GRILLE FOR A VENTILATION SYSTEM

Description

BACKGROUND

The present disclosure relates generally to a ventilation fan that is installed in a wall or ceiling of a room to provide ventilation for the room and particularly to a ventilation fan including a housing that incorporates a blower and a grille to hide the blower from view of the user and prevent a user from obstructing the operation of the blower and/or injuring themselves by reaching into the blower. More particularly, the present disclosure relates to a grille for a ventilation fan that facilitates efficient air flow to the ventilation fan while allowing efficient manufacturing, shipping and storage.

The description provided in the background section should not be assumed to be prior art merely because it is mentioned in or associated with the background section. The background section may include information that describes one or more aspects of the subject technology.

SUMMARY

A ventilation system comprising a main housing configured to be positioned adjacent to a ceiling or wall of a room of a building structure, a blower configured to be positioned in the main housing and draw air out of the room of the building structure, and a grille configured to be releasably secured to one of the main housing and the blower to at least partially block view of the blower, the grille comprising a plate defining an inner side and an opposing outer side, a plurality of legs configured to be removably securable to the plate, wherein the plurality of legs is configured to space the plate from the ceiling. The plate can be flat. The plurality of legs can be four legs. At least one nub can extend from the plate to create a friction fit with at least one leg of the plurality of legs. At least one nub can extend from the plate to create a friction fit with at least one leg of the plurality of legs, wherein the plate comprises more nubs than legs. At least one nub can extend from the plate at least one leg of the plurality of legs comprises a cylindrical wall with an inner perimeter defining a hollow configured to create a friction fit over the nub. The plate can define a periphery and the grille further defines a rail extending along the plate periphery.

A ventilation system configured to be positioned adjacent to a ceiling or wall of a room of a building structure, the ventilation system comprising a grille configured to be releasably secured to the ventilation system, the grille comprising a plate defining an inner side and an opposing outer side, a plurality of legs configured to be removably securable to the plate, wherein the plurality of legs is configured to space the plate from the ceiling. The plate can be flat. The plurality of legs can be four legs. At least one nub can extend from the plate to create a friction fit with at least one leg of the plurality of legs. At least one nub can extend from the plate to create a friction fit with at least one leg of the plurality of legs, wherein the plate comprises more nubs than legs. At least one nub can extend from the plate and at least one leg of the plurality of legs comprises a cylindrical wall with an inner perimeter defining a hollow configured to create a friction fit over the nub. The plate can define a periphery and the grille further defines a rail extending along the plate periphery.

A stack of grilles configured for a ventilation system, the stack comprising a first grille plate and a second grille plate, and each of the first and second grille plates a plate defining an inner side and an opposing outer side, wherein the first grille plate outer side rests on the second grill plate inner side, a plurality of legs configured to be removably securable to the plate. Each of the first and second grille plates can comprise one or more of a grille spring anchor, a grille spring retainer and a nub extending from the plate inner side, wherein the plate outer side of the first grille rests on the grille spring anchor, the grille spring retainer and/or the nub of the second grille. The plate of each of the first and second grille plates can be rectangular. At least one nub can extend from the plate to create a friction fit with at least one leg of the plurality of legs. At least one nub can extend from the plate to create a friction fit with at least one leg of the plurality of legs, wherein the plate comprises more nubs than legs. The plate of each of the first and second grilles can define a periphery and a rail extends along the periphery.

A full discussion of the features and advantages of the present disclosure is deferred to the following detailed description, which proceeds with reference to the accompanying drawings.

BRIEF DESCRIPTION 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 bottom-side perspective view of an exemplary embodiment of a ventilation fan grille in accordance with the present disclosure.

FIG. 2 is a top-side perspective view of the grille of FIG. 1.

FIG. 3 is a cross-sectional view of the grille of FIG. 1

FIG. 4 is an exploded view of the cross-sectional view of FIG. 3.

FIG. 5 is an exploded view of a bottom-side perspective view of the grille of FIG. 1.

FIG. 6 is a bottom-side perspective view of various elements of the grille of FIG. 1 with legs disassembled from a plate.

FIG. 7 is a cross-sectional view of a stack of a plurality of plates of the type shown in FIG. 6.

In one or more implementations, not all of the depicted components in each figure may be required, and one or more implementations may include additional components not shown in a figure. Variations in the arrangement and type of the components may be made without departing from the scope of the subject disclosure. Additional components, different components, or fewer components may be utilized within the scope of the subject disclosure.

DETAILED DESCRIPTION

One embodiment of a ventilation system 1, in accordance with the present disclosure, is depicted in FIG. 4B. The ventilation system 1 is configured to be positioned in a room of a building structure to provide ventilation for the room of the building structure. For example, the ventilation system 1 may be positioned in a wall or ceiling panel 18 of the room and aligned with a cutout 18a in the panel 18 to ventilate the room. The ventilation system 1 may include a main housing 10 defining an internal region to house a blower 12. The main housing 10 defines an inlet 14 at the cutout 18a through which the blower can draw air and an outlet 16 through which the blower can expel air.

