VENTILATION FAN TRIM RING AND SYSTEM

Abstract

A ventilation fan trim ring is disclosed, and may include a base, a wall extending from the base, an opening defined by a concave portion of the base, and at least one slot defined by a slot portion of the base. The base may have a first surface and a second surface opposing the first surface. The wall may extend from the base in a first direction. The wall may define an interior space of the base. The opening may be arranged in the interior space of the base. The concave portion of the base may extend in the first direction.

Claims

1. A ventilation fan trim ring, comprising: a base having a first surface and a second surface opposing the first surface; a wall extending from the base in a first direction, the wall defining an interior space of the base; an opening defined by a concave portion of the base arranged in the interior space of the base, the concave portion of the base extending in the first direction; and at least one slot defined by a slot portion of the base.

2. The ventilation fan trim ring of claim 1, wherein the base of the trim ring is configured to extend beyond an edge of an opening in a drywall, ceiling, or other wall material in which the ventilation fan trim ring is configured to be installed.

3. The ventilation fan trim ring of claim 1, wherein the walls on the second surface of the base are closer to the opening than outward edges of the base.

4. The ventilation fan trim ring of claim 1, wherein the slot portion of the base extends in the first direction from the second surface of the base, wherein each slot has an entry end and an exit end, each slot defining: a first stage section on the entry end of the slot, the first stage section having opposing walls parallel with a longitudinal axis of the slot; a second stage section adjacent to the first stage section opposite the entry end of the slot, the second stage section having opposing walls oblique to the longitudinal axis of the slot; and a third stage section on the exit end of the slot and adjacent to the second stage section, the third stage section having opposing walls parallel with a longitudinal axis of the slot.

5. The ventilation fan trim ring of claim 1, wherein each slot of the at least one slot has a first opening and a second opening opposite the first opening, wherein the first opening is integrally formed in the first surface of the base.

6. The ventilation fan trim ring of claim 1, wherein the base includes a rim extending around a periphery of the opening.

7. The ventilation fan trim ring of claim 1, wherein the opening is configured to receive a portion of a ventilation fan.

8. The ventilation fan trim ring of claim 1, wherein the at least one slot includes two slots arranged on opposing sides of the base.

9. The ventilation fan trim ring of claim 1, wherein each slot of the at least one slot is configured to accommodate one or more spring clips therein.

10. The ventilation fan trim ring of claim 1, wherein the at least one slot is positioned in the interior space of the base.

11. The ventilation fan trim ring of claim 1, wherein the slot portion of the base extends in the first direction farther than the wall.

12. The ventilation fan trim ring of claim 1, wherein the ventilation fan trim ring is configured to couple to a shield by way of a connector extending through the at least one slot.

13. The ventilation fan trim ring of claim 1, wherein the wall includes a first wall portion, a second wall portion, a third wall portion, and a fourth wall portion, wherein the first wall portion is parallel to the second wall portion, wherein the third wall portion is parallel to the fourth wall portion, wherein the first and second wall portions are transverse to the third and fourth wall portions.

14. The ventilation fan trim ring of claim 13, wherein the first wall portion, the second wall portion, third wall portion, and the fourth wall form a continuous polygonal shape.

15. A ventilation fan assembly, comprising: a ventilation fan having a housing; a trim ring including a base removably coupled to an internal portion of the housing; and a shield coupled to the trim ring and substantially covering the housing and trim ring.

16. The ventilation fan assembly of claim 15, wherein the trim ring includes a slot configured to receive a connection device of the shield therethrough, the connection device configured to couple the shield to the trim ring.

17. The ventilation fan assembly of claim 15, wherein ventilation fan assembly is configured such that an end of the connection device enters the internal portion of the housing when a width of the first end of the spring clip is expanded to be greater than a distance between opposing walls of an exit end of the slot.

18. The ventilation fan assembly of claim 15, wherein the trim ring includes an opening configured to receive a component from the ventilation fan.

19. The ventilation fan assembly of claim 15, wherein the shield is spaced apart from the trim ring.

20. The ventilation fan assembly of claim 19, wherein the shield is spaced apart from the trim ring by way of a fastener extending from the shield, and wherein the trim ring is configured to receive the fastener in a surface of the trim ring.

