OFFSET-BALANCED LOUVER VENT ASSEMBLIES AND METHODS FOR MAKING THE SAME

Description

CLAIM OF PRIORITY AND CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No. 19/419,489, which was filed on Dec. 15, 2025, is now pending, and claims the benefit of priority to U.S. Provisional Patent App. No. 63/739,821, which was filed on Dec. 30, 2024, and is now lapsed. Both of the foregoing applications are incorporated herein by reference in their respective entireties and for all purposes.

TECHNICAL FIELD

The present disclosure relates generally to vents for transmitting gases through wall structures. More specifically, aspects of this disclosure relate to passive-type dynamic louver vent assemblies that affix onto exteriors of buildings and other structures.

INTRODUCTION

A louver vent—often spelled “louvre” due to its Old French etymology-13 is a fluid flow-control device that allows the ventilation of air or other gases through a wall structure while inhibiting the unwanted ingress of ambient elements, pests, debris, etc. A traditional “static” louver vent has a rigid construction that may consist of a wall-mounted frame which contains a series of fixed-angle slats or “louvers”. Many modern louver vents, in contrast, may have variable-angle “dynamic” designs that incorporate adjustable slats for enabling the mutable flow of gases through the vent. These variable-angle louver designs may have motorized or manually adjustable “active” slats or fluid-driven “passive” slats, depending on the intended application. Passive-type dynamic louver vent designs typically use hinged, lightweight blades that automatically open and close under the forces of airflow and gravity, respectively, without the use of motors or springs.

Nearly all residential and commercial buildings have exterior exhaust vents for evacuating air from the interior of the building. Vent applications may include, as some non-limiting examples, dryer vents, bathroom fan vents, furnace vents, hot water heater vents, range hood vents, and more. A louver vent is a simple and cost-effective device for controlling the flow of air from building vents while preventing unwanted pests (e.g., insects, rodents, etc.) and backdrafts (e.g., minimize energy losses in homes). Louver vents are also required by state building code for many applications, including furnace closets and dryer vents. Building ducts are typically vented through a sidewall-mounted (vertical) vent or a rooftop-fitted (roof) vent. In some instances, however, the contractor may determine that venting through a roof eave (soffit) vent or a porch ceiling (horizontal) vent is the best option for an intended application. For soffit and horizontal vents, there are few options for a low-profile vent that has passive-type dynamic louvers.

SUMMARY

Presented herein are louver vent assemblies with counterbalanced louvers and adjustable-height faceplates, methods for making and methods for using such louver vent assemblies, and buildings equipped with such louver vent assemblies. In a non-limiting example, a louver vent assembly is a tripartite construction that consists essentially of a rigid backplate frame that securely mounts onto a support structure around a duct hole, a faceplate shell that mounts onto and covers an outboard face of the backplate frame, and a solitary louver flap that pivotably mounts onto the faceplate shell and covers/uncovers a central vent hole that extends through the backplate and faceplate. The faceplate and backplate may be joined together at a one-way ratchet type interface such that the faceplate has a locking adjustable height to sit flush against one or more exterior siding panels. For instance, the faceplate's adjustable height may place the backplate inside the faceplate so that both the backplate and faceplate seat against the siding panel(s), or may create a pocket between the faceplate and backplate that sandwiches therebetween the siding panel(s) so the backplate and faceplate seat against opposite sides of the panel(s). The louver flap is hinged to the faceplate at an offset axis of rotation that is engineered to balance the louver flap to allow the vent assembly to be installed on both a vertical plane or a horizontal plane with the louver flap remaining closed absent the flow of air through the vent assembly.

Aspects of this disclosure are directed to offset-balanced louver vent assemblies, such as wall-mounted and soffit louver vents for residential and commercial buildings. In an example, a louver vent assembly includes a backplate that mounts, e.g., via threaded fasteners, onto a support surface and has a vent hole that aligns with and fluidly connects to a duct hole in the support surface. A faceplate mounts, e.g., via snap-fit interface, onto the backplate and has a flap hole that aligns with and fluidly connects to the backplate's vent hole. At least one louver flap is movably mounted, e.g., via a uniaxial pivot joint, to the faceplate such that the louver flap passively rotates back-and-forth between closed and open positions to thereby selectively cover and uncover the faceplate's flap hole. The rotation joint is located at predefined longitudinal and transverse offset distances relative to the louver flap's length and depth, respectively, such that the flap's center of mass (COM) biases the louver flap to the closed position when the louver vent assembly is in a vertically mounted orientation and a horizontally mounted orientation.

