GRILLE ATTACHMENT SYSTEM FOR A VENTILATION SYSTEM

BACKGROUND

[0001]Conventional ventilation fans, such as those typically installed in a room of a building structure (e.g. a bathroom) can draw air from within an area of the room, through the fan and exhaust the air to another location, such as through a vent in the gable or roof of a home or other building structure. Many conventional ventilation fans include a housing positioned within or adjacent an aperture formed in a wall or ceiling of the room and include a grille covering the opening to obscure view of the aperture and access to fan. Grilles are typically removable for cleaning or maintenance and may be retained to the ventilation fan using conventional grille springs. The grille springs may need to be compressed during installation of the grille. In some instances, it may be difficult to simultaneously compress the spring and position the spring in a proper location for installation. Other examples of retaining a grill to a ventilation fan can be seen in U.S. Pat. Nos. 11,300,305, 11,326,792 and 11,732,914. Additionally, the user may need to be elevated to reach the ventilation fan to install the grille such as, for example, when the ventilation fan is installed in a ceiling.

[0002]Therefore, a need exists for an apparatus that allows the grille to be installed with minimal effort from the user. A full discussion of the features and advantages of the present disclosure is deferred to the following detailed description, which proceeds with reference to the accompanying drawings.

[0003]The description provided in the background section should not be assumed to be prior art merely because it is mentioned in or associated with the background section.

SUMMARY

[0004]A ventilation system has a housing defining an internal region and the housing configured to be positioned adjacent to a room of a building structure, a blower in the internal region and configured to draw air out of the room of the building structure, and a grille configured to at least partially block view of the housing and the blower, the grille having a trim cover configured to connect to at least one of the main housing, the blower and the room, the trim cover having at least one side element configured to define an aperture, a hanger connected to the at least one side element, the hanger comprising a base; and a grille cover configured to engage the base. The hanger can also have a guide plate. The trim cover can also have a second hanger connected to the at least one side element. The grille cover can be configured to be biased by gravity to engage the base. The grille cover can have a clip having an engagement face configured to engage the base. The grille cover can further have an arm connecting the hanger to the at least one side element and extending the hanger into the aperture. The trim cover can have four straight side elements connected to form a rectangle.

[0005]A grille for connection to a ventilation system, the grille having a trim cover having at least one side element configured to define an aperture, a hanger connected to the at least one side element, the hanger comprising a base; and a grille cover configured to engage the base. The hanger can have a guide plate. The trim cover can have a second hanger connected to the at least one side element. The grille cover can be configured to be biased by gravity to engage the base. The grille cover can have a clip having an engagement face configured to engage the base. The grille cover can have an arm connecting the hanger to the at least one side element and extending the hanger into the aperture. The trim cover can have four straight side elements connected to form a rectangle.

[0006]A method for installing a grille of a ventilation system having a blower and a housing configured to be positioned adjacent to a room of a building structure, the method having the steps of: (a) providing a trim cover having at least one side element, a hanger connected to the at least one side element, wherein the hanger defines a base; (b) providing a grille cover; and (c) engaging the grille cover to the base. The method can also have the step of (d) connecting the trim cover to at least one of the housing, the blower and the room. The method can also have the step of (d) allowing the grille cover to be biased by gravity toward the base. When the grille cover has a clip having an engagement face, the method can also have the step of (d) engaging the engagement face to the base. The method can also have the step of aligning the clip with the base. When the base defines a length, the method can also have the step of moving the grille cover in the direction of the length.

BRIEF DESCRIPTION OF THE DRAWINGS

[0007]The accompanying drawings, which are included to provide further understanding and are incorporated in and constitute a part of this specification, illustrate disclosed embodiments and together with the description serve to explain the principles of the disclosed embodiments. In the drawings:

[0008]FIG. 1 is a bottom, perspective view of a grille of the present disclosure for a ventilation system.

[0009]FIG. 2 is a top view of the grille of FIG. 1.