Description

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

[0012] FIG. 1 illustrates a front perspective view of a conventional ventilation fan.

[0013] FIG. 2 illustrates an internal perspective view of a trim ring cover for a ventilation fan, according to one example embodiment of the present disclosure.

[0014] FIG. 3 illustrates an external perspective view of the trim ring cover of FIG. 2.

[0015] FIG. 4 illustrates a cross-sectional view of the trim ring cover of FIG. 2.

[0016] FIG. 5 illustrates the trim ring cover of FIG. 2 coupled to a ventilation fan system positioned in a drywall ceiling or subfloor, according to one example embodiment.

[0017] FIG. 6 illustrates an exploded view of a ventilation fan system of the present disclosure, including the trim ring cover of FIG. 2.

[0018] FIG. 7 illustrates a front-side view of an assembled ventilation fan system as shown in FIG. 6.

[0019] FIG. 8 illustrates a cross-sectional view of the trim ring cover of FIG. 2 during a first step of installation of a trim ring shield for a ventilation fan.

[0020] FIG. 9 illustrates a cross-sectional view of the trim ring cover of FIG. 2 during a second step of installation of a trim ring shield for a ventilation fan.

[0021] FIG. 10 illustrates a cross-sectional view of the trim ring cover of FIG. 2 during a third step of installation of a trim ring shield for a ventilation fan.

[0022] FIG. 11 illustrates a cross-sectional view of the trim ring cover of FIG. 2 following installation of a trim ring shield for a ventilation fan.

DETAILED DESCRIPTION

[0023] In the following description, certain specific details are set forth in order to provide a thorough understanding of various disclosed implementations. However, one skilled in the relevant art will recognize that implementations may be practiced without one or more of these specific details, or with other methods, components, materials, etc. In other instances, well-known structures associated with exhaust fans, ventilation fans, fan motors, and other ventilation system components have not been shown or described in detail to avoid unnecessarily obscuring descriptions of the implementations.

[0024] Unless the context requires otherwise, throughout the specification and claims which follow, the word comprise and variations thereof, such as, comprises and comprising are to be construed in an open, inclusive sense, that is as including, but not limited to.

[0025] Referring initially to FIG. 1, shown therein is a conventional ventilation fan 100 commonly known within the art, that is mounted to a ceiling, drywall, or subfloor 119. The ventilation fan 100 is typically installed within a building structure to ventilate a residential or commercial space. The ventilation fan 100 in FIG. 1 is installed in the drywall 119 using a conventional installation method, wherein the ventilation fan 100 is positioned within an opening or hole in the drywall 119 such that a portion of the ventilation fan is exposed, and a portion is protruding and/or extending into a wall space or an attic space 107. The ventilation fan 100 includes a grille 105 that serves as a cover for the ventilation fan 100.

[0026] A portion of the ventilation fan 100 comprises a can or housing 123 that protrudes into the attic space 107, and a portion that comprises the grille 105 which is adjacent to the surface of the drywall 119 (the grille 105 in FIG. 1 is illustrated in a translucent manner for illustrative purposes). The housing 123 may be metal. Ventilation fans are generally equipped with a type of metal housing that is structured around the fan. The metal housing 123 is configured with mounting brackets (not shown) and a plurality of openings on one or more surfaces of the metal housing 123.

[0027] The metal housing 123 comprises a fan motor (not shown) that is secured within an internal portion of the metal housing 123. The grille 105 is arranged on a front portion of the ventilation fan 100 to conceal the motor for aesthetic reasons. However, in this configuration and design of the ventilation fan 100 and grille 105, several perforations exist in both the external and internal components of the ventilation fan 100. Airflow or air leakage within a building structure, such as drafts and ineffective seals around openings, can further cause the airflow to weep out of the metal housing openings or other openings in the metal housing that may be part of the mounting system or electrical outlets, such as wiring knockouts. For example, air flow 103 may flow through crevices where the grille 105 mates with the drywall 119 or may escape directly from the openings in the metal housing, as illustrated with arrows 103 flowing through the grille 105, through the crevices between the grille 105 and the drywall 119, or directly out of the metal housing 123 into the attic space 107.