Further aspects of this disclosure are directed to methods for fabricating and methods for installing any of the herein described vent assemblies. In an example, a method is presented for manufacturing a louver vent assembly for a duct hole in a support surface. This representative method includes, in any order and in any combination with any of the above and below disclosed options and features: forming a backplate that is configured to mount onto the support surface and defines a vent hole that is configured to align with and fluidly connect to the duct hole; forming a faceplate that is configured to mount onto the backplate and defines a flap hole that is configured to align with and fluidly connect to the vent hole; forming a louver flap; and mounting the louver flap to the faceplate via a pivot joint such that the louver flap passively rotates between a closed position, whereat the louver flap covers the flap hole, and an open position, whereat the louver flap uncovers the flap hole, wherein the pivot joint is located at predefined longitudinal and transverse offset distances relative to a longitudinal length and a transverse depth of the louver flap, respectively, such that a flap center of mass of the louver flap biases the louver flap to the closed position when the louver vent assembly is in a vertically mounted orientation and a horizontally mounted orientation.

For any of the herein described louver vent assemblies, systems, and methods, the pivot joint's predefined longitudinal offset distance may extend longitudinally from a first (top) end towards an opposing second (bottom) end of the louver flap about 20% to about 45% a total longitudinal length of the louver flap. Moreover, the pivot joint's predefined transverse offset distance may extend transversely from a front (outboard) surface towards an opposing back (inboard) surface of the louver flap about 70% to about 90% the transverse depth of the louver flap. As a further option, the louver flap's COM may be located at an oblique angle relative to transverse (depth-wise) and longitudinal (length-wise) planes that are orthogonal to and intersect each other at the pivot joint. This oblique angle may be about 15° to about 25° from the transverse plane such that the flap's COM is interposed between the pivot joint and the front surface of the louver flap. With this design, the louver vent assembly may be characterized by a lack of a biasing device (e.g., springs, motors, pneumatic/hydraulic cylinders, smart materials, elastic cushions, etc.) that biases the louver flap to the closed position.

For any of the herein described louver vent assemblies, systems, and methods, the louver flap has an arcuate front wall, a pair of sidewalls that project substantially orthogonally from the arcuate front wall, and flap-balancing moment mass (MM) structure that is interposed between the louver flap's sidewalls. The MM structure is isolated to one longitudinal end of the arcuate front wall and shaped/sized to locate the flap's COM at a predefined COM location that is designed to bias the louver flap to the closed position. The MM structure may include multiple ribs and/or multiple pockets that are integrally formed with the flap's arcuate front wall. For instance, the MM structure may include a crisscross pattern of the ribs that is located adjacent to a laterally spaced pair of the pockets.

For any of the herein described louver vent assemblies, systems, and methods, the backplate may include an annular (e.g., square or rectangular) central hub with a polygonal (e.g., square or rectangular) mounting flange that is integrally formed with and projects outward from the polyhedral central hub. In this example, the backplate's central hub may define therethrough the vent hole, and the mounting flange may be designed to sit flush against and fasten to the support surface. By way of comparison, the faceplate may include an arcuate outer shell with multiple internal mounting walls that are integrally formed with and project inward from the outer shell. In this example, the faceplate's outer shell may define therethrough the flap hole, and the mounting walls may be designed to slide against and snap-fit to the central hub of the backplate.

For any of the herein described louver vent assemblies, systems, and methods, the pivot joint may include a pair of hinge pins, each of which is integrally formed with and projects inward from a respective internal mounting wall of the faceplate, and a pair of hinge slots, each of which extends through a respective lateral sidewall of the louver flap and receives therein a respective hinge pin. Alternatively, the louver flap may include the hinge pins and the faceplate may include the complementary hinge slots. It may be desirable that the louver vent assembly be a tripartite construction that consists essentially of the backplate, the faceplate, and the louver flap. As a further option, the backplate may be fabricated as a distinct (first) single-piece polymeric structure, the faceplate may be fabricated as another (second) single-piece polymeric structure, and the louver flap may be fabricated as a separate (third) single-piece polymeric structure.

Aspects of this disclosure are also directed to louver flaps for selectively covering and uncovering a duct hole in a support surface. In an example, a louver flap includes a louver flap body that movably mounts to the support surface via a pivot joint such that the louver flap passively rotates between a closed position, whereat the louver flap covers the duct hole, and an open position, whereat the louver flap uncovers the duct hole. The pivot joint is located at predefined longitudinal and transverse offset distances relative to a longitudinal length and a transverse depth of the louver flap, respectively, such that the flap's center of mass biasing the louver flap to the closed position when the louver flap is in a vertically mounted orientation and a horizontally mounted orientation.