A grille 20 is removably coupled to the main housing 10 or blower 12 and is configured to obscure view of, and access to, the cutout 18a in the ceiling panel 18, the main housing 10, and the blower 12 from within the room. The grille 20 thus provides a more aesthetic appearance of the system 1 from the room to which the system 1 is connected. The grille 20 is depicted as being removably coupled to the main housing by a grille spring 22, but other known methods of coupling the grille 20 to the main housing 10 or the blower 12 are also contemplated.

The grille 20 has a plate 30 depicted as a rectangle that extends in all four directions to a plate periphery 30a that causes the plate 30 to span at least the ceiling cutout 18a and preferably extends beyond the perimeter of the ceiling cutout 18a to obscure the view of the cutout 18a from a user in the room. The plate defines an inner side 30b configured to face the blower 12 and an outer side 30c configured to face the user in the room. The plate 30 can be shaped as other than the depicted rectangular configuration. The plate 30 is depicted as planar, but can vary the depicted configuration. The depicted plate 30 defines no apertures through which air can flow, but such apertures are contemplated in other embodiments. The depicted plate 30 comprises no lighting, speakers, sensors or other accessories, but all such accessories are contemplated in other embodiments.

A pair of grille spring anchors 36 extend from the plate inner side 30b to receive and hold the grille springs 22. An end of each of the grille springs 22 is rotatably held in each of the grille spring anchors 36. A pair of grille spring retainers 38 also extend from the plate inner side 30b, with each of the grille spring retainers 38 being adjacent to one of the grille spring anchors 36 to allow the grille spring 22 from the adjacent grille spring anchor 36 to be rotated to a position parallel to the plate 30 and snapped into grille spring retainer 38 to hold the grille spring 22 flat against the plate 30 for shipping, storage, etc. A plurality of nubs 40 also extend from the plate inner side 30b.

In one embodiment, either the grille spring anchors 36 or the grille spring retainers 38 extend a height H from plate inner side 30b and the nubs 40 extend the same height H from the plate inner side 30b. In an alternative embodiment, all of the grille spring anchors 36, the grille spring retainers 38 and the nubs 40 extend the same height H from the plate inner side 30b. The height H is preferably in the range of 0.20 inches to 0.50 inches. In various particular embodiments, the height H is 0.200, 0.250, 0,290, 0.295, 0.300, or 0.400 inches.

A plurality of legs 32 extend from the plate inner side 30b to a leg distal end 32a. The legs 32 are configured to extend toward the ceiling panel 18 when installed and the leg distal ends 32a to contact the ceiling panel 18 as the grille 20 is biased toward the ceiling panel by the grille spring 22. The plurality of legs 32 in the depicted embodiment has a total of four legs 32, however other numbers of legs 32 are also contemplated in the rectangular embodiment as well as embodiments in which the plate 30 has non-rectangular configurations. For example, three legs are contemplated when using a circular plate 30 (not shown).

Each of the plurality of legs 32 is removably securable to the plate 30 on the plate inner side 32b. In the depicted embodiment, the each of the plurality of legs 32 is removably attached to the plate 30 by one of the nubs 40. In the depicted embodiment, each of the nubs 40 comprises a cylindrical wall 40a extending from the plate 30 and each of the legs 32 comprises a cylindrical wall 32b defining an inner perimeter 32c defining a hollow 32d and sized to create a friction fit with one of the nubs 40. The legs 32 in depicted embodiment have a cap 32e closing the hollow 32d at the leg distal end 32a.

In alternative embodiments, the legs 32 can be secured to the plate 30 in a variety of ways. In one example, the legs 32 can comprise a magnet (not shown) and the plate 30 can comprise a complementary magnet to create a magnetic connection between each leg 32 and the plate 30. Alternatively, the nubs 40 could comprise a plurality of fingers (not shown) to fit within the hollow cylindrical legs 32 depicted. In yet another embodiment, each leg 32 could comprise threads (not shown) and the nubs 40 comprise complementing thread (not shown) to allow each of the legs 32 to be threaded onto one of the nubs 40. These configurations facilitate fast, easy and tool less attachment of the legs 32 to the plate 30. Other configurations are contemplated.

The plurality of legs 32 can be located in any patterns on the plate 30 to stabilize the plate 30 against the ceiling panel 18 and space the plate 30 from the ceiling panel 18, as discussed more below. In one embodiment (not shown), one leg 32 is located adjacent to each corner of the plate 30, when defining a rectangular shape. In the depicted embodiment, one of the legs 32 is located adjacent to the plate periphery 32a at approximately the midway along each of the four sides of the rectangular shaped plate 30. Locating the legs 32 midway along the length of each of the sides of the plate 30 resists forces from the grille springs 22 (or other connection mechanism) that might bend or otherwise distort the plate 30 from its flat configuration. In the depicted embodiment, one leg is located adjacent to each of the grille spring anchors 36. Because the upward force of the grille springs 22 are applied to the plate 30 at the grille spring anchors 36, placing a leg 32 adjacent each grille spring anchor minimizes the distance between the grille spring anchors 36 and the nearest legs and minimizes the bending force applied to the plate 30 by the grille springs 22. It has been found that locating a leg 32 within 1.0 inches of a grille spring anchor 36 will sufficiently reduce the distortion force of the grille springe 22.