[0010]FIG. 3 is a side view of the grille of FIG. 1.

[0011]FIG. 4 is a cross-sectional view of the grille of FIG. 1.

[0012]FIG. 5A is a perspective view of a trim cover of the grille of FIG. 1.

[0013]FIG. 5B is a cross-sectional view of the trim cover of FIG. 5A.

[0014]FIG. 5C is a perspective view of the cross-section of FIG. 5B.

[0015]FIG. 6A is a top, perspective view of the grille cover of the grille of FIG. 1.

[0016]FIG. 6B is a side view of the grille cover of FIG. 6A.

[0017]FIG. 7A is a perspective view of a clip of the grille of FIG. 1.

[0018]FIG. 7B is a top view of a clip of FIG. 7A.

[0019]FIG. 8 is a top view of the grille of FIG. 1 with an alternate trim cover and grille cover.

[0020]FIG. 9 is a side view of the grille of FIG. 8

[0021]FIG. 10 is a cross-sectional view of the grille of FIG. 8.

[0022]FIG. 11A is a perspective view of a trim cover of the grille of FIG. 8.

[0023]FIG. 11B a cross-sectional view of the trim cover of FIG. 8.

[0024]FIG. 11C is a perspective view of the cross-section of FIG. 11B.

[0025]FIG. 12A, is a top, perspective view of the grille cover of the grille of FIG. 8.

[0026]FIG. 12B is a side view of the grille cover of FIG. 12A.

[0027]In one or more implementations, not all of the depicted components in each figure may be required, and one or more implementations may include additional components not shown in a figure. Variations in the arrangement and type of the components may be made without departing from the scope of the subject disclosure. Additional components, different components, or fewer components may be utilized within the scope of the subject disclosure.

DETAILED DESCRIPTION

[0028]FIGS. 1-7B depicts one embodiment of a ventilation system 10 in accordance with the present disclosure. The ventilation system 10 is configured to be positioned in a room of a building structure (not depicted) to provide ventilation for the room of the building structure. For example, the ventilation system 10 may be positioned in a ceiling panel (not shown) of the room and aligned with a cutout in the ceiling panel to selectively ventilate the room. The ventilation system 10 includes a ventilation fan 12 having a housing 14 with an external wall structure 16 that defines an internal region 18. A blower 20 is located in the internal region 18 of the housing 14. The main housing defines an inlet 22 through which air can be drawn and an outlet 24 through which air can be expelled. The inlet 22 is cooperatively shaped and dimensioned to align with the cutout formed in the ceiling of the room of the building structure. The blower 20 can include a motor and a bladed rotor that is configured to rotate about an axis within the housing 14 and move air from the inlet 22 to the outlet 24 through the housing and provide ventilation to the room.

[0029]The housing 14 can be formed of any material known to those skilled in the art capable of withstanding varying temperatures, namely to withstand any heat radiated and/or conducted from the blower 20 and/or other components while providing structural integrity to the ventilation system 10. In some embodiments, the housing 14 is formed of sheet metal, but could instead be formed of a ceramic or a polymer having a relatively high melting temperature and/or glass transition temperature. The housing 14 can have any shape, including a box-like or cubical shape, a hemi-spherical shape, a spherical shape, a pyramidal shape, and the like. The housing 14 can form a base or frame for the ventilation system 10, thereby providing points and areas of attachment for other components of the ventilation system 10.

[0030]In one embodiment, the blower 20 is a centrifugal fan including the motor and the bladed rotor, as is well-known to those skilled in the art. However, other types of blower assemblies can be employed as desired. Illustratively, the blower 20 is located entirely within the housing 14, however in other embodiments, the blower 20 can be in fluid communication with the housing 14 via one or more ducts coupled to the housing 14. In yet another embodiment, the internal region 18 may include multiple sub-cavities and the blower 20 may be located in only one of the sub-cavities.

