VENTILATION SYSTEM AND METHOD

Description

BACKGROUND

The present disclosure relates, generally, to a ventilation fan. Ventilating fans, such as those typically installed in bathrooms, draw air from within an area and pass the exhausted air out to another location, such as through a vent in the gable or roof of a home or other building structure. Ventilation fans often have a housing configured to be positioned within a building structure adjacent an aperture in a wall or ceiling. The housing is often attached to wall or ceiling joists to position the ventilation fan adjacent to, and aligned with the wall or ceiling aperture. Properly aligning the ventilation fan adjacent the wall or ceiling aperture while simultaneously securing the housing to the joists can be difficult and can result in misalignment which may reduce the efficiency of the ventilation fan and/or create frustration for the installer or damage to the ventilation fan.

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 housing having at least one sidewall defining an interior space, an inlet opening into the interior space, and an outlet aperture spaced apart from the inlet, wherein the housing is configured to contain a blower assembly in the interior space; at least one of a prong and a recess having at least one nail extending away from the at least one of a prong and a recess toward an aperture in the housing; wherein the at least one of a prong and a recess is configured to be deformable to allow the at least one nail to pass through the aperture in the housing. The housing can further comprise at least one mounting flange extending from any exterior of the fan housing and the mounting flange comprising the at least one of a prong and a recess. The at least one of a prong and a recess can be a prong having an arm extending from the housing and at least one nail extending from the arm. The at least one nail can be three nails. The at least one nail can be aligned perpendicular to the housing. The nail can define a triangular shape. The nail can define a triangular shape and a first ear extend from the triangular shape. The at least one of a prong and a recess is a prong and the prong comprises a nail head defining a nail head aperture, and the nail defines a nail shank extending from the perimeter of the nail head aperture.

A ventilation fan housing configured to house a blower, the ventilation fan housing comprising at least one sidewall defining an interior space, an inlet opening into the interior space, and an outlet aperture spaced apart from the inlet; at least one of a prong and a recess having at least one nail extending away from the at least one of a prong and a recess toward an aperture in the housing; wherein the at least one of a prong and a recess is configured to be deformable to allow the at least one nail to pass through the aperture in the housing. The housing can further comprise at least one mounting flange extending from any exterior of the fan housing and the mounting flange comprising the at least one of a prong and a recess. The at least one of a prong and a recess can be a prong having an arm extending from the housing and at least one nail extending from the arm. The at least one nail can be three nails. The at least one nail can be aligned perpendicular to the housing. The nail can define a triangular shape.

A ventilation fan housing configured to house a blower, the ventilation fan housing comprising at least one sidewall defining an interior space, an inlet opening into the interior space, and an outlet aperture spaced apart from the inlet; at least one recess defining a crest and a base, wherein the base defines a base aperture in the housing; at least one nail extending away from the recess toward the base aperture; wherein the at least one recess is configured to be deformable to allow the at least one nail to pass through the base aperture. The housing can further comprise at least one mounting flange extending from any exterior of the fan housing and the mounting flange comprising the at least one recess. The at least one mounting flange can define at least one mounting aperture to receive a fastener. The at least one recess can be defined in the at least one sidewall. The dome can define a crest aperture at the crest and the at least one nail extends from a perimeter of the crest aperture. A fastener can pass through the crest aperture after the recess has been deformed.

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 front perspective view of a ventilation fan assembly according to one embodiment of the disclosure.

FIG. 2 is a rear perspective view of the ventilation fan assembly of FIG. 1.

FIG. 3A is an enlarged view of a mounting flange and prong of the ventilation fan of FIG. 1.

FIG. 3B is an enlarged view of the reverse side of the mounting flange of FIG. 3A.

FIG. 3C is a cross-sectional view of the mounting flange and prong of FIG. 3A.

FIG. 3D is an enlarged view of an alternate mounting flange having a plurality of the prongs depicted in FIG. 3A.

