Abstract:
Apparatus, systems and methods of 70 (seventy) CFM (cubic feet per minute) ventilation fans for bathrooms with recessed cans for lights with the motor inside and beneath the blower. A housing for the bath fan can be attached to joists in the ceiling by a telescoping brackets. The motor and blower can be removed as a single unit to allow the motor to be easily replaced or repaired, and to allow for the inside to be inspected during and after installation. A decorative ring shaped pan about the light can have vents that receive the incoming air into the fan, which is exhausted by the blower. Sealing members can seal the can to the light, and to the decorative ring shaped pan.

Description:
This invention claims the benefit of priority to U.S. Provisional Patent Application 61/385,016 filed Sep. 21, 2010 and U.S. Provisional Patent Application 61/385,697 filed Sep. 23, 2010. The entire disclosure of each of the applications listed in this paragraph are incorporated herein by specific reference thereto. 
    
    
     FIELD OF INVENTION 
     This invention relates to ventilation exhaust fans, and in particular to apparatus, systems and methods of 70 CFM ventilation fans for bathrooms with recessed cans and telescoping side mounted slide suspension mounting brackets. 
     BACKGROUND AND PRIOR ART 
     Various types of bathroom ventilation fans have been proposed over the years. See for example, U.S. Pat. No. 4,867,640 to Penlesky et al.; U.S. Pat. No. 4,510,851 to Sarnosky et al.; U.S. Pat. No. 6,261,175 to Larson et al.; U.S. Pat. No. 6,488,579 to Larson et al.; U.S. Pat. No. 6,802,770 to Larson et al.; U.S. Pat. No. 7,203,416 to Craw et al.; and U.S. Pat. No. 7,654,495 to Adrian et al. 
     There have been many problems with the prior art. For example, many bath fans are difficult to be installed into a ceiling since the housings cannot be easily attached to different locations of joists in the ceiling. If a joist is off center to the middle of bathroom ceiling the bath fan is not easy to center in the room. Additionally, many of the bath fans have numerous parts which add extra manufacturing costs. And as a result a bath fan that requires assembly of the bath fan at a job site will incur undesirable extra labor and material costs to install. Additionally, many bath fans have to be wired to components inside of the housings which also requires extra expensive labor costs to make the connections onside during the installation of the bath fan. 
     Thus, the need exists for solutions to the above problems with the prior art. 
     SUMMARY OF THE INVENTION 
     A primary objective of the present invention is to provide ventilation fans, apparatus, systems and methods for installing bathroom fans with recessed cans that provides 70 (seventy) CFM (cubic feet of air per minute) in ventilation. 
     A secondary objective of the present invention is to provide ventilation fans, apparatus, systems and methods for installing bathroom fans with slide suspension brackets that provides 70 (seventy) CFM (cubic feet of air per minute) in ventilation. 
     A third objective of the present invention is to provide ventilation fans, apparatus, systems and methods for installing bathroom fans with slide suspension brackets with internal mounted motor and blower without a separate blower housing. 
     A fourth objective of the present invention is to provide ventilation fans, apparatus, systems and methods for installing bathroom fans with slide suspension brackets using two piece deflectors around a blower to direct airflow. 
     A fifth objective of the present invention is to provide ventilation fans, apparatus, systems and methods for installing bathroom fans with slide suspension brackets with blowers formed from minimal components. 
     A sixth object of the present invention is to provide ventilation fans, apparatus, systems and methods for installing bathroom fans where the motor and blower can be removed in one piece from the housing in order to replace or repair the components, and/or to allow for inspection of the components during installation. 
     A seventh objective of the present invention is to provide ventilation fans, apparatus, systems and methods for installing bathroom fans, having recessed lights with sealing members that prevent air and moisture from a bathroom from entering into and contacting light components such as bulbs inside of the fan. 