[0031]A grille 100 is configured to couple to the housing 14 or the blower 20 and obstruct view of the housing 14 and the blower 20, thereby providing a more aesthetic appearance of the ventilation system 10 from the room to which the ventilation system 10 is connected. The grille 100 includes a trim cover 102 and a grille cover 104. The trim cover 102 is configured to be secured to one or more of the housing 14, the blower 20 or the building structure to which the ventilation system 10 is to be installed.

[0032]The depicted trim cover 102 comprises four side elements 106 arranged in a square to define a trim cover aperture 108. When the trim cover 102 is placed against the fan housing 14 in the installed position, the trim cover aperture 108 provides easy access to the fan housing 14 and the blower 20 to facilitate easy access to secure the trim cover 102 to the fan housing 14 or the blower 20. The trim cover 102 can be secured by screw, bolt, snap-fit or other known element. Alternatively, the trim cover 102 could be secured to room (e.g. ceiling) itself. The trim cover 102 can have greater or fewer side elements 106, including a single side element 106 defining a circle. Additionally, the trim cover 102 can form any shape and can define any shape aperture 108.

[0033]One or more of the side elements 106 of the trim cover 102 has an internal leg 110 and a face leg 112 extending generally perpendicularly to the internal leg 110. The internal leg 110 defines the innermost portion of the side element 106, thus defining the trim ring aperture 108, and is oriented to extend inward toward the fan housing 14 and cover at least a portion of the aperture cut into the wall of the room in which the grille 100 is to be installed. In one embodiment, the internal leg 110 can extend into the fan housing 14 to cover the entirety of the wall in which it is installed and the seam between that wall and the fan housing 14. The face leg 112 extends generally perpendicular to the internal leg 110, thus outward and away from the aperture in the wall of the room in which the grille 100 is to be installed. In the depicted embodiment, the face leg 112 defines a curvature away from the wall of the room in which the grille 100 is to be installed and adds structural rigidity to the face leg 112. Because of this curvature, an outer support leg 114 extends from the outer edge of the face leg 112 toward the wall of the room in which the grille 100 is to be installed.

[0034]One or more hangers 116 are supported by the trim cover side elements 106. The depicted embodiment has two hangers 116, each extending from an opposite one of the trim cover side elements 106. More hangers or fewer hangers are contemplated. The depicted hangers 116 each comprise a base 118 with an inner guide plate 120 and an outer guide plate 122 extending from either side. In the depicted embodiment, the base 118 is depicted as a flat plate having a width W and a length L. The inner guide plate 120 extends from the innermost side of the base 118 and the outer guide plate 122 extends from the outermost side of the base 118. Both the inner and outer guide plates 120, 122 extend generally perpendicular to the base 118, but other angles are contemplated consistent with the function described herein. The width W of the base 118 extends generally perpendicular to the side element 106 on which the hanger is supported and is sized generally to accommodate a clip 200 depicted in FIGS. 7A and 7B and discussed herein. The length L of the base 118 extends generally parallel to the side element 106 on which it is supported and is sized to support the clip 200, consistent with discussion herein. Although the base 118, the inner guide plate 120 and the outer guide plate 122 are depicted as flat plates, other configurations consistent with the functionality discussed herein are also contemplated. By way of example only, the base 118 could be a prong, a pin, a series of prongs or pins. As mentioned above, each hanger 116 is supported by a side element 106. In the depicted embodiment, each hanger 116 comprises a pair of arms 124 extending from the outer guide plate 122 to the adjacent side element 106, thus allowing the hanger 116 to extend inward from the side element 106 and be less visible after the installation of the grille cover 104. More or fewer arms 124 are contemplated for holding each base outer guide plate 122. Alternatively, the arms 124 could connect to the base 118 instead of the outer guide plate 122. The depicted embodiments also show an optional top plate 126 extending between the inner guide plate 120 and the outer guide plate 122 opposite the base 118 to provide structural rigidity to the inner and outer guide plates 120, 122.