The above summary does not represent every embodiment or every aspect of the present disclosure. Rather, the foregoing summary merely provides a synopsis of some of the novel concepts and features set forth herein. The above features and advantages, and other features and attendant advantages of this disclosure, will be readily apparent from the following Detailed Description of illustrated examples and representative modes for carrying out the disclosure when taken in connection with the accompanying drawings and the appended claims. Moreover, this disclosure expressly includes any and all combinations and subcombinations of the elements and features presented above and below.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an elevated, front perspective-view illustration of a representative offset-balanced louver vent assembly in accordance with aspects of the present disclosure.

FIG. 2 is a front-view illustration of the representative louver vent assembly of FIG. 1.

FIG. 3 is a side-view illustration of the representative louver vent assembly of FIG. 1.

FIG. 4 is a rear-view illustration of the representative louver vent assembly of FIG. 1.

FIG. 5 is an elevated, rear perspective-view illustration of the representative louver vent assembly of FIG. 1.

FIG. 6 is an elevated, front perspective-view illustration of a representative offset-balanced louver flap of the louver vent assembly of FIG. 1.

FIG. 7 is a side-view illustration of the representative louver flap of FIG. 6.

FIG. 8 is a rear-view illustration of the representative louver flap of FIG. 6.

FIG. 9 is an elevated, rear perspective-view illustration of the representative louver flap of FIG. 6.

FIG. 10 is an enlarged, rear-view illustration of the representative louver flap of FIG. 6 showing the section lines for FIGS. 11 and 12.

FIG. 11 is a side-view illustration of the representative louver flap of FIG. 6 taken in cross-section along line 11-11 of FIG. 10.

FIG. 12 is a plan-view illustration of the representative louver flap of FIG. 6 taken in cross-section along line 12-12 of FIG. 10.

FIG. 13 is an elevated, front perspective-view illustration of a representative faceplate shell of the louver vent assembly of FIG. 1.

FIG. 14 is a front-view illustration of the representative faceplate of FIG. 13.

FIG. 15 is a lowered, front perspective-view illustration of the representative faceplate of FIG. 13.

FIG. 16 is an elevated, rear perspective-view illustration of the representative faceplate of FIG. 13.

FIG. 17 is a rear-view illustration of the representative faceplate of FIG. 13.

FIG. 18 is a lowered, rear perspective-view illustration of the representative faceplate of FIG. 13.

FIG. 19 is an elevated, front perspective-view illustration of a representative backplate frame of the louver vent assembly of FIG. 1.

FIG. 20 is a front-view illustration of the representative backplate of FIG. 19.

FIG. 21 is a side-view illustration of the representative backplate of FIG. 19.

FIG. 22 is an elevated, rear perspective-view illustration of the representative backplate of FIG. 19.

FIG. 23 is a lowered, rear perspective-view illustration of the representative backplate of FIG. 19.

FIG. 24 is a rear-view illustration of the representative backplate of FIG. 19.

FIG. 25 is an enlarged, front-view illustration of the representative louver vent assembly of FIG. 1 showing the vent assembly mounted in a vertical orientation, the louver flap in a closed position, and the section line for FIG. 26.

FIG. 26 is a side-view illustration of the representative louver vent assembly of FIG. 1 taken in cross-section along line 26-26 of FIG. 25.

FIG. 27 is an elevated, front perspective-view illustration of the representative louver vent assembly of FIG. 1 showing the vent assembly mounted in a vertical orientation and the louver flap in an open position.

FIG. 28 is an enlarged, front-view illustration of the louver vent assembly of FIG. 27 showing the section line for FIG. 29.

FIG. 29 is a side-view illustration of the representative louver vent assembly of FIG. 27 taken in cross-section along line 29-29 of FIG. 28.

FIG. 30 is an end-view illustration of the representative louver vent assembly of FIG. 1 showing the vent assembly mounted in a horizontal orientation, the louver flap in an open position, and the section line for FIG. 32.

FIG. 31 is a side-view illustration of the representative louver vent assembly of FIG. 30.

FIG. 32 is a side-view illustration of the representative louver vent assembly of FIG. 30 taken in cross-section along line 32-32.

FIG. 33 is an end-view illustration of the representative louver vent assembly of FIG. 1 showing the vent assembly mounted in a horizontal orientation, the louver flap in a closed position, and the section line for FIG. 35.

FIG. 34 is a side-view illustration of the representative louver vent assembly of FIG. 33.

FIG. 35 is a side-view illustration of the representative louver vent assembly of FIG. 33 taken in cross-section along line 32-32.

