ASSEMBLY 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. An 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; and 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.

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

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

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

5. The exhaust vent cap assembly according to claim 1, wherein hollow tube, the mouth, and the flange are integral.

6. The exhaust vent cap assembly 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 exhaust vent cap assembly according to claim 1, wherein the cap and the mouth are configured for snap-fitting the cap onto the mouth.

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

9. The exhaust vent cap assembly according to claim 1, wherein the cap and the mouth are configured for a friction fit.

10. An 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; and a duct, the duct has a proximal end and a distal end, the proximal end of the duct is coupled to the distal end of the hollow tube.

11. The exhaust vent cap assembly according to claim 10, wherein the mouth and the hollow tube are integral, and the flange is mechanically attached.

12. The exhaust vent cap assembly according to claim 10, wherein the flange and the hollow tube are integral, and the mouth is mechanically attached.

13. The exhaust vent cap assembly according to claim 10, wherein the flange and the mouth are integral and elongated cylindrical hollow tube is mechanically attached.

14. The exhaust vent cap assembly according to claim 10, wherein the hollow tube, the mouth, and the flange are integral.

15. The exhaust vent cap assembly according to claim 10, 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.

16. The exhaust vent cap assembly according to claim 10, wherein the cap and the mouth are configured for snap-fitting the cap onto the mouth.

17. The exhaust vent cap assembly according to claim 16, wherein the cap is having a furrow as a handle for lifting the cap.

18. The exhaust vent cap assembly according to claim 10, wherein the cap and the mouth are configured for a friction fit.

Description

BRIEF DESCRIPTION OF DRAWINGS

[0020] 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.

[0021] FIG. 1 is a perspective view of the disclosed exhaust vent cap assembly, according to an exemplary embodiment of the present invention.

[0022] 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.

[0023] FIG. 3 is a side planar view of the exhaust vent cap assembly, according to an exemplary embodiment of the present invention.

[0024] 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.

[0025] FIG. 5 is a bottom view of the exhaust vent cap assembly, according to an exemplary embodiment of the present invention.

[0026] FIG. 6 is an exploded perspective view of another exemplary embodiment of the exhaust vent cap assembly, according to the present invention.

[0027] FIG. 7 is a perspective view of another exemplary embodiment of the exhaust vent cap assembly, according to the present invention.

[0028] 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.

[0029] 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.

[0030] 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.

[0031] FIG. 11 shows a flange of the exhaust vent cap assembly that has apertures with sealed knockouts, according to an exemplary embodiment of the present invention.

[0032] FIG. 12 is a sectional view of the exhaust vent cap assembly with a tie to secure the duct, according to an exemplary embodiment of the present invention.

[0033] FIG. 13 shows another embodiment of the exhaust vent cap assembly for a wall, according to an exemplary embodiment of the present invention.

DETAILED DESCRIPTION

[0034] 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.

[0035] 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.

[0036] 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.

[0037] 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.

[0038] 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.

[0039] 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 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. 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.

[0040] 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.

[0041] 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.

[0042] 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.

[0043] 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 secured to the mouth for preventing the ingress of water into the duct.

[0044] 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 the 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.

[0045] 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 a 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.

[0046] The different components of the disclosed exhaust vent cap assembly can be made of different materials, such as virgin or recycled plastics, sheet metal, metal casting, PVC, or any material that is commonly used.

[0047] Referring to FIG. 11 shows an exemplary embodiment of a cylindrical hollow tubular body 1100 with a flange 1110. The flange 1110 has holes 1120 that are sealed by one or more knockouts 1130. The knockouts 1130 can be broken to gain access through the holes 1120. Insulation foam can be delivered through the holes, such as a tip of a foam insulating tool can be inserted into the holes for applying foam insulation. The foam insulation can fill in any gaps created by drilling holes in the roof or the wall. For example, the diameter of the hole drilled in a structure for installing the vent can be larger than the tubular body of the disclosed assembly. The space between the structure and the tubular body can be filled with insulation foam. The knockout can sealably cover the holes and can be of a thin profile that can be broken, such as using a sharp object. For example, plastic can be used for knockouts that can easily rupture. When using metal for the knockouts, perforation in the periphery or a similar line of weakness can be provided.