[0035]The grille cover 104 has a plate 150 configured to be spaced from the trim cover 102 to define a grille inlet 152 between the trim cover 102 and the grille cover 104 about the entire periphery of the grille 100. Alternatively, the grille inlet 152 could be partially blocked by extensions from the trim cover 102 and/or the grill cover 104. Although the grille cover plate 150 is substantially solid, the grille cover plate 150 could, alternatively, define one or more apertures to allow air to flow through the plate 150 in addition to, or instead of, through the peripheral inlet 152.

[0036]A clip 200 is mounted to the grill cover 104. The clip 200 can be mounted directly to the plate 150 of the grille cover. Alternatively, grille cover 104 can comprise a mounting boss 154 for each clip 200. The depicted embodiment shows two clips 200, each having an associated mounting boss 154. Other numbers of clips 200 are also contemplated. The mounting boss extends from an inner side 156 of the grill cover plate 150 to allow the clips 200 to extend away from the plate 150. In the depicted embodiment, each mounting boss 154 has a base 158 extending perpendicular to the plate 150 as well as two parallel legs 160 extending from the plate 150 and the base 158. The legs 160 are spaced from one another that, along with the base 158, define a pocket 162. The clips 200 can be comprised of any appropriate material, including various plastics and metals.

[0037]The clip 200 has a proximate mounting end 202, an engagement face 204, a lock ridge 206 and an articulation tab 208. The proximate mounting end 202 is configured to engage the base 158 of the grille cover mounting boss 153. In the depicted embodiment, the proximate mounting end 202 defines an aperture through which a screw, etc, is passed and secured in the mounting boss base 158. The grille cover 104 can be provided as a subassembly including the clip 200 mounted thereon.

[0038]As best depicted in the cross-sectional view of FIG. 4, the grille cover 104 can be mounted to the trim cover 102 by sliding the articulation tab 208 and lock ridge 206 over the base 118 of the hanger 116 and between the inner and outer guide plates 120, 122. This can be accomplished by a user aligning the clips 200 with the associated hangers 116 and then sliding the grille cover 104 along the length L of each hanger base 118. The articulation tab 208 is angled to guide the clip 200 into the hanger in the event of misalignment. This will deform the clip 200 slightly such that the lock ridge 206 will ride along the hanger base 118 as the grille cover 104 slides. The use continues to slide the grille cover 104 along the length of the hanger base 118 until the lock ridge 206 passes the far end of the hanger base 118 and the engagement face 204 snaps against the hanger base 118. This snap creates an audible noise to provide the user assurance that assembly is complete. The lock ridge 206 prevents the grille cover 104 from sliding backwards unless the user applies force to the articulation tab 208.

[0039]After the grille cover 104 has been installed in this manner, the engagement face 204 of each clip 200 engages the associated hanger base 118 and the grille cover 10 hangs from the trim cover hangers 116. Sizing of the hangers 116, hanger arms 124, mounting bosses 154 and clips 200 can control the spacing of the grille cover plate 150 from the trim cover 102 and, thus, the wall of the room in which the ventilation system 10 is to be installed. Controlling this spacing allows control over the area of the air intake of the grille 100.

[0040]One or more additional features may be provided to the trim cover 102 and/or the grille cover 104. For example, the trim cover 102 and/or the grille cover 104 may be provided with features such as lighting, speakers, sensors (e.g., occupancy, humidity or other air quality, etc.) and/or radio frequency connectivity (e.g., Bluetooth, WiFi, etc.) or any other desired feature. Apparatus for providing these features can be secured, for example, with one or more prongs 164 extending from the grille cover 104 and lighting or signaling can be provided at an accessory aperture 166 in the grille cover 104 for convenient viewing by a user. Additionally, once the grille cover 104 is separated from the trim cover 102, the ventilation system 10 may be retrofitted with a grille cover 104 having a different aesthetic look or different features, such as lighting, sensors (e.g., occupancy, humidity or other air quality, etc.) and/or radio frequency connectivity (e.g., Bluetooth, WiFi, etc.).