FIG. 36 is a sectional, side-view illustration of the representative louver vent assembly of FIG. 1 showing the vent assembly mounted in a vertical orientation, the louver flap in a closed position, and a first center of mass (COM) target and a first engineered marginal zone (MZ) in accordance with aspects of the present disclosure.

FIG. 37 is a sectional, side-view illustration of the representative louver vent assembly of FIG. 36 showing the louver flap in an open position.

FIG. 38 is a sectional, side-view illustration of the representative louver vent assembly of FIG. 1 showing the vent assembly mounted in a horizontal orientation, the louver flap in a closed position, and the first COM target and the first engineered MZ of FIG. 36.

FIG. 39 is a sectional, side-view illustration of the representative louver vent assembly of FIG. 38 showing the louver flap in an open position.

FIG. 40 is a table showing different examples of COM targets and engineered MZs for vertically mounted and horizontally mounted louver vent assemblies in accordance with aspects of the present disclosure.

FIG. 41 is an enlarged, sectional side-view illustration of the representative louver flap of FIG. 6 showing a second COM target and a second engineered MZ in accordance with aspects of the present disclosure.

FIGS. 42-46 are sectional, end-view illustrations of the representative louver vent assembly of FIG. 1 showing the faceplate at a first (lowest/0-inch) locking height (FIG. 42), a second (second-lowest/0.25-inch) locking height (FIG. 43), a third (middle/0.5-inch) locking height (FIG. 44), a fourth (second-highest/0.75-inch) locking height (FIG. 45), and a fifth (highest/1.0-inch) locking height (FIG. 46) in accordance with aspects of the present disclosure

The present disclosure is amenable to various modifications and alternative forms, and some representative embodiments of the disclosure are shown by way of example in the drawings and will be described in detail below. It should be understood, however, that the novel aspects of this disclosure are not limited to the particular forms illustrated in the above-enumerated drawings. Rather, this disclosure covers all modifications, equivalents, combinations, permutations, groupings, and alternatives falling within the scope of this disclosure as encompassed, for example, by the appended claims.

DETAILED DESCRIPTION

This disclosure is susceptible of embodiment in many different forms. Representative embodiments of the disclosure are shown in the drawings and will herein be described in detail with the understanding that these embodiments are provided as an exemplification of the disclosed principles, not limitations of the broad aspects of the disclosure. To that extent, elements and limitations that are described, for example, in the Abstract, Technical Field, Introduction, Summary, Brief Description of the Drawings, and Detailed Description sections, but not explicitly set forth in the claims, should not be incorporated into the claims, singly or collectively, by implication, inference or otherwise. Moreover, recitation of “first”, “second”, “third”, etc., in the specification or claims is not per se used to establish a serial or numerical limitation; unless specifically stated otherwise, these designations may be used for ease of reference to similar features in the specification and drawings and to demarcate between similar elements in the claims.

For purposes of this disclosure, unless specifically disclaimed: the singular includes the plural and vice versa (e.g., indefinite articles “a” and “an” should generally be construed as meaning “one or more”); the words “and” and “or” shall be both conjunctive and disjunctive; the words “any” and “all” shall both mean “any and all”; and the terms “including,” “containing,” “comprising,” “having,” and the like, shall each mean “including without limitation.” Moreover, words of approximation, such as “about,” “almost,” “substantially,” “generally,” “approximately,” and the like, may each be used herein to denote “at, near, or nearly at” or “within 0-5% of” or “the same or practically the same as” or “within acceptable manufacturing tolerances” or any logical combination thereof, for example.

Referring now to the drawings, wherein like reference numbers refer to like features throughout the several views, there is shown in FIG. 1 a representative louver vent assembly, which is designated generally at 100 and portrayed herein for purposes of discussion as a passive-type dynamic louver vent for residential and commercial buildings. The illustrated louver vent assembly 100—also referred to herein as “vent assembly” or “louver vent” for short—is merely an exemplary application with which novel aspects of this disclosure may be practiced. In the same vein, utilization of the present concepts for unidirectional airflow control on the exterior of a residential or commercial building should also be appreciated as a non-limiting implementation of disclosed concepts. As such, it will be understood that aspects of this disclosure may be implemented for other louver vent designs, may be mounted both inside and outside of a building, and may be utilized for any logically relevant type of louver application.