[0028] In accordance with the present disclosure in FIGS. 2 and 3, shown therein is a ventilation fan trim ring 200 for a ventilation fan 204, according to one example embodiment. The trim ring 200 is designed in a manner that minimizes air loss from conditioned air in the room to non-conditioned air in attics and subfloors, which is persistent with conventional ventilation fans as demonstrated in FIG. 1. The trim ring 200 generally comprises a ventilation fan cover that improves the ability to seal and cut airflow drafting and heat exchange loss when integrated with a ventilation fan/system. For example, the inventor(s) conducted tests to determine an amount of air loss that occurred when the trim ring 200 was attached to a ventilation fan. Test results showed that when used in conjunction with a ventilation fan, the trim ring 200 reduced air loss by 75%.

[0029] The trim ring 200 is configured with a substantially planar base 206 having a first side or surface 201 and a second side or surface 202. The first surface 201 of the trim ring 200 is exposed to the conditioned area or room, and the second surface 202 is exposed to the attic space 107. The base 206 of the trim ring 200 is configured to mesh with the drywall 119 such that the first surface 201 of the base 206 extends beyond one or more edges 120 of the drywall 119 whereupon an opening or hole is present for placement of the ventilation fan 200. The extension of a portion of the base 206, more particularly the first surface 201, is advantageous because the over-extension across the one or more edges 120 of the drywall prevents unwanted air loss that may flow through the edge of the drywall and/or ventilation fan, as typically seen in conventional ventilation fan designs. With the trim ring 200 extending beyond the one or more edges 120 and onto the drywall 119, a type of sealing is created allowing air only to flow into the center opening e.g., the ventilation fan, which would flow out of the vent pipe only. In other words, the trim ring 200 may control and mitigate air loss.

[0030] The second surface 202 of the base 206, shown in FIG. 2, comprises a wall 203 positioned apart from an edge of the base 206. The wall 203 extends around the base 206 of the trim ring 200, and is integrally formed having a first side 203a, a second side 203b, a third side 203c, and a fourth side 203d. However, in some embodiments, the wall 203 may be structured in a different configuration, and/or may be positioned or coupled to the base 206 in an alternative manner. In this embodiment, wall 203 vertically extends in a first direction D1, away from the base 206 of the trim ring 200, and together define an interior space 208 of the trim ring 200. The walls 203 are configured to frame or enclose the opening in the drywall 119, such that the interior space 208 completely occupies any free space remaining within the opening in the drywall between the conditioned space and the unconditioned space, effectively sealing off further potential gaps and crevices to prevent air loss.

[0031] The trim ring 200 further includes a concave opening 215 positioned in the interior space 208 between the plurality of walls 203. The opening 215 may be centrally positioned in the interior space 208, but this central positioning is not required. The opening 215 is defined by one or more chamfered or angled walls 213 (most clearly shown in FIG. 3) that extend in the first direction, culminating in a circular ring or rim 211 configured to fit a ventilation fan. In some embodiments, the size and structure of the opening 215 may differ and may be determinative by the size of the ventilation fan, system, or other relevant factors deemed necessary by the manufacturer and/or user. The wall 203 may be closer to the concave opening 215 than edges of the base 206.

[0032] The trim ring 200 further comprises, on two opposite sides of the concave opening 215, a pair of slots or spring slots 205. A portion of each spring slot 205 is interposed between the wall 203 and the concave opening 215 on the second surface 202 of the base 206. Each spring slot 205 is configured to receive a spring clip that couples a shield 221 to the trim ring 200, which will be described in further detail below. Although two spring slots 205 are shown in the embodiment shown in the figures, any number of spring slots 205 may be utilized.

[0033] Each spring slot 205 is coupled to the base 206 of the trim ring 200 and constructed in a chimney-shaped structure. The chimney-shaped structure comprises both straight and angled portions. Such a configuration enables a user to straightforwardly insert a spring clip into the spring slot 205 on one side, proceeding to the next spring clip on the other side without having to hold the first spring on the first side, and then pushing the shield up, snapping the spring clips into place and coupling the shield 221 to the trim ring 200.

