shank extending from the plate peripheral portion and a bend extending from the shank. The sump can comprise a shank extending from the plate peripheral portion and a bend extending from the shank, wherein the shank and/or the bend defines a pocket. The plate inlet can be located adjacent to the fan blade distal end.

A plate configured to be located in a fan housing of a ventilation fan between a fan wheel and a fan housing inlet defined by the fan housing, the plate comprising a sump defining a plate inlet and a plate peripheral portion, wherein the sump is configured to extend away from the plate peripheral portion toward the fan housing inlet such that the plate inlet is spaced from the plate peripheral portion to define a gap. The sump can comprise a shank extending from the plate peripheral portion to define the gap. The sump can comprise a shank extending from the plate peripheral portion and a bend extending from the shank. The sump can comprise a shank extending from the plate peripheral portion and a bend extending from the shank, wherein the shank and/or the bend defines a pocket. A beam can extend across the plate inlet. The gap can be configured to be located at distal end of at least one fan blade of the fan wheel.

A ventilation fan comprising a fan housing defining an interior space, an inlet and an outlet; a fan wheel configured to be located in the interior space; a plate configured to be located between the fan wheel and the fan housing inlet, the plate defining a plate inlet, a plate peripheral portion and an outlet wall, wherein the outlet wall protrudes from the plate peripheral portion and terminates in an outlet wall distal end configured to be located adjacent to the fan housing outlet. The outlet wall can define a hyperbola protruding from the plate peripheral portion. A duct connector can be located at the fan housing outlet, wherein the outer wall distal end contacts the duct connector. The duct connector can define an inner perimeter and the plate outlet wall is configured to align with the duct connector inner perimeter. The outlet wall can protrude from the plate toward the fan housing inlet. The plate can segregate the fan housing inlet from the fan housing outlet in all areas except for the plate inlet. The plate can comprise a sump defining the plate inlet.

Additional features of the present disclosure will become apparent to those skilled in the art upon consideration of illustrative embodiments exemplifying the best mode of carrying out the disclosure as presently perceived.

BRIEF DESCRIPTIONS OF THE DRAWINGS

The accompanying drawings, which are included to provide further understanding and are incorporated in and constitute a part of this specification, illustrate disclosed embodiments and together with the description serve to explain the principles of the disclosed embodiments. In the drawings:

FIG. 1 is a perspective assembly view of a ventilation fan of the present disclosure adapted to be secured to a building and placed adjacent to a room of the building.

FIG. 2 is the view of FIG. 1 with the motor removed.

FIG. 3A is a perspective cross section of the view of FIG. 2 taken through the inlet of the ventilation fan.

FIG. 3B is an elevational view of the cross section of FIG. 3A.

FIG. 4A is a perspective cross sectional view of the perspective view of FIG. 2 taken through the outlet of ventilation fan.

FIG. 4B is an elevational view of the cross section of FIG. 4A.

FIG. 5A is a top-side perspective view of the partition plate.

FIG. 5B is a bottom-side perspective view of the partition plate of FIG. 5A.

FIG. 5C is a perspective cross-sectional view of the partition plate of FIG. 5A taken through the inlet.

FIG. 5D is a elevational view of the cross section of FIG. 5C.

FIG. 5E is an elevational view of the partition plate of FIG. 5A viewing the side of the partition plate with the outlet.

DETAILED DESCRIPTION

A ventilation fan 10 is configured to be mounted to a building and is configured to ventilate at least one room of the building. The ventilation fan 10 has a housing 12 with a plurality of sidewalls 14 defining an interior space 16 of the fan housing 10. The plurality of walls 14 may form a substantially rectangular prism shape, as depicted in the exemplary embodiment, having four sidewalls 14S and a top wall 14T. The plurality of walls 14 of the fan housing 12 may form a different shape in other embodiments. The fan housing 12 is configured to define a housing inlet 12a and a housing outlet 12b spaced apart from the inlet. The fan housing inlet 12a may be formed by an edge of the plurality of sidewalls 14S (as in the depicted embodiment) without any bottom wall. In this embodiment, the housing inlet 12a can be located adjacent to an opening in a ceiling (not shown) when the ventilation fan 10 is installed to a building.