The louver vent 100 of FIGS. 1-5 is portrayed as tripartite assembly that may consist essentially of: (1) a rigid backplate frame (“backplate”)104 that securely mounts onto a support structure (e.g., vertical substrate 402 of FIG. 26 or horizontal substrate 403 of FIG. 34) around a duct hole (e.g., air exhaust duct hole 101 of FIG. 26); (2) a rigid faceplate shell (“faceplate”) 102 that securely mounts onto and covers an outboard face of the backplate frame 104; and (3) a solitary adjustable louver flap (“louver flap” or “flapper”) 106 that pivotably mounts to the faceplate 102 and selectively covers/uncovers a central ventilation channel 112 that extends through the faceplate 102 and backplate 104. In accord with the illustrated example, the backplate 104 mounts, e.g., via threaded fasteners (not shown), onto the support surface 402, 403 such that a central vent hole 103 (FIG. 21) in the backplate 104 aligns with and fluidly connects to the duct hole 101 in the support surface 402, 403. The faceplate 102 mounts, e.g., via snap-fit interface (e.g., FIGS. 42-46), onto the backplate 104 such that a central flap hole 105 (FIG. 15) in the faceplate 102 aligns with and fluidly connects to the backplate's vent hole 103 and, thus, the duct hole 101. At least one louver flap 106 is movably mounted, e.g., via a uniaxial pivot joint (e.g., hinge slots 113 (FIG. 9) and hinge pins 115 (FIG. 14)), to the faceplate 102 such that the flap 106 passively rotates back-and-forth between a closed position (FIGS. 25 and 34), whereat the flap 106 covers the faceplate's flap hole 105, and an open position (FIGS. 27 and 31), whereat the flap 106 partially or completely uncovers the faceplate's flap hole 105. It should be appreciated that the shapes and sizes of the faceplate 102, backplate 104, and flap 106 may be adapted and scaled to an assortment of different applications.

The louver flap 106 of FIGS. 6-12 has an arcuate front wall 117 with a pair of flat sidewalls 119 that each projects substantially orthogonally from a respective lateral end of the front wall 117. As best seen in FIGS. 6 and 7, the louver flap's sidewalls 119 have a generally triangular shape and extend less than half the top-to-bottom longitudinal length of the flap 106. As will be described in further detail below, the louver flap 106 is fabricated with flap-balancing moment mass (MM) structure 109 that is interposed between the louver flap's sidewalls 119. This MM structure 109 is isolated to one (top) longitudinal end of the arcuate front wall 117 to locate the flap's center of mass (COM) at a predefined COM location (FIG. 41) that is engineered to bias the flap 106 to its closed position, irrespective of whether the louver vent assembly 100 is mounted vertically or horizontally. While shown with a single louver, it is envisioned that disclosed vent assemblies may include multiple flaps within the scope of this disclosure.

The backplate 104 of FIGS. 19-24 includes a ring-shaped central hub 135 with a polygonal mounting flange 121 that is integrally formed with and projects outward from an outer perimeter of one end of the central hub 135. The central hub 135 is shown as a square/rectangular annulus with four mutually orthogonal flat sides, whereas the mounting flange 121 is shown as a substantially flat four-sided square frame. As best seen in FIG. 19, the backplate's central hub 135 defines therethrough the central vent hole 103. The backplate's mounting flange 121, in contrast, may be flat so as to sit flush against the support surface 402, 403. A series of elongated fastener slots 123 (FIG. 19) are spaced around the perimeter of the mounting flange 121; each fastener slot 123 receives therethrough a respective fastener to thereby mount the backplate 104 and, thus, the vent assembly 100 to the support surface 402, 403.

With reference next to FIGS. 13-18, the faceplate 102 includes an arcuate outer shell 125 with a set of internal mounting walls 127, each of which is integrally formed with and projects inward from the outer shell 125. As best seen in FIGS. 16-18, the faceplate 102 may include four mounting walls 127 that are interconnected to form a square/rectangular annulus with an inner perimeter that is substantially coterminous with an outer perimeter of the backplate's central hub 135. As best seen in FIG. 13, the faceplate's outer shell 125 defines therethrough the flap hole 105. The faceplate's internal mounting walls 127 slide against and snap-fit to the backplate's central hub 135, e.g., via ratchet pawls 303 interlocking with ratchet teeth 203, to thereby securely mount the faceplate 102 to the backplate 104. While shown as two separate parts, it is plausible to form the faceplate 102 and backplate 104 as one piece; alternatively, the backplate 104 could be altogether eliminated from the vent assembly 100 and the faceplate 102 mounted directly to the support surface 402, 403.

