Assembly and method for preventing water damage to insulated exhaust ducts

Abstract

An exhaust vent cap assembly can be installed in a roof deck of a building to allow a one-time connection of the insulated duct to the roof from exhaust fans within the building.

Claims

1. A method for installing an insulated duct of a ventilation system, the method comprising the steps of: providing an exhaust vent cap assembly, the exhaust vent cap assembly comprising: a tubular body, the tubular body comprising: a hollow tube having a proximal end and a distal end, a flange extends around a periphery of the proximal end perpendicularly to the hollow tube, and a mouth upstanding from the proximal end of the hollow tube, a cap configured to sealably fasten to the mouth, the cap and the mouth having a fastening mechanism, wherein an outer diameter of the cap is substantially same as an outer diameter of the mouth; making a hole in a roof deck, the diameter of the hole permits the mouth of the tubular body to slide into the hole; inserting the mouth of the tubular body into the hole, wherein the flange rests against an underneath of the roof deck; securing the flange to the roof deck using one or more screws; upon securing the flange, securing the insulated duct to the tubular body; and later removing the cap from the mouth; and upon removing the cap, installing a permanent roof cap.

2. The method according to claim 1, wherein the mouth and the hollow tube are integral, and the flange is mechanically attached.

3. The method according to claim 1, wherein the flange and the hollow tube are integral, and the mouth is mechanically attached.

4. The method according to claim 1, wherein the flange and the mouth are integral and hollow tube is mechanically attached.

5. The method according to claim 1, wherein the hollow tube, the mouth, and the flange are integral.

6. The method according to claim 1, wherein the cap and the mouth are having threads for securing the cap to the mouth, the cap is having a handle for turning the cap.

7. The method according to claim 1, wherein the cap and the mouth are configured for snap-fitting the cap onto the mouth.

8. The method according to claim 7, wherein the cap is having a furrow as a handle for lifting the cap.

9. The method according to claim 1, wherein the cap and the mouth are configured for friction fit.

10. The method according to claim 1, wherein the exhaust vent cap assembly further comprises an O-ring between the cap and the mouth for water tightness.

11. The method according to claim 1, wherein the flange is planar.

Description

BRIEF DESCRIPTION OF DRAWINGS

(1) The accompanying figures, which are incorporated herein, form part of the specification and illustrate embodiments of the present invention. Together with the description, the figures further explain the principles of the present invention and to enable a person skilled in the relevant arts to make and use the invention.

(2) FIG. 1 is a perspective view of the disclosed exhaust vent cap assembly, according to an exemplary embodiment of the present invention.

(3) FIG. 2 is an exploded view showing the cap and the tubular body of the disclosed exhaust vent cap assembly, according to an exemplary embodiment of the present invention.

(4) FIG. 3 is a side planar view of the exhaust vent cap assembly, according to an exemplary embodiment of the present invention.

(5) FIG. 4 is a sectional view of the exhaust vent cap assembly taken along the line 8-8 of FIG. 3, according to an exemplary embodiment of the present invention.

(6) FIG. 5 is a bottom view of the exhaust vent cap assembly, according to an exemplary embodiment of the present invention.

(7) FIG. 6 is an exploded perspective view of another exemplary embodiment of the exhaust vent cap assembly, according to the present invention.

(8) FIG. 7 is a perspective view of another exemplary embodiment of the exhaust vent cap assembly, according to the present invention.

(9) FIG. 8 is a side view of the exhaust vent cap assembly shown in FIG. 7, according to an exemplary embodiment of the present invention.

(10) FIG. 9 is a sectional view of the exhaust vent cap assembly taken along the line 27-27 shown in FIG. 8, according to an exemplary embodiment of the present invention.

(11) FIG. 10 shows the exhaust vent cap assembly installed in a roof deck and connected to a duct, according to an exemplary embodiment of the present invention.

DETAILED DESCRIPTION

(12) Subject matter will now be described more fully hereinafter with reference to the accompanying drawings, which form a part hereof, and which show, by way of illustration, specific exemplary embodiments. Subject matter may, however, be embodied in a variety of different forms and, therefore, covered or claimed subject matter is intended to be construed as not being limited to any exemplary embodiments set forth herein; exemplary embodiments are provided merely to be illustrative. Likewise, a reasonably broad scope for claimed or covered subject matter is intended. Among other things, for example, the subject matter may be embodied as methods, devices, components, or systems. The following detailed description is, therefore, not intended to be taken in a limiting sense.

(13) The word “exemplary” is used herein to mean “serving as an example, instance, or illustration.” Any embodiment described herein as “exemplary” is not necessarily to be construed as preferred or advantageous over other embodiments. Likewise, the term “embodiments of the present invention” does not require that all embodiments of the invention include the discussed feature, advantage, or mode of operation.

(14) The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of embodiments of the invention. As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises”, “comprising,”, “includes” and/or “including”, when used herein, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof.

(15) The following detailed description includes the best currently contemplated mode or modes of carrying out exemplary embodiments of the invention. The description is not to be taken in a limiting sense but is made merely for the purpose of illustrating the general principles of the invention, since the scope of the invention will be best defined by the allowed claims of any resulting patent.