     An embodiment of the ventilation exhaust fan, can include a housing having closed top, side walls and open bottom, and an outlet, a blower wheel inside of the housing, a motor mounted partially inside of and extending from an inside of the blower wheel, a recessed can mounted to the open bottom of the housing adjacent to the wheel and motor, the recessed can having a generally conical shape with a large open end, and a narrow open end, and a light in the recessed can adjacent to the narrow open end, the light being air sealed with the narrow open end, wherein air enters into the housing about the large open end of the can about the can, and not through the can, with the air exhausted from the outlet of the housing by the motor run blower. 
     The motor can be an approximately 70 (seventy) CFM (cubic feet per minute) generating motor. The fan can include an first elongated side telescoping bracket directly mounted along one side wall of the housing for mounting the housing to structural supports within a ceiling. The fan can include a second elongated side telescoping bracket directly mounted along an opposite side wall of the housing for mounting the housing to structural supports within the ceiling, the second elongated side telescoping bracket being shorter than the first elongated side telescoping bracket. 
     The fan can include can be a recessed shade, such as a decorative pan having vents about the large open end of the light shade, wherein air enters through the vents into the exhaust fan and passes about an exterior surface of the light shade. 
     The fan can include an elastomeric sealing ring for sealing the large open end of the can to the decorative pan, so that moisture and air does not pass into the recessed can. The fan include an elastomeric sealing ring for sealing the narrow open end of the can to the light, so that moisture and air does not pass into the recessed can. 
     The fan can include a motor mounting plate having an opening therethrough, and a generally U-shaped motor bracket attached to the motor mounting plate for mounting the motor in the opening of the motor mounting plate, with the blower wheel to one side of the motor mounting plate, wherein the motor mounting plate with the mounted motor and blower wheel are both insertable into the housing as a single unit, and are removable from the housing as the single unit. 
     The fan can include a removable vertical panel in the housing between the recessed can and the motor mounted blower wheel, and a first male plug and a first female receptacle connecting power to the light, and a second male plug and a second female receptacle connecting power to the motor. 
     The ventilation exhaust fan can include a housing having closed side walls, open top end and closed bottom, a blower wheel inside of the housing, a motor partially inside of and extending from the blower wheel in the housing, a recessed can in the housing next to the blower wheel and motor, the recessed can having a large open end and a narrow open end, a light mounted in the narrow open end of the recessed can, a ring shaped pan having vents about a perimeter edge of the pan positioned about the large open end of the recessed can, the vents for allowing incoming air to pass into the housing through the motor run blower, a sealing member attached to the recessed can for preventing the incoming air from entering into the recessed can and contacting the light, and an outlet for exhausting the air outside of the exhaust fan. 
     The sealing member can include an elastomeric sealing ring for sealing the large open end of the can to the ring shaped pan, so that moisture and air does not pass into the recessed can. The sealing member can also include an elastomeric sealing ring for sealing the narrow open end of the can to the light, so that moisture and air does not pass into the recessed can. 
     The fan can include a motor mounting plate having an opening therethrough, and a generally U-shaped motor bracket attached to the motor mounting plate for mounting the motor in the opening of the motor mounting plate, with the blower wheel to one side of the motor mounting plate, wherein the motor mounting plate with the mounted motor and blower wheel are both insertable into the housing as a single unit, and are removable from the housing as the single unit. 
     The fan can include a removable vertical panel in the housing between the recessed can and the motor mounted blower wheel, a first male plug and a first female receptacle connecting power to the light, and a second male plug and a second female receptacle connecting power to the motor. 
     The fan can include an elongated side telescoping bracket directly mounted along one side wall of the housing for mounting the housing to structural supports such as joist(s) within a ceiling. 
     The ventilating exhaust fan can include a housing having closed sides, an open top and a closed bottom, and an outlet, a blower wheel inside of the housing, a motor mounted to the blower wheel, a motor mounting plate having an opening therethrough, a generally U-shaped motor bracket attached to the motor mounting plate for mounting the motor in the opening of the motor mounting plate, with the blower wheel to one side of the motor mounting plate, wherein the motor mounting plate with the mounted motor and blower wheel are both insertable into the housing as a single unit, and are removable from the housing as the single unit, a light inside of the housing, and a seal member for preventing air coming into the housing from contacting the light. 