In an alternative embodiment (not depicted), the plate 30 can comprise more nubs 40 than legs 32, allowing a user options for different patterns or numbers of legs 32. Providing nubs 40 in multiple configurations can allow a single plate 30 to be used with different ventilation systems 1, a ventilation system using a mechanism other than the grille springs 22 to attach the grille 20 to the ventilation system 1 or locate the legs 32 for different sized ceiling cutouts 18a. In yet another configuration, a plate 30 can have a first set of nubs 40 to receive legs 32 located adjacent to the plate periphery 30a (and in the depicted embodiment), and a second set of nubs 40 to receive legs 32 closer to, or even adjacent to, the ceiling cut out 18a in the intended application, so that the user can determine during the installation process whether or not they would like to see the legs after installation.

In some embodiments, the plate 30 can be provided with multiple sets of differently configured legs 32 to allow the user to determine which of the leg 32 configurations the user wants. For example, a grille 20 could be provided with one plate 30 and two different sets of legs 32, one of which is longer than the other to space the plate 30 further from the ceiling panel 18. If the ventilation system 1 has a multi-speed blower 12, it might be preferable to have a larger gap between the ceiling panel 18 and the plate 30 when running the blower at a higher speed. Providing two different sets of legs 32 allows the user to determine which set of legs 32 to use, allowing the user to optimize the system based on the user's choices. Additionally, or alternatively, a grille 20 can be provided with one plate 30 and multiple sets of legs 32 having different shapes, colors, finishes, etc for aesthetic purposes so that the user has options during installation.

An optional rail 34 extends along the plate periphery 30a, in the depicted embodiment, perpendicular to the plate 30 and from the plate inner side 32b toward the ceiling panel 18 to a rail distal end 34a. The rail 34 can stiffen the plate 30 against distortion due to the bias of the grille spring 22, sagging due to gravity, or other distortions. In alternative embodiments, the rails 34 can be removed entirely or replaced by other stiffening structure, such as ribs on the plate inner side 30b or a plate thick enough to resist distortion.

When assembled to the plate 30, the leg distal end 32a extends beyond the rail distal end 34a to define a gap G between each rail distal end 34a and the location of the ceiling panel 18 after installation. The gap G provides an intake area for the blower 12 to draw air between the plate 30 and the ceiling panel 18, then into the inlet 14. It has been found that a gap G of 0.5 inches or more between the rail distal end 34a and the ceiling panel 18 facilitates efficient flow of air through the gap G. In the alternative embodiment grille in which no rails exist (not shown), the gap G is measured from the plate inner side 30b to the ceiling panel 18 or leg distal end 32a. In one preferred embodiment, the gap G is 0.625 inches. In one embodiment, the height H is in the range of 20%-40% of the height of the legs 32 extending from the plate inner side 30b.

The configuration of the grille 20 described herein allows a plurality of the grilles 20 to be stored and/or delivered with a stack 50 of a plurality of plates 30, as depicted in FIG. 7, along with one or more separated sets of the legs 32 for each plate 30. With the legs 32 absent from the plate 30, a first 50a of a plurality of plates 30 can be placed on a second 50b of a plurality of plates 30 such that the plate outer side 30c of the first 50a of the plurality of plates 30 rests on the nubs 40, grille spring retainers 38 and/or grille spring anchors 36 of the second 50b of the plurality of plates 30. Similarly, the second 50b of a plurality of plates 30 can be placed on a third 50c of the plurality of plates 30 such that the plate outer side 30c of the second 50b of the plurality of plates 30 rests on the nubs 40, grille spring retainers 38 and/or grille spring anchors 36 of the third 50c of the plurality of plates 30. A stack 50 of plates 30 can comprise any number of plates 30 stacked in this manner. This stacked configuration significantly reduces space requirements for storing and shipping a plurality of the plates 30. In one embodiment, stacking in this manner can save from 50% to 80% of the space otherwise required to ship the grilles 20 individually.

The legs 32 separated from the plate 30 can be provided as a set of legs 60, as shown in FIG. 6. A grille 20 can be provided with one or more sets of legs 60 as discussed above. Each set of legs 60 can be segregated from the other set(s) of legs 60 according to length, color, shape, etc. in bags or other compartmentalization. In one embodiment, one or more of the legs 32 has a nub (not shown) on the leg cap 32c, allowing the nub of each of the legs 32 to be inserted into the hollow 32d of a different one of the legs 32 such that the legs form a column for storage or delivery.

While preferred embodiments have been described above and illustrated in the accompanying drawings, it will be evident to those skilled in the art that modifications may be made without departing from this disclosure. Such modifications are considered as possible variants comprised in the scope of the disclosure. Headings and subheadings, if any, are used for convenience only and do not limit the disclosure. 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. Also, 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.

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 disclosure (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.