[0048] The above embodiments describe the assembly for use in roof vents, however, the disclosed assembly can also be adapted for vents in the wall. Vents can be provided on the walls of a building, in particular, multistory buildings, such as multi-family dwellings, offices, or commercial places. Currently, the exhaust vents that are inside the building envelope for bathroom fans, dryers, or other equipment that need exhaust vents to outside are commonly placed in the band boards, exterior walls, attic gable ends, or roof area. Typically, a hole for the vent is drilled in the perimeter of the house and through the band board. Band boards are usually a wood product that covers the ends of the floor joists. The hole for the vent can also be made in the exterior sheeting or bandboard. The disclosed exhaust vent assembly can be adapted for such wall vent holes. Advantage of the disclosed vent assembly in the side mount applications is that it can be installed from inside the house instead of outside as it is currently done. Thus, making installation of the vent assembly much easier. FIG. 12 illustrates an exhaust vent assembly 1200 that includes a cap 1210 and a tubular body 1220. The tubular body is a cylindrical hollow tubular body that is rigid and made of durable material. The cylindrical hollow tubular body has a proximal end and a distal end. Around the periphery of the proximal end of the cylindrical hollow tubular body is a flange 1225 that extends perpendicular to the cylindrical hollow tubular body. The flange can be used to secure the disclosed exhaust vent cap assembly to a band board 1230. At the proximal end of the tubular body can be seen a mouth 1260 of the tubular body. The exhaust vent assembly adapted for mounting to a wall vent can be similar to the above-described exhaust vent assembly in FIGS. 1-10 and thus the details are not repeated herein.

[0049] For installation, the tubular body can be inserted into the vent hole. The duct 1240 extending from the vent of the room’s exhaust system can be coupled to the tubular body of the disclosed assembly and the cap can be secured. Alternatively, the cap can be pre-secured to the mouth. In another implementation, the duct can be a part of the disclosed assembly, wherein the duct, the tubular body, and the cap can be pre-assembled i.e., the cap is secured to the mouth and the duct is secured to the tubular body. The free end of the duct can be coupled to the fan 1250. The cap is accessible from outside of the wall and can be removed later and a permanent cap can be placed over the vent hole. The disclosed assembly with or without the duct can be installed from inside of the wall. Perhaps, installing from inside can be safer avoiding the need for climbing tall ladders thus addressing the fall or injury concerns using tall ladders or complications associated with installation from outside. Moreover, installing from inside the wall can be easier and quicker. A tie strap 1270 can secure the duct mounted over the tubular body.

[0050] For Installation, a hole can be drilled in an exterior sheeting of a structure from the inside. Then the tubular body with the cap secured to the mouth can be inserted from the inside and the flange of the tubular body can be secured using multiple fasteners, such as screws. The flexible duct may already be attached to the tubular body or can be attached to the tubular body. The free end of the duct can be extended to the fan of the ventilation system. The removable and disposable cap of the disclosed exhaust vent assembly can seal the vent hole preventing ingress of dust and water. Upon finishing the exterior of the wall (structure), the cap of the disclosed exhaust vent assembly can be removed, and a permanent cap of choice can be installed. The temporary cap can be designed in several ways as shown in FIGS. 1-10.

[0051] Referring to FIG. 13 shows an exemplary embodiment of the disclosed exhaust vent assembly 1300. The exhaust vent assembly 1300 includes a tubular body 1310, the tubular body has a mounting flange 1320 and removable cap 1330 coupled to the mouth 1340. The tubular body 1310 has a rim-like profile that can receive a flexible duct, the tubular body has protrusions to prevent the flexible duct from slipping out. Also, a zip tie 1360 is shown wrapped around the duct tightening the duct around the tubular body. The flexible duct can also be taped to the tubular body using foil tape or other adhesives appropriate for this application. Instead of flexible ducts, rigid ducts can also be used and are within the scope of the present invention. For a rigid duct, the end of the tubular body can be tapered inwards so that the duct can easily go over the sleeve of the tubular body.

[0052] In one implementation, the length of the tubular body can be made of different sizes to allow for various thicknesses in the framing structures. The length of the tubular body and its diameter is of sufficient size to allow ease of use. This invention is designed to fit various sizes of flexible or rigid ducts in the market, such as 4", 6", 8", 10", or any other conceivable size. Rigid ducts are typically made of sheet metal and flexible ducts with plastic tubes with wire reinforcement having outer insulation and some are made of aluminum.

[0053] 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.