     The fan can include a recessed can in the housing next to the blower wheel and the motor, the recessed can having a large open end and a narrow open end, wherein the light being mounted in the narrow open end of the recessed can, and a ring shaped pan having vents about a perimeter edge of the pan positioned about the large open end of the recessed can, the vents for allowing the incoming air to pass into the housing through the motor run blower. 
     The sealing member can include a first elastomeric sealing ring for sealing the large open end of the can to the ring shaped pan, so that moisture and air does not pass into the recessed can, and a second elastomeric sealing ring for sealing the narrow open end of the can to the light, so that moisture and air does not pass into the recessed can. 
     Further objects and advantages of this invention will be apparent from the following detailed description of the presently preferred embodiments which are illustrated schematically in the accompanying drawings. 
    
    
     
       BRIEF DESCRIPTION OF THE FIGURES 
         FIG. 1  is an exploded view of all components of the 70 CFM bath fan (with no heater) with recessed can. 
         FIG. 2  is an exploded perspective view of the bath fan of  FIG. 1  with the motor attached to impeller and lamp socket assembly plug attached to the motor mounting plate. 
         FIG. 3  is another exploded view of the bath fan of  FIG. 1  without exterior decorative ring, outer plate cover and light panel. 
         FIG. 4  is another exploded view of the bath fan housing of  FIG. 1  with the plug panel holding the female plugs and separated male plugs. 
         FIG. 5  is a perspective top side view of an assembled bath fan of  FIG. 1  without the exterior decorative ring and without the outer plate cover. 
         FIG. 6  is a top view of an assembled bath fan of  FIG. 5  without the exterior decorative ring and without the outer plate cover. 
         FIG. 7  is another top view of the assembled bath fan of  FIG. 6  with the outer plate cover and without the exterior decorative ring. 
         FIG. 8  is another top view of the assembled bath fan of  FIG. 7  with the outer plate cover and with the exterior decorative ring. 
         FIG. 9  is a perspective side view of an assembled bath fan of  FIGS. 1 and 8 . 
         FIG. 10  is another perspective side view of the assembled bath fan of  FIG. 9 . 
         FIG. 11  is a side cross-sectional view of the assembled bath fan of  FIGS. 8-10 . 
         FIG. 12  is another perspective view of the assembled bath fan of  FIGS. 8-10  attached to joists within a ceiling. 
         FIG. 13  is a side view of the assembled and ceiling installed bath fan of  FIG. 12  showing airflow directions into and out of the bath fan. 
     
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     Before explaining the disclosed embodiments of the present invention in detail it is to be understood that the invention is not limited in its applications to the details of the particular arrangements shown since the invention is capable of other embodiments. Also, the terminology used herein is for the purpose of description and not of limitation. 
     A list of the components for  FIGS. 1-13  will now be described.
       1 . 70 CFM bath fan housing embodiment     10 . outlet pivotal plate/deflector     20 . outlet     30 . hanger bar (galvanized steel)(4)     32 . bent tab end     34 . bent flange pair     36 . bent flange pair     38 . bent tab end     40 . rectangular curved wind deflector (galvanized steel)     50 . rectangular curved wind deflector (galvanized steel)     60 . impeller     70 . electrical motor     72 . male plug from motor     76 . fasteners on top of the motor     80 . motor mounting plate (galvanized steel)     85 . opening in mounting plate     90 . rubber pad (2)     100 . inverted generally U-shaped motor bracket (steel)     102 . footer end     108 . footer end.     110 . plate (galvanized steel)     114 . bent edges on plate     120 . decorative trim ring with vents     130 . rubber ring (silicone rubber)     140 . light panel (galvanized steel)     144 . bent edges     145 . opening in panel     146 . upwardly protruding ring     150 . lampshade (aluminum)     151 . flat ring shaped bottom     152 . narrow bottom opening     153 . fasteners in bottom of lampshade     158 . enlarged upper opening     160 . rubber ring (silicon rubber)     170 . lamp socket assembly (E27 porcelain socket)     172 . male plug from lamp socket     180 . plug panel (galvanized steel)     184 . bent side edges     186 . upper bent edge     187 . openings for female receptacles     190 . female plug, for lamp socket, 2-pin (2)     192 . external power supply line to lamp socket     196 . female plug, for motor     198 . external power supply line to motor     200 . lamp socket bracket (galvanized steel)     210 . lampshade bracket (galvanized steel)(2)     212 . upper bent end     218 . lower bent end     220 . housing assembly (galvanized steel) with closed sides and closed bottom     221 . L brackets with slots, mounted to inner walls of housing     223 . side opening for exhaust outlet     225 . open top of housing     229 . opening for electrical lines     230 . hole plug (galvanized steel)     240 . spring clips     242 . leg(s) of spring clips     243 . apex(s) of spring clips     244 . bent lower edge(s)     250 . joist     260 . ceiling   

       FIG. 1  is an exploded view of all components of the 70 CFM bath fan (with no heater)  1  with recessed can  150 .  FIG. 2  is an exploded perspective view of the bath fan  1  of  FIG. 1  with the motor attached to blower wheel (impeller) 60  and lamp socket assembly plug  172  attached to the motor mounting plate  80 .  FIG. 3  is another exploded view of the bath fan  1  of  FIG. 1  without exterior decorative ring  120 , outer plate cover  110  and light panel  140 .  FIG. 4  is another exploded view of the bath fan housing of  FIG. 1  with the plug panel  180  holding the female plugs  190 ,  196  and separated male plugs  72 ,  172 . 
       FIG. 5  is a perspective top side view of an assembled bath fan  1  of  FIG. 1  without the exterior decorative ring  120  and without the outer plate cover  110 .  FIG. 6  is a top view of an assembled bath fan  1  of  FIG. 5  without the exterior decorative ring  120  and without the outer plate cover  110 .  FIG. 7  is another top view of the assembled bath fan  1  of  FIG. 6  with the installed outer plate cover  110  and without the exterior decorative ring  120 .  FIG. 8  is another top view of the assembled bath fan  1  of  FIG. 7  with the outer plate cover  110  and with the exterior decorative ring  120 .  FIG. 9  is a perspective side view of an assembled bath fan  1  of  FIGS. 1 and 8 .  FIG. 10  is another perspective side view of the assembled bath fan  1  of  FIG. 9 .  FIG. 11  is a side cross-sectional view of the assembled bath fan  1  of  FIGS. 8-10 . 
     Referring to  FIGS. 1-11 , the bath fan  1  can include a generally rectangular housing  220  having four closed sidewalls, and a closed bottom, that can be attached together by fasteners, such as rivets, screws, and the like, together as a single unit. A side opening  223  can allow for a square end  22  of an exhaust outlet  20  to be attached thereto by fasteners, as rivets, screws, and the like. The outlet  20  can have a pivotable damper  10  mounted in the cylindrical exhaust end. 
     Along opposite sidewalls of the housing  220  can be a slidable telescoping bracket  30  having an elongated portion and opposite bent tab ends  32 ,  38  having openings for allowing the slidable bracket to be mounted to structures inside of a ceiling such as joists, and the like, with fasteners, such as screws, bolts, and the like. Each bracket  30  can be a single elongated bracket with bent ends, or can be two brackets that telescoping slide into and out of each other. Each bracket  30  can be slidably mounted to sides of the housing by a first pair of bent flanges  34 , and a second pair of bent flanges  36  that can be formed from the sidewalls of the housing, wherein each of the pairs  34 ,  36  wraps about side edges of the elongated portion of the slidable/telescoping brackets  30 . 
     Referring to  FIGS. 1-6 , and  11 , inside the opening  225  of the housing  220  can be an electrical motor  70 , such as SP83-413F shaded pole motor, having a rotatable rod  78  that attached to a central axis portion  65  inside of a blower wheel  60 , which can be a cylindrical impeller type wheel with fins about the perimeter thereof. The motor  70  with attached impeller (blower wheel)  60  can be mounted to a mid portion of an inverted U-shaped motor bracket  100  by fasteners  76 , which can include screws, bolts, nuts, and the like. Footer ends  102 ,  108  of the inverted U shaped motor mount  100  can be attached to the surface of the motor mount plate  80  by fasteners, such as rivets, screws, and bolts, so that the motor  70  can hang downward through the opening  85  in the motor mount plate  80 , with the blower wheel  60  on the other side of the plate  80 . Antivibration and anti-noise members,  90  such as rubber pads, and the like, can be sandwiched between the footers  102 ,  108  and the upper surface of the mounting plate  80 . 