A fan wheel 18 is configured to be arranged in the fan housing interior space 16 and configured to be connected to the motor 20, which can also, optionally, be located in the fan housing interior space 16. A plate 22 is configured to be positioned in the housing interior 16 and connect with each of the fan housing sidewalls 14S. In an alternative embodiment, the plate 22 can be located at the fan housing inlet 12a. The plate 22 defines a plate inlet 22a through which air can flow.

The plate 22 has a peripheral portion 30 extending from adjacent to the fan housing sidewalls 14S. In the depicted embodiment, the peripheral portion 30 of the plate 22 defines a first edge 30a, a second edge 30b, a third edge 30c and a fourth edge 30d all configured to be located adjacent to one of the four depicted fan housing sidewalls 14S. A flange 32 can extend from each of the peripheral portion edges 30a,b,c,d to provide a force fit of the plate 22 into the fan housing 12 to substantially prevent air flow around the perimeter of the plate 22. The flanges 32 may optionally accommodate one or more elements to secure the plate 22 to the fan housing 12. In the depicted embodiment, the plate 22 defines tabs 34 deformed from the second flange 30b and the fourth flange 30d to slide into complementary apertures in the fan housing sidewalls 14S, providing a fast, tool less method of assembling the plate 22 to the fan housing 12.

In the depicted embodiment, the plate peripheral portion 30 is substantially planar and impervious to air flow, but other embodiments are contemplated in order to accomplish the objective of directing the flow path F through the plate inlet 22a. Portions of the plate peripheral portion 30 may define apertures that will be substantially filled by other elements upon completed assembly of the ventilation fan 10.

The plate inlet 22a can be comprised of one or more apertures extending from the plate inlet side 22b to the opposing plate outlet side 22c. In the depicted embodiment, the plate 22 has an optional beam 36 extending across the plate inlet 22a, dividing the plate inlet 22a into two distinct, but identical, inlet apertures. The beam 36 can support the motor 20. The beam 36 can be eliminated in other embodiments, such as when a different motor or motor location is used. In one embodiment, the plate inlet 22a is the only portion of the plate 22 through which air can flow. Since the plate 22 extends between all fan housing sidewalls 14S, the plate inlet 22a is the only area through which air from the housing inlet 12a can pass the plate 22 to reach the fan wheel 18. As depicted in the exemplary embodiment, the plate inlet 22a is located directly over the fan wheel 18.

The plate 22 defines a sump 38 that extends integrally from the plate peripheral portion 30. In an alternative embodiment, the sump 38 could be a discrete piece secured to the plate peripheral portion 30. The sump 38 extends 360 degrees about the plate inlet 22a between the plate peripheral portion 30 and the plate inlet 22a. When the beam 36 is present, the sump 38 extends around the ends of the beam 36, as depicted.

In the depicted embodiment, the sump 38 extends from the plate peripheral portion 30 defining a hook-shape extending from the plate inlet side 22b away from the fan wheel 18 and toward the fan housing inlet 12a. The sump 38 comprises a shank 38a extending from a shank proximal end 38a′ at the plate peripheral portion 30 toward the fan housing inlet 12a to a shank distal end 38a″. The sump 38 also comprises a bend 38b having a bend proximal end 38b′ extending from the shank distal end 38a″ to a bend distal end 38b″. The bend 38b is convex toward the fan housing inlet 12a and concave toward the fan wheel 18. A pocket 40 is defined by an imaginary line 42 extending horizontally from the plate inlet 22a to the shank 38a or bend 38b (the shank 38a in the depicted embodiment).