(16) Disclosed is an exhaust vent cap assembly for a ventilation system of a building. The disclosed exhaust vent cap assembly secures the insulated exhaust ducts of the ventilation system to the roof deck or outer wall of the building. Disclosed exhaust vent cap assembly eliminates the redundant work and the extra costs associated with replacing the insulated exhaust ducts in the attic that are damaged by water and stopping water from entering the house through the exhaust fans.

(17) Referring to FIG. 1, which shows the disclosed exhaust vent cap assembly 100 having a cap 110 and a tubular body 120. FIG. 2 is an exploded view of the exhaust vent cap assembly 100 showing the cap 110 separated from the tubular body 120. The tubular body 120 having a cylindrical hollow tubular body 130 that is rigid and made of durable material. The cylindrical hollow tubular body 130 having a proximal end and a distal end. Around the periphery of the proximal end of the cylindrical hollow tubular body 130 extends a flange 140 perpendicular to the cylindrical hollow tubular body 130. The flange 140 can be used to secure the disclosed exhaust vent cap assembly 100 to the roof deck or the outer wall. The flange 140 can be welded to the tubular body 130, mechanically fastened or can be continuous with the wall of the tubular body. At the proximal end of the tubular body can be seen a mouth 150 of the tubular body 120. The mouth and the cap can have a fastening mechanism for securing the cap to the mouth. The cap sealably engages with the mouth 150 of the tubular body 120 to prevent the ingress of water into the tubular body and the ducts. FIG. 2 shows the cap and the mouth having corresponding threads 160 and 170 for securing the cap 110 to the mouth. An O-ring may be used between the cap 110 and mouth 150 to further assist in water tightness. FIG. 3 is a side planar view and FIG. 4 is a sectional view showing the cap secured to the mouth wherein the threads of the cap are engaged to the threads of the mouth of the tubular body. A ridge 190 can also be seen in FIG. 4 which helps in retaining the duct over the tubular body. FIG. 5 is a bottom view of the tubular body 120 showing the hollow cylindrical tubular body. The cap can also include a handle 180 for turning the cap 110 over the mouth 150 of the tubular body 130.

(18) The fastening mechanism and the handle can be varied for desired water tightness. FIG. 2 shows the roof cap assembly having the screw mechanism. The screw mechanism can be replaced by the snap-fit mechanism. FIG. 6 shows the assembly 200 having the cap and mouth, wherein the cap can be snap-fit over the mouth of the tubular body. The cap can be plane from inside, wherein vertical ridges 210 are shown on an outer surface of the mouth. The vertical ridges around the mouth can be replaced by horizontal ridges that surround the mouth. The top of the cap is planar and may not have any handle.

(19) FIG. 7 shows another exemplary embodiment of the exhaust vent cap assembly 300, wherein the cap 305 is having a furrow 310 which can act as a handle for lifting the cap 305. FIG. 8 is a side view of the exhaust vent cap assembly 300. FIG. 9 is a cross-sectional view of the exhaust vent cap assembly shown in FIG. 8 taken along line 27-27. The tubular body can have circling recess 320 which engages with a dimple 330 in the outer wall of the cap 305. This assembly can be made from a variety of materials, such as plastics, metal, composite materials, etc. The shape of the cap and handle can be varied. Similarly, any fastening mechanism for sealably securing the cap to the tubular body is within the scope of the present invention.

(20) The removable cap can have different shapes to achieve water tightness. It can be snapped onto the top of the tubular member. It can also be a shape of a lid that goes over the tube having friction fit, a cap that can be screwed onto the tubular member by fasteners, or other methods of securing the cap to the tubular member so it is not easily removed by wind. All these methods are meant to produce a waterproof assembly so water may not be able to seep inside the insulated ducts.

(21) FIG. 10 shows the exhaust vent cap assembly installed on an underside of a roof deck 430 and secured to the duct 400 of the ventilation system. First, a hole can be made in the roof deck 430. The diameter of the hole in the roof deck can be the same as the external diameter of the mouth of the tubular body 410, such as the mouth can slide into the hole. The mouth is inserted into the hole while the flange 420 rests against the underneath of the roof deck 430. The flange 420 can then be secured to the roof deck using fasteners. The mouth of the tubular body can extend above the roof surface. Cap 450 can be secure to the mouth for preventing the ingress of water into the duct.

(22) The duct 400 can be pushed onto the distal end of the tubular body and secured using fasteners 440 and/or a strap. A tubular body can have a protrusion 460 that further prevents slipping of the duct over the tubular body. An instruction label will be affixed or printed on the cap for a roofer to remove before they install the permanent roof cap 470.

(23) Alternatively, this disclosed exhaust vent cap assembly can also be attached to one end of the exhaust duct in a factory for ease of installation in the field. All the installer has to do is to make a hole in the roof deck, as usual, insert the device through the hole and screw the flange with few fasteners underneath the roof deck and connect the other end to the exhaust fan. Roofers can remove the removable cap later without the chance of water entering the house or damaging the duct insulation.

(24) While the foregoing written description of the invention enables one of ordinary skill to make and use what is considered presently to be the best mode thereof, those of ordinary skill will understand and appreciate the existence of variations, combinations, and equivalents of the specific embodiment, method, and examples herein. The invention should therefore not be limited by the above-described embodiment, method, and examples, but by all embodiments and methods within the scope and spirit of the invention as claimed.