FIG. 3E is an enlarged view of the prong of FIG. 3A.

FIG. 4A is a perspective view of a ventilation fan assembly of FIG. 1 with an alternative prong.

FIG. 4B is an enlarged view of the mounting flange and alternative prong of FIG. 4A.

FIG. 4C is a side view of the mounting flange and the alternative prong of FIG. 4B.

FIG. 5A is an enlarged perspective view of the mounting flange of the ventilation fan of FIG. 1 with the prong replaced by a recess.

FIG. 5B is an enlarged view of the reverse side of the mounting flange of FIG. 5A.

FIG. 6A is the same as FIG. 5A with an alternative recess.

FIG. 6B is the same as FIG. 5B with the alternative recess of FIG. 6A.

FIG. 7A is the same as FIG. 5A with a second alternative recess.

FIG. 7B is the same as FIG. 5B with the second alternative recess of FIG. 7A.

DETAILED DESCRIPTION

One embodiment of a ventilation fan assembly 10 of the present disclosure is depicted in FIG. 1 and FIG. 2. As shown, some embodiments of the ventilation fan assembly 10 can include several components and devices that can perform various functions. In the depicted embodiment, the ventilation fan assembly 10 has a housing 12 comprised of a first sidewall 14, a second sidewall 16, a third sidewall 18, and a fourth sidewall 20 and a bottom wall 22 collectively defining an interior space 24 of the housing 12. The first, second, third and fourth sidewalls 14, 16, 18, 20 define a housing inlet 26 through which air can be drawn from the surrounding environment. An outlet aperture 28 is defined in one of the first, second, third and fourth sidewalls 14, 16, 18, 20 or the bottom wall 22 of the housing 12 to direct outflow of air from the housing 12. A blower assembly (not depicted) can be located within the interior space 24 of the housing 12 to move air through the housing 12. A duct connector assembly (not depicted) is optionally attached to the housing at or adjacent to the outlet aperture 28.

The housing 12 can be constructed of any material which can provide self-supporting structural support to the ventilation fan assembly 10, while also being able to accommodate varying temperatures and environmental conditions (e.g., to withstand any heat radiated and/or conducted from the motor, or other components). In some embodiments, the housing 12 can be formed of sheet material comprising a relatively high melting temperature. In some embodiments, the housing 12 can be formed from a sheet metal, including, but not limited to an aluminum-based metal, a steel or iron-based metal, a zinc-based metal such as galvanized steel, or a nickel and tin-based metal. The housing first, second, third and fourth sidewalls 14, 16, 18, 20 and the bottom wall 22 can be formed from sheets of metal (e.g., galvanized steel), and joined using a variety of conventional joining techniques include welding, soldering, friction-bonding, crimping, riveting, and screw-attachment and the like. In some embodiments, one or more conventional flanges or tabs can be including in any one of the sidewalls 14, 16, 18, 20 and the bottom wall 22 to facilitate connection of each of the sidewalls 14, 16, 18, 20 and the bottom wall 22 to one or more adjacent ones of the sidewalls 14, 16, 18, 20 and the bottom wall 22.

In some other embodiments, the housing 12 can be formed from a polymer-based material, including, but not limited to injection molded polymers, thermo-formed polymers, thermosetting polymers, or any other suitable material. Some embodiments can include a housing 12 that comprises a wood-based product, such as wood, or particle-board or wood laminate. In some other embodiments, the housing can comprise a ceramic or ceramic-composite based product. In some further embodiments, the housing 12 can comprise a glass-fiber or other fiber-reinforced laminate material.

The housing 12 can be formed into any shape, including, but not limited to, a rectangular box-like shape, an oval shape, a hemispherical shape, a spherical shape, a pyramidal shape, or any other shape. The housing 12 can form a base or a similar support structure of the ventilation fan assembly 10. Further, in some embodiments, the housing 12 can provide points and areas of attachment for other components of the ventilation fan assembly 10, as described in further detail below.