The shank 38a has a length configured such that the pocket 40 is located on the plate inlet side 22b of the plate 22, closer to the fan housing inlet 12a than the fan wheel 18, and spaced from the plate 22 to define a gap G between the pocket 40 and the plate outlet side 22c. Stated differently, the gap G extends along a rotational axis R of the fan wheel 18 between the plate inlet 22a and the plate outlet side 22c. The sump 38 can, optionally, include a leg 38c havine a leg proximal end 38c′ extending from the bend distal end 38b″ to a leg distal end 38c″ to increase the width and/or depth of the pocket 40. The leg distal end 38c″ constitutes the plate inlet 22a.

The sump 40 is configured to direct the flow of air through the plate inlet 22a in a smooth, preferably laminar, manner. The lengths, curvature and angle of the sump shank 38a, sump bend 38b and sump leg 38c are configured to facilitate the smooth air flow through the plate inlet 22a. The sump 40 can be of various heights, as measured along the rotational axis R of the fan wheel 18, in one embodiment, the sump 40 has a height between 0.20 and 0.40 inches. The sump 38 can take various other forms to create the pocket 40.

When driven by the motor 20, the fan wheel 18 is configured to displace air through the housing inlet 12a into the interior space 16, then through the plate inlet 22a, then through the fan wheel 18 and then expel the air through the housing outlet 12b, where it can be transported away from the ventilation fan 10 by a duct, for example. The shape of the sump 38 on the plate inlet side 22b is configured to provide smooth air flow through the inlet 22a. In one example, the ventilation fan 10 is mounted above a ceiling panel (not shown) of the building and the fan wheel 18 is configured to withdraw air from at least one room adjacent the ceiling through an opening in the ceiling. The air follows a flow path F through the fan housing interior space 16. The withdrawn air may be exhausted through the fan housing outlet 12b and to an exterior of the building.

The ventilation fan 10 can optionally include a fan grille (not shown) arranged to overlie the opening in the ceiling to block substantial view of the ceiling opening and the housing interior space 14 and to prevent a user from being injured by the fan wheel 18 during operation. One or more grille springs 24 can facilitation removable attachment of a fan grille to the housing 12 or plate 22.

The fan wheel 18 is mounted to the fan housing top wall 14T for rotation about the rotational axis R and relative to the fan housing 12. The fan wheel 18 comprises a wheel hub 50 and a plurality of fan blades 52 extending from the wheel hub 50. In the depicted embodiment, the plurality of fan blades 52 are arranged circumferentially around the rotation axis R and extend parallel to the rotational axis R. In the depicted embodiment, the wheel hub 50 is located adjacent to the housing top wall 14T opposite the inlet 12a defined by the fan housing 12. The fan blades 52 extend from a proximal end 54 at the wheel hub 50 toward the housing inlet 12a and terminate at a distal end 56.

A support ring 58 extends about the fan blade distal ends 56 to provide stability to the fan blades. In the depicted embodiment, the support ring 58 connects to the outermost radial portion adjacent to each fan blade distal end 56. In alternative embodiments, the support ring 58 could be located across the fan blade distal ends 56 as a cap on the fan blade distal ends. It has been discovered that some portions of the fan wheel 18 are effective at moving air, while other portions of the fan wheel 18 are not effective at moving 18. On the depicted fan wheel 18, the support ring 58 impedes air flow radially from the fan blades 52 rending the portion of that portion of the fan blades 52 covered by the support ring 58 ineffective for moving air through the ventilation fan 10. Not only does the support ring 58 render the covered portion of the fan blades 52 ineffective at moving air, but the support ring 58 can, in some configurations, create a wake in the air flow at the radially outermost portion of the support ring 58.

In the present disclosure, the support ring 58 is located within the gap G created by the sump 38. Locating the support ring 58 in the gap G moves the ineffective portion of the fan wheel 18 into the gap G. In this configuration, the wake created by the support ring 58 is minimized or eliminated. Turbulence in the flow path F through the ventilation fan 10 is thereby reduced and the efficiency of the fan wheel 18 in particular, and the ventilation fan 10 in general, is increased. Moreover, the gap G allows a taller fan wheel 18 than would otherwise fit in the fan housing 12, thus allowing an increased length of the fan blades 52 while blocking the turbulence created by the support ring 58. The overall efficiency of the ventilation fan 10 is thereby increased. In one respect, the available flow rate at a given RPM and motor power is increased. In another respect, the same flow rate can be obtained at a lower RPM and/or motor power. Moreover, the reduced turbulence and lower RPM for a desired flow rate reduces noise created by the ventilation fan 10.