[0041]FIGS. 8-12B depict an alternate embodiment of a ventilation system 10 in accordance with the present disclosure having a grille 300 of a different configuration than grille 100. Like reference numerals are used for grille 300 as for grille 100. Grille 300 has a trim cover 302 and a grille cover 304. The trim cover 302 is similar in most ways to the trim cover 102. However, the side elements 306 of the grille cover 302 each have an internal leg 310 that is longer than internal leg 110 and extends deeper into the aperture in the wall of the room in which the ventilation system 10 will be installed. The internal wall 301 also extends outward, beyond the face leg 312 of the trim cover 302. Furthermore, the trim cover 302 defines a plurality of reinforcement ribs 350 that extend across an aperture 308 defined by the internal wall 301.

[0042]Additionally, the trim cover 302 has hangers 316 extending from the face legs 310 of the side elements 306, instead of extending into the trim cover aperture on an arm, as with trim cover 102. The hangers 316 have a base 318 with an inner guide plate 320 and an outer guide plate 322 extending from either side of the base 318.

[0043]The grille cover 304 is similar in most ways to the grille cover 104. However, the mounting bosses 354 of the grille cover 304 are located farther apart from each other than the mounting bosses 154 of the grille cover 104 to account for the wider spread between the hangers 316 and the handers 116. The mounting bosses 354 are constructed the same as mounting bosses 154. The same clips 200 are secured to the grille cover 304 as to grille cover 104 and secured in the same manner.

[0044]The trim cover 302 is secured to the ventilation fan 12, blower 20 and/or room in the same manner as discussed above for the trim cover 102. The grille cover 304 is assembled to the trim cover 302 in the same manner discussed above for assembling the grille cover 104 to the trim cover 102.

[0045]The trim cover 302 of this embodiment includes optional spring mount brackets 350 extending inward from the internal leg 310 into the trim cover aperture 308 to allow for a grille cover to be connected to the trim cover 302 by old fashioned springs often used to mount grill covers to ventilation fans. The brackets 350 could similarly be provided on the trim cover 102 of the first embodiment depicted in FIGS. 1-7B.

[0046]The various components and features described above can be combined in a variety of ways, so as to provide other non-illustrated embodiments within the scope of the disclosure. As such, it is to be understood that the disclosure is not limited in its application to the details of construction and parts illustrated in the accompanying drawings and described hereinabove. The disclosure is capable of other embodiments and of being practiced in various ways. It is also to be understood that the phraseology or terminology used herein is for the purpose of description and not limitation.

[0047]Although the present disclosure has been described in the foregoing description by way of illustrative embodiments thereof, these embodiments can be modified at will, without departing from the spirit, scope, and nature of the subject disclosed.

[0048]Headings and subheadings, if any, are used for convenience only and do not limit the invention. The word exemplary is used to mean serving as an example or illustration. To the extent that the term include, have, or the like is used, such term is intended to be inclusive in a manner similar to the term comprise as comprise is interpreted when employed as a transitional word in a claim. Relational terms such as first and second and the like may be used to distinguish one entity or action from another without necessarily requiring or implying any actual such relationship or order between such entities or actions.

[0049]Phrases such as an aspect, the aspect, another aspect, some aspects, one or more aspects, an implementation, the implementation, another implementation, some implementations, one or more implementations, an embodiment, the embodiment, another embodiment, some embodiments, one or more embodiments, a configuration, the configuration, another configuration, some configurations, one or more configurations, the subject technology, the disclosure, the present disclosure, other variations thereof and alike are for convenience and do not imply that a disclosure relating to such phrase(s) is essential to the subject technology or that such disclosure applies to all configurations of the subject technology. A disclosure relating to such phrase(s) may apply to all configurations, or one or more configurations. A disclosure relating to such phrase(s) may provide one or more examples. A phrase such as an aspect or some aspects may refer to one or more aspects and vice versa, and this applies similarly to other foregoing phrases.