The ventilation fan assembly 10 has at least one mounting flange 100 extending outward from the housing 12. In the depicted embodiment, the ventilation fan assembly 10 has a first mounting flange 100′ and a second mounting flange 100″ (referred to collectively as mounting flanges 100). In the depicted embodiment, the second sidewall 16 of the housing 12 has the first mounting flange 100′ extending from one end and the second mounting flange 100″ extending from the second end. The mounting flange 100 can be formed separately from the housing 12 and secured thereto afterward or formed integrally with the housing 12. Each of the one or more mounting flanges 100 can be used to mount the ventilation fan assembly 10 to a surface or a support structure. One or more additional mounting flanges 100 (not depicted) can be added to the housing 12. For example, each intersection of sidewalls 14, 16, 18, 20 (i.e. corners of the housing 12) could include a mounting flange 100.

In some embodiments, the ventilation fan assembly 10 can be used to ventilate any room, area or space. The ventilation fan assembly 10 can be secured within or to a wall, ceiling, or other building structure in a partially, or fully recessed position. The ventilation fan assembly 10 can be installed within an intermediate space, outside of the room, area or space, and coupled with one or more ventilation duct assemblies to provide ventilation to the room, area or space. In some other embodiments, the fluid may comprise air, or other gases, or vapor, such as water vapor. In some embodiments, the fluid may comprise a smoke, ash, or other particulate in addition to air or other gases. The ventilation fan assembly 10 can be installed as a new, original equipment installation in a room or building where none had previously existed or replace a pre-existing ventilation fan assembly.

At least one of the mounting flanges 100 can define a mounting aperture 102 to allow a fastener to be passed though the mounting aperture 102 and into an adjacent joist of wall to secure the housing to the joist or wall. In the depicted embodiment, both the first mounting flange 100′ and the second mounting flange 100″ define the mounting aperture 102. In other embodiments, the mounting flanges 100 can define more than one mounting aperture 102 to facilitate use of multiple fasteners or to provide an installer with multiple options of where install a fastener. In some other embodiments, the mounting flanges 100 may comprise more or fewer mounting apertures 102 than depicted, and may include one or more mounting apertures that comprise a different shapes and/or diameters.

In some instances during installation, the ventilation fan assembly 10 may need to be secured to one or more surfaces that are uneven over a distance or not parallel with one of the sidewalls 14, 16, 18, 20. In these instances, one or both of the mounting flanges 100 can be moved forward or backward by bending to a new position that better facilitates coupling of the mounting flange 100 to the surface (e.g. a joist or wall) by a fastener through one of the mounting apertures. In some embodiment, the first mounting flange 100 and/or the second mounting flange 100 can be moved by bending to a new position that results in one or both being angled from each of the sidewalls 14, 16, 18, 20.

To facilitate bending of the mounting flanges 100, at least one of the first and second mounting flanges 100 can include features to case the ability to rotate the mounting flange 100 with respect to the housing 12. In some embodiments, the mounting flanges 100 can include regions of reduced thickness. For example, in some embodiments, material forming the mounting panel 100 can comprise a reduced thickness and/or reduce tensile strength. In the depicted embodiment, the mounting flanges 100 define one or more bending apertures 104 (depicted as elongated slots). The one or more bending apertures 104 reduce the force needed to bend the mounting flange 100 in which the bending aperture 104 is defined. In some other embodiments, the mounting flanges 100 define more or less numbers of bending apertures 104 than depicted and/or bending apertures 104 with different geometry.

In one embodiment, at least one prong 110 extends from at least one of the mounting flanges 100 adjacent to a prong aperture 112 defined in the mounting flange 100. The prong 110 can optionally be created from material removed from the mounting flange 100 to create the prong aperture 112, such as by stamping or the like. One embodiment of the prong 110 is depicted in FIGS. 1, 2 and 3A-3D. This embodiment of the prong 110 has an arm 114 extending from the associated mounting flange 100 at a proximal end 114a to a distal end 114b. A nail 116 extends from the arm distal end 114b. The nail 116 has a proximal end 116a attached to the arm distal end 114b and an opposing distal end 116b.