[0034] Each respective spring slot 205 comprises an internal slot opening 207 and an external slot opening 209. This configuration of the spring slot 205 also allows easy accessibility during installation of the ventilation fan. For example, during installation of the ventilation fan 100 described with reference to FIG. 1, a user would blindly freehand spring clips into the housing in order to find the holes or slots inside of the metal can. In the present disclosure, the spring slots 205 and the slot openings 207, 209 are advantageously positioned on the first surface 201 of the trim ring 200, as demonstrated in FIG. 3.

[0035] Furthermore, the spring slots 205 may be utilized to guide spring clips 223 (shown in FIGS. 8-11) therethrough. Each respective spring clip 223 may extend from the shield 221. After proceeding through the respective spring slot 205, the respective spring clip 223 may be coupled to a spring clip receptacle 224 (shown in FIG. 6) of the housing 123. The spring clip receptacle 224 may be positioned in an interior space of the housing 123. The spring clip receptacle 224 may include at least one aperture configured to receive a portion of a respective spring clip 223 therethrough. The spring clip receptacle 224, specifically the at least one aperture thereof, may be positioned against the internal slot opening 207 of a respective spring slot 205 when the trim ring 200 is installed.

[0036] FIG. 4 shows a cross-sectional view of the trim ring 200 taken along line 4-4 of FIG. 2, showing the internal structure of the spring slots 205. The spring slots 205 may define a plurality of stages on an interior 225 thereof. In the embodiment shown in FIG. 4, the spring slots 205 each define a first stage section 227, a second stage section 229, and a third stage section 231.

[0037] The first stage section 227 is adjacent to the external slot opening 209 of the spring slots 205. Put another way, the first stage section 227 may be on the entry end of the spring slot 205. The first stage section 227 includes opposing walls 233 which at least partially define an interior 235 of the first stage section 227. The opposing walls 233 of the first stage section 227 may be generally parallel with a longitudinal axis A1 of the spring slots 205.

[0038] The second stage section 229 is positioned adjacent to the first stage section 227 opposite the external slot opening 209 of the spring slot 205. The second stage section 229 includes opposing walls 237 which at least partially define an interior 239 of the second stage section 229. The opposing walls 237 may be generally oblique to the longitudinal axis A1 of the spring slot 205. Specifically, the opposing walls 237 may be angled relative to each other, such that a distance D2 between the opposing walls 237 adjacent to the first stage section 227 is larger than a distance D3 between the opposing walls 237 at an opposite end of the second stage section 229. In other words, the interior 239 of the second stage section 229 between the opposing walls 237 may narrow as a distance from the first stage section 227 increases. The opposing walls 237 of the second stage section 229 may form a continuous structure with the opposing walls 233 of the first stage section 227.

[0039] The third stage section 231 is positioned adjacent to the second stage section 229 opposite the first stage section 227. The third stage section 231 may have opposing walls 241 which at least partially define an interior 243 of the third stage section 231. The opposing walls 241 of the third stage section 231 may be generally parallel with the longitudinal axis A1 of the spring slot 205. The opposing walls 241 of the third stage section 231 may form a continuous structure with the opposing walls 237 of the second stage section 229.

[0040] The third stage section 231 may be adjacent to the internal slot opening 207 of the spring slot 205 when the spring slot 205 includes three stage sections, as is the case in the embodiment shown in the figures. Put another way, the third stage section 231 may be on the exit end of the spring slot 205. The spring slot 205 may further include any additional number of sections. Preferably, the spring slot 205 includes an odd number of sections. Preferably, the sections of the spring slot 205 alternate between having parallel opposing walls, as shown in the first stage section 227 and the third stage section 231, and oblique opposing walls, as shown in the second stage section 229.

[0041] The spring slots 205 extend in the first direction D1 and are configured to mate with the spring clip receptacle (not shown) inside of the metal housing 123. For example, the internal slot opening 207 may be adjacent to the spring clip receptacle inside the metal housing 123 when the trim ring 200 is installed. The spring slots 205 slightly protrude or extend beyond the plurality of walls 203. The length of the spring slots 205 may be configured in various sizes, contingent upon the configuration of the ventilation fan and system, the ceiling width, and other factors.

[0042] One or more chamfers 212 are placed on the first surface 201 to further provide a coupling mechanism for the shield 221. The one or more chamfers 212 may be placed around an outside edge of the first surface 201.