A duct connector 60 may extend from the fan housing 12 to facilitate easy connection to ducting to direct exhaust flow. The duct connector 60 may attach to an exterior of the fan housing 12 or have a connector flange 62 extending laterally inside the fan housing 12 and the plate 22 can press against the connector flange 62 to keep the duct connector stable and in place.

In some fan housings, the fan housing outlet 12b is defined to be taller than the distance between the fan housing top wall 14T and the designed location of the plate 22. It has been found that using a flat plate 22 without a protruding outlet wall 70 can cause the flow path to abruptly enlarge as the air flows from the fan housing outlet 12b into the duct connector 60. The abrupt enlargement creates significant turbulence as the air flow attempts to fill the enlarged space of the duct connector 60. This turbulences increases the power required to generate air flow and reduces overall efficiency. This turbulence also generates noise that can be undesirable in certain applications.

In the present disclosure, the plate 22 defines an outlet wall 70 protruding from the plate peripheral portion 30 and configured to be located adjacent to the fan housing outlet 12b. The outlet wall 70 protrudes from the plate peripheral portion 30 at an outlet wall perimeter 72 located adjacent to the fan housing outlet 12b. The outlet wall 70 extends from the plate inlet side 22b of the plate peripheral portion 30 toward the fan housing inlet 12a and to provide a smooth transition from the plate peripheral portion 30 to the outlet wall distal end 74 without any abrupt transitions that would create turbulence in the air flow path leaving the fan wheel 18 and moving along the outlet wall 70 toward the housing outlet 12b. In one embodiment, the outlet wall 70 defines a hyperbola, as depicted, raising from the plate peripheral portion 30 at a constant angle of between 15 degrees and 20 degrees. In one embodiment, the outlet wall raises from the plate peripheral portion 30 at a constant angle of 17 degrees. The outlet wall 70 terminates adjacent to the plate peripheral portion first edge 30a at an outlet wall distal end 74 having a curvature protruding from the plate 22 to align with the inner perimeter of the duct connector 60. If a duct connector 60 of the type having a connector flange 62 is used, as depicted, then the outer wall distal end 74 may form firm contact with the connector flange 62 and the outer wall distal end 74 is configured to match the outer walls of the duct connector 60.

The gradual increase of the protrusion of the outer wall 70 creates a gradual change in the flow path F from the fan wheel 18 to the duct connector 60, substantially, or entirely, eliminating the turbulence created by the abrupt enlargement of prior fans, as discussed above. As a result, the plate 22 with the outlet wall 70 reduces overall turbulence in the ventilation fan 10 over prior ventilation fans and thereby increases efficiency, while reducing power consumption and noise.

It should be noted that the various components and features described above can be combined in a variety of ways, so as to provide other non-illustrated embodiments within the scope of the disclosure. As such, it is to be understood that the disclosure is not limited in its application to the details of construction and parts illustrated in the accompanying drawings and described hereinabove. The disclosure is capable of other embodiments and of being practiced in various ways. It is also to be understood that the phraseology or terminology used herein is for the purpose of description and not limitation.

Although the present disclosure has been described in the foregoing description by way of illustrative embodiments thereof, these embodiments can be modified at will, without departing from the spirit, scope, and nature of the subject disclosed.

Headings and subheadings, if any, are used for convenience only and do not limit the invention. The word exemplary is used to mean serving as an example or illustration. To the extent that the term include, have, or the like is used, such term is intended to be inclusive in a manner similar to the term comprise as comprise is interpreted when employed as a transitional word in a claim. Relational terms such as first and second and the like may be used to distinguish one entity or action from another without necessarily requiring or implying any actual such relationship or order between such entities or actions.