The arm 114 is depicted as a flat piece of sheet metal displaced from the mounting flange 100. Other configurations of the arm are contemplated. The nail 116 is depicted as a flat piece of sheet metal removed from the mounting flange 100 and having a triangular shape with a base at the nail proximal end 116a and point at the nail distal end 116b forming a first side 116c and a second side 116d completing the triangle. The embodiment depicted in FIG. 3C further comprises a first car 118a extending from the nail first side 116c and a second car 118b extending from the nail second side 116d. The cars 118a,b are depicted as extending perpendicular to the flat nail 116. Other angles are contemplated. The cars 118a,b define serrations along a distal edge. In embodiments not having the cars 118a,b, the nail first and second sides 116c,d can define serrations.

Each mounting flange 100 defines a structure abutting side 100a and an opposing free side 100b. The structure abutting side 100a is configured to abut a portion of the structure (e.g. joist) to which the housing 12 is intended to be secured. The free side 100b is configured to be free of the structure and accessible by the installer when the housing 12 is aligned against the structure to which it is intended to be installed. As depicted, ventilation fan assembly 10 is configured to be provided to a user with the prong 110 in a first position in which the prong 110 extends away from the mounting flange free side 110b and will not encounter the structure (e.g. joist) when the housing is placed adjacent the structure for installation.

To install the ventilation fan assembly 10, an installer places the housing 12 next to the structure (e.g. joist) to which the housing 12 will be secured with the structure abutting side 100a of the mounting flange 100 in contact with the structure. The installer then aligns the housing 12 in the intended final installed location with respect to the structure and then forces the nail 116 through the prong aperture 112 and into the adjacent structure. The prong 110 ends up in a second position with the nail 116 partially or entirely embedded in the adjacent structure and the arm 114 partially or entirely flattened against the structure and parallel to the mounting flange 100. Hitting the arm 114 with a hammer or other blunt object to drive the nail 116 into the structure is known to force the nail 116 into structures such as wood beams. Other tools or object would similarly force the nail 116 into a wooden beam or structure. Other manners of forcing the nail 116 into the structure are also contemplated. In one embodiment, the first position comprises the nail 116 forming a substantially perpendicular angle to the mounting flange 110 so that the nail 116 will be driven straight into the structure when force is applied to the arm 114.

In some installations, forcing one prong 110 into the second position can hold the housing 12 in the intended installed position for a short period of time, allowing the installer to drive a fastener (e.g. nail, screw, etc.) through a mounting aperture 102 on the mounting flange 100 to more permanently secure the housing 12 to the structure. In some installations, it may be desirable to force two prongs 110 into the second position before driving a fastener through the mounting aperture 102. In some embodiments, each mounting flange 100 comprises at least two prongs 110 to allow an installer to quickly drive two adjacent prongs 110 into the second position. In embodiments in which the mounting flange 100 has a single prong 110, an installer may force one prong 110 on two different mounting flanges 100 into the second position.

In some embodiments, one or more of the prong arms 114 defines a prong mounting aperture 120. An installer can drive a fastener through the prong mounting aperture 120 once the prong 110 is in the second position in addition to, or instead of driving a fastener through the mounting flange mounting aperture 102.

FIGS. 4A-C depict an alternative prong 150 extending from the mounting flange 100 similar to the prong 110 depicted in FIGS. 1-3. The mounting flange 100 having the alternative pong 150 can be identical to the mounting flange 100 having the prong 110 depicted in FIGS. 1-3. The alternative prong 150 comprises an arm 152 defining a proximal end 152a connected to the mounting flange 100 and a distal end 152b spaced away from the mounting flange 100. The alternative prong 150 further comprises a nail head 154 defining a proximal end 154a extending from the arm distal end 152b, and a distal end 154b spaced away from the arm 152 and the mounting flange 100.