[0043] FIG. 5 illustrates a front-upward view of a ventilation fan system 204. The size and dimensions of the ventilation fan system 204 may differ depending on various factors, and therefore may differ in both size and/or shape than shown in FIG. 5. The ventilation fan system 204 comprises the ventilation fan trim ring 200 coupled to the metal housing 123, and the base 206 of the trim ring 200, which extends beyond the drywall opening such that an entire outer edge of the base 206 is overlapping portions of the drywall 119. Ventilation fan blades 243 may be centrally positioned within the concave opening 215 of the trim ring 200. The attic space 107 houses the metal housing 123 of the ventilation fan system 204. As previously mentioned, because the base 206 of the trim ring 200 extends beyond the edge of the drywall opening and onto the surface of the drywall 119, substantial air loss that may occur through the ventilation fan, the metal housing 123, or through the drywall 119 itself may be prevented or reduced.

[0044] With particular reference to FIG. 6, an exploded view is shown of the ventilation fan system 204 comprising a trim ring shield or shield 221 that covers the trim ring 200. The shield 221 may comprise a plurality of fasteners 245 such as bushings, pins, or screws, that are inserted into chamfer holes 212 on the first surface 201 of the trim ring 200, further providing a simplified process of coupling the shield 221 to the trim ring 200. When the plurality of fasteners 245 of the shield 221 are received in the chamfer holes 212 of the trim ring 200, the shield 221 may be spaced apart from the trim ring 200. The shield 221 contributes to the aesthetically pleasing appearance of the ventilation fan system 204, in addition to its functionality of preventing air loss.

[0045] The trim ring 200 is coupled to the metal housing 123 via spring clips 223 extending from the shield 221 and which are inserted through the spring slots 205. The method of inserting the spring clip 223 through the spring slots 205 is described below with reference to FIGS. 8-11.

[0046] The spring slots 205 may be positioned on opposite sides of the concave opening 215 and adjacent to the plurality of walls 203 such that the concave opening 215 can fit the ventilation fan blades 243 of the fan, and for the walls 203 to fit around the metal housing 123. This coupling configuration of the trim ring 200 to the metal housing 123 additionally contributes to preventing air loss from the conditioned area to the unconditioned area. Each external opening 209 in the spring slots 205 may be integrally formed within the trim ring 200, for example, while advantageously being arranged on the external first surface 201 of the trim ring 200, separate and entirely external from the metal housing 123.

[0047] FIG. 7 shows the ventilation fan system 204 comprising the trim ring 200 and trim ring shield 221 in an assembled configuration. The ventilation fan system 204 may further comprise a vent duct 249 protruding from a side of the metal housing 123. A portion of the vertical wall 203 previously mentioned comprises a cut-out that is configured to fit the contours of the duct 249. The cut-out portion of the vertical wall 203 may be on any other side as necessary to accompany the size and configuration of the duct 249 coupled to the metal housing 123.

[0048] A method of inserting a spring clip 223 through the spring slot 205 during mounting of the mounting the shield 221 is described below with reference to FIGS. 8-11. FIGS. 8-11 show a cross sectional view of the trim ring 200 and the shield 221 at different stages of the insertion of the spring clip 223 through the spring slot 205. The housing 123 would be present adjacent to the trim ring 200 during such installation, but is not shown for clarity purposes.

[0049] In a first step of installing the shield 221 to the metal housing 123, a first end 251 of the spring clip 223 may be pinched. Next, the pinched first end 251 of the spring clip 223 may be inserted into the first stage section 227 of the spring slot 205 by way of the external slot opening 209, as shown in FIG. 8. The pinched first end 251 of the spring clip 223 may be partially expanded when present in the first stage section 227, such that the first end 251 of the spring clip 223 contacts the opposing walls 233 of the first stage section 227. In this position, the first end 251 of the spring clip 223 is unable to fully expand due to the position of the opposing walls 233. Additionally, the outward pressure exerted by the first end 251 of the spring clip 223 against the opposing walls 233 enables the spring clip 223 to remain in such a position even without additional force from a user holding the spring clip 223 in such a position.