     When attached the impeller  60  with motor  70  can extend through the middle opening  85  of the mounting plate  80 . The mounting plate  80  can have bent side edges  84  which allow the mounting plate with mounted motor  70  and impeller  60  to be attached to interior sidewalls of the housing  220  by various removable type fasteners, such as screws and bolts, and the like. The edges  84  can sit on plural ledge clip(s)  221  arranged about an interior perimeter edge inside of the housing  220 . 
     In a preferred embodiment, the blower wheel  60  and motor  70  are preattached by the bracket  100  to the mounting plate  800  so that all of these components can be installed at once, and removed at once. The combined one piece motor/impeller/mount assembly allows inspectors, such as home inspectors, and the like to be able to visually see electrical connections by being able to insert and remove this one-piece assembly of components. Additionally, removing the combined plate  80  with bracket  100  mounted motor  70  and impeller  60  allows for replacement of parts, such as a burned out motor to be more easily accomplished after the fan has been installed. 
     To direct air from the rotating blower wheel  60 , a two piece combination of wind deflector components  40 ,  50  can be used. Each deflector  40  can be formed from metal such as but not limited to galvanized steel, having curved shapes that can be fastened together by rivets, and the like. The curved plates  40 ,  50  can be used to guide the airflow and minimizes excess noise. The attached deflectors  40 ,  50  can be positioned about the opening  85  below the plate  80  within the housing  220 . 
     Referring to  FIGS. 7-11 , a cover plate  110  having bent edges  114  on three sides can be used to close off the upper opening of the housing  220  above the motor mounting plate  80 . Bent edges  114  can be attached to upper edges of the housing by fasteners, such as rivets, screws, bolts, and the like. 
     Referring to  FIGS. 1-6  and  11 , a plug panel plate  180  can be installed to separate one half portion of the inside of the housing  220  from another half portion of the housing  220 . The plug panel plate  180  can have bent side edges  184  that can be used to attach the plate  180  to interior walls of the housing  220  by fasteners, such as rivets, screws, bolts, and the like. An upper bent edge  186  can have openings  187  for mounting male plug member for motor  72 , and male plug member for light  172  thereto. External power lines  198  for motor, and external power line  192  for light can pass through a side opening  229  in the housing  220 . Before installation, the side opening  229  can be closed by a plug  230 . Removable female receptacle  196  from power line  198  can be used to provide power to the motor  70 , while removable female receptacle  190  from power line  192  can be used to provide power to light  170 . The plug plate  180  holds both plug-ins for the light  170  and motor  70 , so it is like a centralized place for both plugs  72 ,  172 . Plug plate  180  also acts as a separation between the motor side and the light side of the housing  220  to further enclose the bulb area from any airflow contacting the bulb area. 
     Brackets  210  with bent flange ends  212 ,  218  can further secure the panel plate  180  to the housing  220 . Upper bent ends  212  of brackets  210  can be attached to upper bent edge  186  of panel plate  180 , by fasteners, such as screws, bolts, and the like. Lower bent ends  218  of brackets  210  can be attached to the lower interior floor of the housing  220  by fasteners, such as screws, bolts, and the like. 
     Referring to  FIGS. 1-11 , mounted to another part of the housing  220  can be the recessed can components  120 ,  140 ,  150 ,  160 ,  170 . The main recessed can component can be a metal lamp shade  150  having a narrow lower open end  152 , and enlarged upper open end  158  with an opening therethrough. The lamp shade can have a generally conical lower portion and upper cylindrical portion. 
     The lamp shade  150  can be secured to the interior floor of the housing  220 . A flat ring bottom  151  about the bottom narrow opening  152  in the lampshade  150  can have fasteners  153 , such as screws, bolts and the like, that can attach the flat ring bottom  151  of the shade  150  to the floor of the housing  220 , as shown in  FIGS. 1 ,  2 ,  5 , and  6 . 