One or more nail shank 156 extends from the nail head 154 toward the mounting flange 100. Although the term “shank” may normally connote an elongated shaft, the term “shank” is used in this disclosure to mean any element extending from the nail head 154 and terminating in a shank distal end 156b. The shank distal end 156b is preferably, but not necessarily, sharp to reduce the force necessary to drive the nail shank 156 into the structure to which the housing 12 is to be mounted. In one embodiment, the one or more nail shanks 156 extending from the nail head 154 are dispersed around the perimeter of a nail head aperture 154c defined in the nail head. The exemplary depicted embodiment shows three nail shanks 156 extending from each of two nail head apertures 154c. Other numbers of nail shanks 156 and nail head apertures 154c are contemplated for each nail head 154. In one embodiment, the nail shanks 156 can be formed during the process of creating the nail head aperture 154c and the nail shanks 156 can be created from the material previously existing in the nail head aperture 154c and pressed or stamped from the nail head 154. The nail head aperture 154c are depicted are approximately circular, but other shapes are also contemplated.

Like the prong 110 of FIGS. 1-3, the alternative prong 150 defines a first position depicted in FIGS. 4A-C in which the alternative prong 150 is spaced away from the mounting flange free side 100b so that an installer can place the mounting flange structure abutting side 100a against the structure to which the housing 12 is intended to be secured. The installer can then force (e.g. by hammer tap) the alternative prong nail shank(s) 156 toward the flange 100, through the prong aperture 112 against, and into, the structure (e.g. joist) to which the ventilation fan assembly 10 is to be installed.

FIGS. 5A-5B depict the mounting flange 100 without either the prong 110 or the alternative prong 150. Instead, FIGS. 5A-5B depict a recess 200 extending from the free side 110b of the mounting flange 100. In the depicted embodiment, the recess 200 defines a convex dome-shape extending from the free side 100b of the mounting flange 100. The exemplary embodiment of FIGS. 5A-5B depict a hemispherical dome, but any other convex shape or dome-shape will suffice. An aperture 202 is defined through the crest of the recess 200 from an outer side 200a to an inner side 200b. The base of the dome 200c defines a base aperture 200d in the mounting flange 100. One or more nails 204 extend from the inner side 200b of the recess 200. In the depicted embodiment, the one or more nails 204 extend from the perimeter of the aperture 202 toward the base aperture 200d. The one or more nails 204 could also, or alternatively, extend from any portion of the recess inner side 200b. Three nails 204 are depicted in FIGS. 5A-5B, but other numbers of nails 204 are contemplated. The nails 204 are depicted as triangular shaped, but other shapes are contemplated. One or more of the one or more nails 204 can be sharp and/or have serrations or other features to ease the driving the nail 204 into an adjacent structure or holding the nail 204 in the adjacent structure.

In one embodiment, the nails 204 can be formed during the process of creating the aperture 202 and formed from the material previously filling that aperture 202 by pressing, stamping, etc. The aperture 202 is depicted as circular, but other shapes are also contemplated.

Like the prong 110 and the alternative prong 150, the recess 200 defines a first position depicted in FIGS. 5A-5B in which the recess 200, including its nails 204, is spaced away from the mounting flange free side 100b so that an installer can place the mounting flange structure abutting side 100a against the structure to which the housing 12 is intended to be secured without interference from the recess 200 or its nails 204. The installer can then force (e.g. by hammer tap) the nails 204 toward the flange 100 against and into the structure (e.g. joist) to which the ventilation fan assembly 10 is to be installed. In a preferred embodiment, an installer can tap the recess 200 with a hammer to deform the recess 200 toward the base aperture 200d and drive the nails 204 through the base aperture 200d and into the adjacent structure (e.g. joist).