[0050]All numbers and ranges disclosed above may vary by some amount. Whenever a numerical range with a lower limit and an upper limit is disclosed, any number and any included range falling within the range are specifically disclosed. In particular, every range of values (of the form, “from about a to about b,” or, equivalently, “from approximately a to b,” or, equivalently, “from approximately a-b”) disclosed herein is to be understood to set forth every number and range encompassed within the broader range of values. In addition, the terms in the claims have their plain, ordinary meaning unless otherwise explicitly and clearly defined by the patentee. Moreover, the indefinite articles “a” or “an,” as used in the claims, are defined herein to mean one or more than one of the element that it introduces. If there is any conflict in the usages of a word or term in this specification and one or more patent or other documents that may be incorporated herein by reference, the definitions that are consistent with this specification should be adopted.

[0051]A phrase “at least one of” preceding a series of items, with the terms “and” or “or” to separate any of the items, modifies the list as a whole, rather than each member of the list. The phrase “at least one of” does not require selection of at least one item; rather, the phrase allows a meaning that includes at least one of any one of the items, and/or at least one of any combination of the items, and/or at least one of each of the items. By way of example, each of the phrases “at least one of A, B, and C” or “at least one of A, B, or C” refers to only A, only B, or only C; any combination of A, B, and C; and/or at least one of each of A, B, and C.

[0052]In one aspect, a term coupled or the like may refer to being directly coupled. In another aspect, a term coupled or the like may refer to being indirectly coupled. Terms such as top, bottom, front, rear, side, horizontal, vertical, and the like refer to an arbitrary frame of reference, rather than to the ordinary gravitational frame of reference. Thus, such a term may extend upwardly, downwardly, diagonally, or horizontally in a gravitational frame of reference.

[0053]The title, background, brief description of the drawings, abstract, and drawings are hereby incorporated into the disclosure and are provided as illustrative examples of the disclosure, not as restrictive descriptions. It is submitted with the understanding that they will not be used to limit the scope or meaning of the claims. In addition, in the detailed description, it can be seen that the description provides illustrative examples and the various features are grouped together in various implementations for the purpose of streamlining the disclosure. The method of disclosure is not to be interpreted as reflecting an intention that the claimed subject matter requires more features than are expressly recited in each claim. Rather, as the claims reflect, inventive subject matter lies in less than all features of a single disclosed configuration or operation. The claims are hereby incorporated into the detailed description, with each claim standing on its own as a separately claimed subject matter.

[0054]The use of the terms “a” and “an” and “the” and “said” and similar references in the context of describing the invention (especially in the context of the following claims) are to be construed to cover both the singular and the plural, unless otherwise indicated herein or clearly contradicted by context. An element proceeded by “a,” “an,” “the,” or “said” does not, without further constraints, preclude the existence of additional same elements. Recitation of ranges of values herein are merely intended to serve as a shorthand method of referring individually to each separate value falling within the range, unless otherwise indicated herein, and each separate value is incorporated into the specification as if it were individually recited herein. All methods described herein can be performed in any suitable order unless otherwise indicated herein or otherwise clearly contradicted by context. The use of any and all examples, or exemplary language (e.g., “such as”) provided herein, is intended merely to better illuminate the disclosure and does not pose a limitation on the scope of the disclosure unless otherwise claimed. No language in the specification should be construed as indicating any non-claimed element as essential to the practice of the disclosure.

[0055]Numerous modifications to the present disclosure will be apparent to those skilled in the art in view of the foregoing description. Preferred embodiments of this disclosure are described herein, including the best mode known to the inventors for carrying out the disclosure. It should be understood that the illustrated embodiments are exemplary only, and should not be taken as limiting the scope of the disclosure.