For simplicity of design and manufacture, it may be desirable that the louver vent assembly 100 consist essentially of the faceplate 102, the backplate 104, and the solitary louver flap 106. According to the illustrated example, the backplate 104 is fabricated, in whole or in part, from a polymeric material as a discrete (first) single-piece structure, the faceplate 102 is fabricated, in whole or in part, from a polymeric material as a distinct (second) single-piece structure, and the louver flap 106 is fabricated, in whole or in part, from a polymeric material as another (third) single-piece structure. While not per se required, the faceplate 102, backplate 104, and flap 106 may be injection molded from the same polymeric material, such as polypropylene (PP) or polyvinyl chloride (PVC). For purposes of commercialization, it is expected that the faceplate 102 and flap 106 be preassembled as a subunit, and the subunit packaged with the backplate 104 for subsequent shipment and use.

Louver flap 106 is rotatably mounted to the faceplate 102 at an offset axis of rotation A1 (FIGS. 36-39) that is engineered to balance the louver flap 106 to allow the vent assembly 100 to be installed on both a vertical plane or a horizontal plane - and angles therebetween - with the louver flap 106 remaining closed absent the flow of air through the vent assembly 100. A pair of (first and second) hinge slots 113 (FIG. 9) extend through opposing (first and second) lateral sidewalls 119, respectively, of the louver flap 106; each hinge slot 113 receives therein a respective one of the hinge pins 115 (FIG. 14) that project inward from opposing (first and second) internal mounting walls 127 of the faceplate 102. Once the hinge pins 115 are inserted into the hinge slots 113, the offset-balanced louver flap 106 is attached to the faceplate 102 to rotate about an axis of rotation A1 that is offset from the louver flap's COM. Alternatively, the louver flap 106 may be fabricated with the hinge pins 115 and the faceplate 102 may be fabricated with the hinge slots 113. To operatively attach the louver flap 106 to the faceplate 102, the vent assembly 100 may utilize a pin-and-slot pivot joint (as shown) or other suitable connector configurations, such as ball-and-socket joints, bearing joints, bushing joints, etc.

In contrast to conventional louver vent designs, which employ a rotation pin that is located at the top center of each flap, the pivot joint 113, 115 and axis of rotation A1 of the louver flap 106 is located at a vertical axis offset D_LO (also referred to herein as “predefined longitudinal offset distance”) and a horizontal axis offset D_TO (also referred to herein as “predefined transverse offset distance”). The vertical axis offset D_LO is a longitudinal offset distance of the flap's axis of rotation A1 relative to the longitudinal length (top-to-bottom flap length L_FL in FIG. 8) of the flap 106. It may be desirable that the vertical axis offset D_LO be designed to be as small as possible. If you divide the vertical axis offset D_LO by the louver height (i.e., flap length L_FL), designs typically fall in the 15-50% range for a balanced louver flap. As shown, the longitudinal offset distance D_LO extends longitudinally from a first (top) end 129 of the louver flap 106 towards an opposing second (bottom) end 133 of the flap 106 (FIG. 8) about 20% to about 45% the longitudinal length L_FL of the flap 106 or, in a more specific example, about 35% to about 40% the flap length L_FL.

The horizontal axis offset D_TO is a transverse offset distance of the flap's axis of rotation A1 offset from a front face of the louver flap's front wall 117 relative to a transverse depth (left-to-right flap depth D_FT in FIG. 7) of the flap 106. Conventional designs position the louver's axis of rotation at a center location slightly past the louver's center of mass (e.g., typically around a 0.125″ offset); the illustrated design has a horizontal axis offset D_TO of approximately 1″. As shown, the transverse offset distance D_TO extends transversely from a first (front) surface 107 of the louver flap 106 towards an opposing second (rear) surface 137 (FIG. 11) of the flap 106 about 60% to about 95% the transverse depth D_FT of the flap 106 or, in a more specific example, about 70% to about 90% the flap depth D_FT. By moving the flap's axis of rotation A1 with the vertical offset and the horizontal offset, the offset balanced louver 106 may be strategically designed with its center of mass COM balancing the flap 106 in the closed position.

To help offset balance the louver flap 106, engineered moment mass (MM) structure 109 of a predefined shape and size is integrated into specific areas of the flap 106 in order to locate the flap COM at a predefined COM location that is designed to bias the flap 106 to the closed position. Rather than subjectively adding structure to select locations of a louver, e.g., for aesthetic or manufacturing purposes, the MM structure 109 is specifically designed to balance the louver flap 106 to remain closed sans airflow through the vent assembly 100. As best seen in FIGS. 8 and 9, this MM structure 109 may take on an assortment of different shapes, sizes, and arrangements, including ribs, pockets, features created by lifters and slides, snap-in external pieces, over-molding materials of higher density, inserting materials of higher density, threaded fasteners, etc. In FIG. 8, for example, the flap's engineered MM structure 109 is shown as a crisscross pattern of MM ribs 110 that is located on a top third of the flap's rearward-facing inboard surface 131 immediately adjacent a laterally spaced pair of the MM pockets 111. The MM ribs 110 may be about 50% to about 60% a total thickness of their adjoining surface, e.g., to help ensure that the ribs 110 do not show through flap's outboard show surface 107. In addition to the MM ribs 110, slides were used to create MM pockets 111 that are located on opposing (first and second) lateral sides of the flap's inboard surface 131. These pockets 111 are increased-thickness segments that add mass, e.g., without creating sink marks on the flap's outboard show surface 107.