FIGS. 6A-6B depict the mounting flange 100 with an alternative recess 300. The alternative recess 300 extends from the free side 110b of the mounting flange 100. In the depicted embodiment, the alternative recess 300 defines a convex dome-shape extending from the free side 100b of the mounting flange 100. The exemplary embodiment in FIGS. 6A-6B has a hemispherical dome, but any other convex shape or dome-shape will suffice. An aperture 302 is defined through the crest of the recess 300 from an outer side 300a to an inner side 300b. The base of the dome 300c defines a base aperture 300d in the mounting flange 100. One or more nails 304 extend from the inner side 300b of the recess 300. In the depicted embodiment, the one or more nails 304 extend from the perimeter of the aperture 302 toward the base aperture 300d. The one or more nails 304 could also, or alternatively, extend from any portion of the recess inner side 300b. Three nails 304 are depicted in FIGS. 6A-6B, but other numbers of nails 304 are contemplated. The nails 304 are depicted as triangular shaped, but other shapes are contemplated. One or more of the one or more nails 304 can be sharp and/or have serrations or other features to ease the driving the nail 304 into an adjacent structure or holding the nail 304 in the adjacent structure.

In one embodiment, the nails 304 can be formed during the process of creating the aperture 302 and formed from the material previously filling that aperture 302 by pressing, stamping, etc. The aperture 302 is depicted as circular, but other shapes are also contemplated.

The alternative recess 300 defines a first position depicted in FIGS. 6A-6B in which the recess 300, including its nails 304, is spaced away from the mounting flange free side 100b so that an installer can place the mounting flange structure abutting side 100a against the structure to which the housing 12 is intended to be secured without interference from the recess 300 or its nails 304. The installer can then force (e.g. by hammer tap) the nails 304 toward the flange 100 against and into the structure (e.g. joist) to which the ventilation fan assembly 10 is to be installed. In a preferred embodiment, an installer can tap the recess 300 with a hammer to deform the recess 300 toward the base aperture 300d and drive the nails 304 through the base aperture 300d and into the adjacent structure (e.g. joist).

Unlike the recess 200, the alternative recess 300 defines a plurality of peripheral apertures 306 through the dome from the outer side 300a to the inner side 300b. The peripheral apertures 306 reduce the amount of material in the recess 300, thereby making the recess 300 easier to deform to force the nails 304 into the adjacent structure. The alternative recess 300 depicted in FIGS. 6A-6B comprise four peripheral apertures 306 spaced evenly about the dome, but other numbers of peripheral apertures 306, shapes and spacing are contemplated. Each of the depicted peripheral apertures 306 of the alternative recess 300 is approximately shaped as an oval extending circumferentially around the recess 300. The peripheral apertures 306 have opposing sides 306a and rounded ends 306b. The sides 306a are slightly curved radially about the crest aperture 302. As will be appreciated, the greater the distance between the two sides 306a, the more material that is removed from the alternative recess 300, reducing the amount of force necessary to deform the recess 300 in order to force the nails 304 into the adjacent structure. Furthermore, the portion of the alternative recess 300 that will more easily deform can be controlled by the location of the peripheral aperture 306 between the recess base 300c and the recess crest aperture 302. Specifically, the peripheral aperture 306 depicted in FIGS. 6A-6B are located substantially closer to the crest aperture 302 than the recess base 300c such that the crest of the recess 300 will easily deform, but the deformation of the portion of the recess 300 between the peripheral aperture 306 and the recess base 300c is not significantly changed by the peripheral aperture 306. This configuration allows the crest aperture 302 and the nails 304 to be forced into the adjacent structure with minimal force required for deforming the recess 300 out of the first position. Various sizes and shapes of the peripheral apertures 306 are contemplated.