     An inverted U shaped mounting bracket  200  can have footer ends that attach to a floor portion of the housing  220  by fasteners, such as rivets, screws, bolts, and the like. The bottom of a lamp socket  170  can be attached to a midportion of the inverted U shaped bracket  200  by fasteners, such as rivets, screws, bolts, and the like. The socket  170  can support a bulb, such as but not limited to a  75 W PAR  30  flood lamp bulb, and the like. The socket  170  can be mounted in the narrow open end  152  of the lamp shade and sealed in place by an elastomeric ring  160 , such as a rubber ring, and the like. 
     Covering the upper opening above the recessed can (lampshade)  150  can be a light cover plate  140  having a central opening  145  therethrough with an upper ring shape  146  protruding upward from the opening  145 . Bent edges  144  on three sides of the panel  140  can attach the panel  140  to side edges of the upper open end  225  of the housing  220  by fasteners, such as rivets, screws, bolts, and the like. 
     Referring to  FIGS. 1 ,  2 , and  11 , a pair of spring clips  240  can springably hold the decorative ring  120  with vents  123  to cover the top opening  145  of the light panel cover  140 . The pair of spring clips  240  can each be scissor clips each having an apex  243  that can attach to protruding portions along the lower ring edge  124  of the ring cover  120 . The ring cover  120  can be attached to the housing  220  by pressing together the legs  242  of the clips  240 , so that the bottom bent edges  244  of legs  242  can be inserted to catch into slots in the upper legs of L brackets  221  that are mounted to inner side walls of the housing  220 . 
     The lower ring shape  124  of the decorative ring cover  120  can be inserted into the upwardly protruding ring  145  of the light cover and sealed in place by sealing member  180 , which can be an elastomeric ring, such as but not limited to a rubber ring, and the like. The sealing ring  180  is to seal the decorative trim ring  120  so that moisture and air does not enter the bulb area once the bulb is installed. 
     The sealing members  180  and  160  seal the light to the narrow open bottom end  152  of the lamp shade  150  so that air passing through vents  123  in the rim  122  of the decorative ring cover  120  does not pass into the lamp shade  150  itself. As such, the sealing members  130 ,  160  prevent air and moisture from the incoming air from contacting light bulbs, and the inside exposed components of the light socket  170 . 
       FIG. 12  is another perspective view of the assembled bath fan  1  of  FIGS. 8-10  attached to joists  250  within a ceiling  260 . The suspension brackets  30  can extend to fit any standard joist layout. Each side of the housing  220  has a formed bracket members  34 ,  36  or welded brackets where you can insert the slidable suspension brackets  30 . The slidable brackets  30  with bent ends  32 ,  38  then attaches to the joist  250 . 
       FIG. 13  is a side view of the assembled and ceiling installed bath fan  1  of  FIG. 12  showing airflow directions into and out of the bath fan  1 . As shown, the sealing members  130 ,  160 , prevent incoming air and moisture from bathrooms form passing into the lamp shade  150  and contacting interior light components such as bulbs, and the like. 
     As previously discussed, the lamp housing  1  completely encloses the bulb/socket area so moisture does not flow near electrical components. Instead the air that is being exhausted enters the vents  123  in the trim ring  120  and then flows around the outer parts of the lamp housing  150  towards the right where the blower wheel exhausts the air to the outlet duct. 
     The housing can be directly attached to joists and/or other structural members above ceilings and/or behind walls by the slide brackets and/or the ears and flaps. 
     Although the invention describes the motor as being a 70 CFM (cubic feet per minute) electrical motor, the invention can be used with other CFM generating motors. 
     While the invention has been described, disclosed, illustrated and shown in various terms of certain embodiments or modifications which it has presumed in practice, the scope of the invention is not intended to be, nor should it be deemed to be, limited thereby and such other modifications or embodiments as may be suggested by the teachings herein are particularly reserved especially as they fall within the breadth and scope of the claims here appended.