[0050] The first end 251 of the spring clip 223 may then be advanced into and through the second stage section 229 of the spring slot 205, as shown in FIG. 9. When in the second stage section 229 of the spring slot 205, the first end 251 of the spring clip 223 is further pinched by the opposing walls 237 of the second stage section 229 as the first end 251 of the spring clip 223 further advances into the second stage section 229. Such further pinching is due to the narrowing of the opposing walls 237 of the second stage section 229 and the first end 251 of the spring clip 223 contacting the opposing walls 237 of the second stage section 229. The further pinching of the first end 251 of the spring clip 223 greatly simplifies the installation of the shield 221, as the user is not required to pinch the first end 251 of the spring clip 223 to advance the first end 251 of the spring clip 223. Additionally, the spring slot 205 ensures that the first end 251 of the spring clip 223 is pinched to an extent that enables coupling of the shield 221 to the metal housing 123.

[0051] In the next step, the first end 251 of the spring clip 223 may be advanced into a third stage section 231 of the spring slot 205, as shown in FIG. 10. In this position, the first end 251 of the spring clip 223 is unable to fully expand due to the position of the opposing walls 241. Additionally, the outward pressure exerted by the first end 251 of the spring clip 223 against the opposing walls 241 enables the spring clip 223 to remain in such a position even without additional force from a user holding the spring clip 223 in such a position.

[0052] Further pinching of the first end 251 of the spring clip 223 may not be required to complete installation of the shield 221 at this stage, at least in part to a short distance D3 between the opposing walls 241 of the third stage section 231. While the first end 251 of the spring clip 223 is positioned in the third stage section 231 and held in position by the opposing walls 241 interacting with the first end 251 of the spring clip 223, the user has the opportunity to adjust their hands such that their hands are not positioned between the shield 221 and the metal housing 123. For example, the user may place their hands in a position which will enable the user to push the shield 221 into the installation position, such as on an exposed side 253 of the shield 221.

[0053] To complete installation, the first end 251 of the spring clip 223 is advanced beyond the internal slot opening 207 of the spring slot 205, as shown in FIG. 11. The first end 251 of the spring clip 223 may be advanced, for example, by a user pushing against the exposed side 253 of the shield 221. As the first end 251 of the spring clip 223 advances beyond the internal slot opening 207 of the spring slot 205, the first end 251 of the spring clip 223 expands, because the opposing walls 241 of the third stage section 231 no longer prevent such expansion. Specifically, the first end 251 of the spring clip 223 expands into the spring clip receptacle 224 of the metal housing 123 beyond the internal slot opening 207 of the spring slot 205. When the first end 251 of the spring clip 223 expands into the spring clip receptacle 224, central portions 257 of the spring clip 223 may contact the opposing walls 241 of the third stage section 231 and/or a structure of the housing 123. The outward force exerted by the central portions 257 of the spring clip 223 couples the shield 221 to the metal housing 123.

[0054] The shield 221 may also be removable from the installed position shown in FIG. 11. In order to uninstall the shield 221 from the metal housing 123, a user first pulls the shield 221 away from the metal housing 123 until the first end 251 of the spring clip 223 is positioned in the third stage section 231, as shown in FIG. 10. In this position, the first end 251 of the spring clip 223 engages the opposing walls 241 of the third stage section 231, such that that the user may adjust their hands to complete the removal process.

[0055] Next, the first end 251 of the spring clip 223 is pinched which releases the contact between the first end 251 of the spring clip 223 and the opposing walls 241 of the third stage section 231. The shield 221 may then be pulled away from the metal housing 123 while the first end 251 of the spring clip 223 is pinched, which removes the shield 221 from the metal housing.

[0056] The various embodiments described above can be combined to provide further embodiments. All of the U.S. patents, U.S. patent application publications, U.S. patent applications, foreign patents, foreign patent applications and non-patent publications referred to in this specification and/or listed in the Application Data Sheet are incorporated herein by reference, in their entirety. Aspects of the embodiments can be modified, if necessary to employ concepts of the various patents, applications and publications to provide yet further embodiments.

[0057] These and other changes can be made to the embodiments in light of the above-detailed description. In general, in the following claims, the terms used should not be construed to limit the claims to the specific embodiments disclosed in the specification and the claims, but should be construed to include all possible embodiments along with the full scope of equivalents to which such claims are entitled. Accordingly, the claims are not limited by the disclosure.