FIGS. 36-39 illustrate non-limiting examples of how to determine where to position a louver flap's COM relative to the flap's axis of rotation A1. Each of these figures illustrates two shaded target zones: (1) a COM Target Zone 404, which is shown with crosshatching; and (2) a COM Marginal Zone 405, which is shown with a dot matrix. The COM Target Zone 404 is generally representative of an area in which gravitational forces based on the flap's center of mass COM and the moment created by the center of mass COM relative to the axis of rotation A1 both work together to keep the vent closed. The COM Marginal Zone 405, in contrast, is generally representative of an area in which the flap's center of mass COM can exist, but the gravitational force based on the center of mass COM and the moment created by the center of mass COM relative to the axis of rotation A1 may work against each other in some instances.

FIGS. 36 and 37 show the louver vent assembly 100 installed on a vertical support surface, such as vertical substrate 402 of FIG. 26, and FIGS. 38 and 39 show the louver vent assembly 100 installed on a horizontal support surface, such as substrate 403 of FIG. 34. FIGS. 36 and 38 portray the louver flap 106 in a closed position, thereby obstructing fluid flow through the vent assembly 100. In contrast, FIGS. 37 and 39 portray the louver flap 106 in an open position to thereby unobstruct the central ventilation channel (or “vent open area”) 112 when air flow exits the vent assembly 100. Each Figure also illustrates gravity with a downward-pointed arrow g; a compass is overlaid on each Figure with the compass being fixed relative to the offset balanced louver 106. FIG. 40 is a table that summarizes non-limiting examples of ranges for the Target Zone 404 and the Marginal Zone 405. The bottom row of the table in FIG. 40 provides representative set of design criteria for the louver flap 106 to perform in all conditions in FIGS. 36-39.

FIG. 41 shows an image of the vent assembly 100 with two representative shaded areas for a COM Design Target Zone 408 and a COM Design Marginal Zone 409. It may be desirable to create a vent assembly design that complies with the COM Design Target Zone 408 of FIG. 41. Functionality in the COM Design Marginal Zone 409, however, may be dependent on many factors, especially if higher density materials are used to fabricate the vent assembly components. If the center of mass falls outside the COM Design Target Zone 408 or the COM Design Marginal Zone 409, the louver vent may not function properly when installed on a vertical substrate 402 and/or a horizontal substrate 403 without incorporating other devices, such as magnets or springs, to bias close the flap.

Turning next to FIGS. 42-46, there are shown sectional, end-view illustrations of the representative louver vent assembly 100 of FIG. 1 showing the faceplate at a first (lowest/0-inch) locking height (FIG. 42), a second (second-lowest/0.25-inch) locking height (FIG. 43), a third (middle/0.5-inch) locking height (FIG. 44), a fourth (second-highest/0.75-inch) locking height (FIG. 45), and a fifth (highest/1.0-inch) locking height (FIG. 46). This design feature enables the vent assembly 100 to sit flush against a support surface, including surfaces with construction siding panels. Typically vent designs that install flush to a support surface do not have a back plate concealed by a face plate and, thus, have exposed fasteners that show through the outboard surface of the face plate. The disclosed vent assembly 100 may be used for vinyl siding by having adjustable snaps that help to create a siding pocket 410 (FIGS. 44-46) to hide cuts in the siding panels. Typical siding panels are at least ½ inch thick; it may therefore be desirable that the siding pocket 410 be at least ½ inch high. The one-way ratchet type interface of FIGS. 42-46 may enable at least four distinct siding pocket heights; it is envisioned, however, that the vent assembly 100 may provide greater or fewer than four pocket heights for the siding pocket 410.

As best seen in FIG. 42, a back edge 204 (FIG. 3) of the faceplate 102 may be installed flush with a back mounting surface 302 (FIG. 21) of the backplate 104 (e.g., within a tolerance of approximately 1/16″) such that both the faceplate 102 and backplate 104 seat directly on the support substrate 402, 403. This may be very useful for soffit-type installations as well as application in which the vent assembly is installed on brick cladding. Moreover, the adjustable-height faceplate design allows the back edge 204 of the faceplate 102 to be installed flush with an outboard surface of one or more neighboring siding panels while the back mounting surface 302 of the backplate 104 sits flush against the vertical/horizontal substrate 402, 403.