Phrases such as an aspect, the aspect, another aspect, some aspects, one or more aspects, an implementation, the implementation, another implementation, some implementations, one or more implementations, an embodiment, the embodiment, another embodiment, some embodiments, one or more embodiments, a configuration, the configuration, another configuration, some configurations, one or more configurations, the subject technology, the disclosure, the present disclosure, other variations thereof and alike are for convenience and do not imply that a disclosure relating to such phrase(s) is essential to the subject technology or that such disclosure applies to all configurations of the subject technology. A disclosure relating to such phrase(s) may apply to all configurations, or one or more configurations. A disclosure relating to such phrase(s) may provide one or more examples. A phrase such as an aspect or some aspects may refer to one or more aspects and vice versa, and this applies similarly to other foregoing phrases.

All numbers and ranges disclosed above may vary by some amount. Whenever a numerical range with a lower limit and an upper limit is disclosed, any number and any included range falling within the range are specifically disclosed. In particular, every range of values (of the form, “from about a to about b,” or, equivalently, “from approximately a to b,” or, equivalently, “from approximately a-b”) disclosed herein is to be understood to set forth every number and range encompassed within the broader range of values. In addition, the terms in the claims have their plain, ordinary meaning unless otherwise explicitly and clearly defined by the patentee. Moreover, the indefinite articles “a” or “an,” as used in the claims, are defined herein to mean one or more than one of the element that it introduces. If there is any conflict in the usages of a word or term in this specification and one or more patent or other documents that may be incorporated herein by reference, the definitions that are consistent with this specification should be adopted.

A phrase “at least one of” preceding a series of items, with the terms “and” or “or” to separate any of the items, modifies the list as a whole, rather than each member of the list. The phrase “at least one of” does not require selection of at least one item; rather, the phrase allows a meaning that includes at least one of any one of the items, and/or at least one of any combination of the items, and/or at least one of each of the items. By way of example, each of the phrases “at least one of A, B, and C” or “at least one of A, B, or C” refers to only A, only B, or only C; any combination of A, B, and C; and/or at least one of each of A, B, and C.

In one aspect, a term coupled or the like may refer to being directly coupled. In another aspect, a term coupled or the like may refer to being indirectly coupled. Terms such as top, bottom, front, rear, side, horizontal, vertical, and the like refer to an arbitrary frame of reference, rather than to the ordinary gravitational frame of reference. Thus, such a term may extend upwardly, downwardly, diagonally, or horizontally in a gravitational frame of reference.

The title, background, brief description of the drawings, abstract, and drawings are hereby incorporated into the disclosure and are provided as illustrative examples of the disclosure, not as restrictive descriptions. It is submitted with the understanding that they will not be used to limit the scope or meaning of the claims. In addition, in the detailed description, it can be seen that the description provides illustrative examples and the various features are grouped together in various implementations for the purpose of streamlining the disclosure. The method of disclosure is not to be interpreted as reflecting an intention that the claimed subject matter requires more features than are expressly recited in each claim. Rather, as the claims reflect, inventive subject matter lies in less than all features of a single disclosed configuration or operation. The claims are hereby incorporated into the detailed description, with each claim standing on its own as a separately claimed subject matter.

The use of the terms “a” and “an” and “the” and “said” and similar references in the context of describing the invention (especially in the context of the following claims) are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. An element proceeded by “a,” “an,” “the,” or “said” does not, without further constraints, preclude the existence of additional same elements. Recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range, unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., “such as”) provided herein, is intended merely to better illuminate the disclosure and does not pose a limitation on the scope of the disclosure unless otherwise claimed. No language in the specification should be construed as indicating any non-claimed element as essential to the practice of the disclosure.

Numerous modifications to the present disclosure will be apparent to those skilled in the art in view of the foregoing description. Preferred embodiments of this disclosure are described herein, including the best mode known to the inventors for carrying out the disclosure. It should be understood that the illustrated embodiments are exemplary only, and should not be taken as limiting the scope of the disclosure.