FIGS. 7A-7B depict the mounting flange 100 with a second alternative recess 400, which is identical to the alternative recess 300 shown FIGS. 6A-6B and discussed above, except that the peripheral apertures 306 of the alternative recess 300 are replaced by alternative peripheral apertures 406. The alternative peripheral apertures 406 also approximate an oval shape having opposing sides 406a and rounded ends 406b. The opposing sides 406a of the alternative peripheral apertures 406 extend from the recess base 400c approximately radially toward the crest aperture 402. The rounded end 406b closest to the recess base 400c is depicted as extending from the recess into the mounting flange 100 of which it is a part. That rounded end 406b could, however be located exactly at the recess base 400c or fully on the recess 400. The rounded end 406b closest to the crest aperture 402 is approximately as close to the crest aperture 402 as the peripheral aperture side 306a of the alternative recess 300.

One or more of the mounting flanges 100 of the housing 12 of the instant disclosure can have one or both of the prongs 110, 150 and/or one or more recess 200, 300, 400 in any combination. In some embodiments, one or more of the first, second, third and fourth housing sidewalls 14, 16, 18, 20 can have one or both of the prongs 110, 150 and/or one or more recess 200, 300, 400 in any combination and the housing has no mounting flanges 100. In some embodiments, one or more of the first, second, third and fourth housing sidewalls 14, 16, 18, 20 can have one or both of the prongs 110, 150 and/or one or more recess 200, 300, 400 in any combination and the housing also comprises one or more mounting flanges 100 having one or both of the prongs 110, 150 and/or one or more recess 200, 300, 400 in any combination. In any embodiment in which one or more of the first, second, third or fourth sidewalls 14, 16, 18, 20 have one or more of the prongs 110, 150 and one or more recess 200, 300, 400 each of the prongs 110, 150 and the recesses 200, 300, 400 extend into the housing interior space 24 so that the outer sides of the sidewalls 14, 16, 18, 20 can lie flat against the structure (e.g. joist) to which the housing 12 is intended to be secured for easy positioning and alignment prior to deforming the prongs 100, 150 and/or recess 200, 300, 400 from the first position.

In some embodiments, the prongs 110, 150 and the recess 200, 300, 400 can be formed from the material of the housing 12, including where applicable, the mounting flange 100. The formation of the prongs 110, 150 and the recess 200, 300, 400 can be conducted during the formation process of the mounting flange 100 and/or housing 12 to streamline production. In these embodiments, the prongs 110, 150 and the recess 200, 300, 400 are integral to the remainder of the housing 12. In other embodiments, any of the prongs 110, 150 and the recess 200, 300, 400 can be formed separately from the housing 12 and secured to the housing 12 at a later time.

It will be recognized that because the prongs 110, 150 and the recess 200, 300, 400 extend from the free side 100b of the mounting flange 100 or into the housing interior space 24, the housing 12 can be positioned against the structure (e.g. joist) to which the housing 12 is intended to be secured without the prongs 110, 150 or the recess 200, 300, 400 interfering with alignment of the housing 12 to the structure. Once aligned, the installer can force the prongs 110, 150 and/or the recess 200, 300, 400 out of the first position and into the structure, such as by a hammer stroke to temporarily or permanently secure the housing 12 to the structure. The installer can then drive additional fasteners through the mounting aperture 102 in the mounting flange 100, where present, the prong mounting aperture 120 and/or other apertures in the housing 12 to provide additional securement of the housing 12 to the structure.

As will be recognized by the person of ordinary skill in the art, hanger bars (see e.g. U.S. Pat. No. 7,654,495) are often used to suspend a ventilation fan housing between two joists when, for example, the aperture in the ceiling or wall does not permit securing the housing directing to one of the joists. These hanger bars (not depicted) can comprise the mounting flanges 100 described herein as having one or more of any of the prongs 110, 150 and/or the recess 200, 300, 400 in any combination on one or both ends of the hanger bars to allow simple securement of the hanger bars to the joist.

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.