The faceplate 102 and backplate 104 may join together via a snap-fit interface. By way of example, and not limitation, the backplate 104 has one or more ratchet pawls 303 (also referred to herein as “locking tooth”) that is/are located at one or more designated areas of the central hub 135. Each locking tooth 303 mates with and locks to a corresponding set of ratchet teeth 203 (also referred to herein as “lock receivers”) located on the internal mounting walls 127 of the faceplate 102. It is envisioned that this design may be reversed with the lock receivers (203) located on the backplate 104 and the locking tooth 303 located on the faceplate 102. If the louver vent assembly 100 is shipped with the faceplate 102 secured to the backplate 104 with a zero depth siding pocket 410, as seen in FIG. 42, a finger access hole 304 may be formed or machined into the backplate 104 to allow the installer to separate the two pieces for installation.

Aspects of this disclosure are directed to vent assemblies with an offset balanced louver that can function as both a vertically mounted utility vent or a horizontally mounted soffit/ceiling vent. The offset balanced louver may include an axis of rotation with a horizontal offset and a vertical offset that utilizes Moment Mass of the louver flap to create an object that has a center of mass in the range of 345-90 degrees from the axis of rotation, with 180 degrees being the direction of gravity when installed on a vertical substrate. The moment mass may be fabricated from various materials, including metal or plastic. The moment mass material may have a separate (higher) density than the material used to fabricate the louver flap. The flap's center of mass may range from about 30-90 degrees from the axis of rotation, with 190 degrees being the direction of gravity when the vent assembly is installed on a vertical substrate. The axis of rotation may correspond with, but is not per se limited to, a hole, dowel or other rotation feature.

Disclosed vent assemblies may be implemented for exhaust only or intake only applications. As a further option, a backplate is not per se critical to disclosed vent designs; for flush mount only applications, the backplate could be eliminated from the assembly. Disclosed louver vent assemblies may take on multiple louver designs or single-louver (flapper) designs. A rearmost edge of the faceplate may install flush with the mounting surface such that the backplate is located entirely inside the faceplate, sandwiched between the faceplate and support surface. The vent assembly may have an adjustable-height faceplate design that provides a siding pocket with a variable depth/height. A finger hole may be included in the faceplate or backplate to help separate faceplate and backplate when preassembled and distributed at a zero pocket depth.

For at least some embodiments, the louver may rotate in only two directions (as shown) or may take on multi-axis designs that swing in more than two directions. This allows the louver vent assembly to be used in multiple orientations, with multiple louver flaps, and with different vent installation methods/designs. It is also envisioned that the louver vent assembly may be a tripartite construction (as shown), a bipartite construction that consists essentially of the faceplate and the louver flap, or a single-piece construction that consists essentially of the louver flap. As a further option, the MM structure may be the same material as the louver flap, may be a different material from the flap, or may be fabricated from composite or mixed-density materials.

For at least some embodiments, the faceplate and backplate may be fabricated as a single-piece structure or, alternatively, the louver vent may consist essentially of a louver flap that mounts directly to the support structure. Alternatively, the louver vent assembly may include components in addition to the faceplate, backplate, and flap, such as seals, gaskets, additional flaps, etc. Other configurations may mount directly to a siding panel, may slide into a duct collar, may use screws or bolts instead of a snap-fit interface, or may be integrated into a soffit panel. It may also be desirable that the louver vent assembly be characterized by a lack of magnets, springs, motor, pneumatic/air cylinders, etc. for biasing closed the louver flap.

For at least some embodiments, the louver vent assembly may include one or more segmented louvers. It is also envisioned that the counterweight MM structure may be positioned at locations that are not interposed between the louver flap's sidewalls. For example, a counterweight may be attached to a pivot rod between the outside area of the faceplate edge and the backplate. To that end, MM structure could be positioned anywhere within the envelope of the part. As a further option, the pivot joint may only have a height offset but no depth offset, or a depth offset but no height offset.

Aspects of the present disclosure have been described in detail with reference to the illustrated embodiments; those skilled in the art will recognize, however, that many modifications may be made thereto without departing from the scope of the present disclosure. The present disclosure is not limited to the precise construction and compositions disclosed herein; any and all modifications, changes, and variations apparent from the foregoing descriptions are within the scope of the disclosure as defined by the appended claims. Moreover, the present concepts expressly include any and all combinations and subcombinations of the preceding elements and features.