Abstract:
A chimney cap that permits compact storage and quick installation is described. The chimney cap is at least partially hinged, which permits the cage to be quickly set up from a folded condition. This is accomplished by hingeably coupling the sides of the cage to the bottom of the cage. The sides are coupled together by inserting a pin into concentric knuckles formed when corresponding edges are joined together. The folded product may be stored for transport or sale in a substantially flat box.

Description:
BACKGROUND  
       [0001]     The present invention relates generally to a chimney cap for protecting the upper open end of a chimney flue from the ingress of undesirable elements.  
         [0002]     Chimney caps may be used to prevent the ingress of undesirable elements into the upper end of the chimney flue. For example, the undesirable elements may include birds, squirrels, and rain. Chimney caps can also be used to prevent the egress of embers from the upper end of the chimney flue.  
         [0003]     The prior art does not permit compact and convenient handling of chimney caps and/or components for shipping and storage. It would be desirable to store new caps in flat storages boxes. Such a storage system can provide various advantages related to space. For example, flat boxes would save a chimney sweep space in his or her vehicle. Chimney cap components stored individually in flat boxes can also save retailers and wholesalers storage space. Furthermore, manufacturers using caps and components that will fit into flat boxes can reduce material handling and shipping costs, packaging requirements and storage space.  
         [0004]     There is known in the related art, a chimney cap having a four-sided cage having rectangular cage components. See, for example, U.S. Pat. No. 4,549,473 (Alexander et al.), U.S. Pat. No. 4,535,686 (Hisey), U.S. Pat. No. 4,334,360 (Simmons et al.) and U.S. Pat. No. 2,976,796 (Anthony et al.). The resulting caps generally could not be easily stored because of their rectangular shape. Additionally, in certain chimney caps the studs used to secure the lid to the top of the cage are secured, e.g., welded, to brackets and the brackets are secured, e.g., welded, to the top of the cage. These brackets are also typically substantially right-angled in shape, having one leg substantially parallel to the side of the cage and one leg extending substantially perpendicular from the side into the interior of the cage. Consequently, these inconsistently shaped trapezoidal cages with angled brackets further made compact storage difficult.  
         [0005]     Therefore, it would be desirable to have consistently shaped chimney caps that permit compact storage.  
         [0006]     Additionally, it would be desirable to have compactly stored caps that permit relatively quick, easy setup.  
       SUMMARY  
       [0007]     The invention relates to a chimney cap that is reasonably uniformly manufactured and permits compact storage. The invention also relates to a compactly stored chimney cap that permits relatively quick and easy setup. In one exemplary embodiment, a chimney cap has a lid and a cage. The cage is five sided and collapsible so that the cage can be stored substantially flat and easily setup on location. The side walls of the cage are hinged to the base area of the cage enabling the side walls to be folded over and/or under the base area for compact storage. The cage is setup by unfolding the side walls so that all the side walls are on the same side of the base of the cage. Each side wall has a hinge leaf configured such that corners of adjacent walls are coupled together by inserting a pin through the leaves.  
         [0008]     These and other features and advantages of the invention will be more readily understood from the following detailed description of the invention which is provided in connection with the accompanying drawings. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0009]      FIG. 1  is an exploded perspective view of a chimney cap according to an exemplary embodiment of the present invention.  
         [0010]      FIG. 2  is a plan view of the chimney cage portion of the chimney cap of  FIG. 1  in an unfolded condition.  
         [0011]      FIG. 3  is a perspective view of the lid in the cap of  FIG. 1 .  
         [0012]     FIGS.  4 ( a ) and ( b ) are orthogonal views of a securing mechanism used in the installation of the cap of  FIG. 1 .  
         [0013]      FIG. 5  is a perspective view of an assembled cap of  FIG. 1  installed on a flue.  
         [0014]     FIGS.  6 ( a ) and ( b ) are perspective views of a folded cap of  FIG. 1 .  
         [0015]      FIG. 7  is an exploded perspective view of chimney cap according to another exemplary embodiment of the present invention.  
         [0016]      FIG. 8  is a perspective view of another securing mechanism used in the installation of the cap of  FIG. 1  or  7 .  
         [0017]     FIGS.  9 ( a )-( c ) are orthogonal views of the securing mechanism of  FIG. 8 . 
     
    
     DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS  
       [0018]     In the following detailed description, reference is made to the accompanying drawings, which form a part hereof, and in which is shown by way of illustration specific exemplary embodiments of the invention. These embodiments are described in sufficient detail to enable those of ordinary skill in the art to make and use the invention, and it is to be understood that other changes may be made to the specific embodiments disclosed without departing from the spirit and scope of the present invention.  
         [0019]      FIGS. 1 and 2  show chimney cap  100  according to an embodiment of the present invention which includes a cage  110  and a lid  140 . The cage  110  is a substantially square shaped figure having sides with perforations that permit the egress and ingress of limited elements. The lid  140  is disposed above the cage  110  and serves as the top of the chimney cap  100  and the lid  140  is secured to the sides of the cage  110 .  
         [0020]     As seen in  FIGS. 1 and 2  the cage  110  is formed from a perforated material with perforations sufficiently large to permit air flow through the cage, but sufficiently small enough to reasonably prevent embers from egressing the chimney flue through the cage  110  and also to prevent the ingress of undesirable elements, e.g., small animals. The cage  110  is initially generally either substantially square or rectangular in shape. The cage  110  has four side walls  170 ,  180  that may all be of substantially identical dimensions and contour thereby forming a square-like cage. Alternatively, the side walls  180  may both be either larger or smaller than the side walls  170  thereby presenting a rectangular cage.  
         [0021]     The bottom portion, floor, of the cage  110  is provided with four flanges: a first pair of flanges  172  and a second pair of flanges  182 . As seen in  FIG. 2 , the flanges  172 ,  182  are configured in a square shape in substantially a single plane with flanges  182  on the top and bottom sides  1212 ,  1210  of the square  1208  and the flanges  172  on the right and left sides  1216 ,  1214  of the square  1208 . Thus portions of flanges  172 ,  182  overlap. In an exemplary embodiment, parts of the overlapping flange portions are spot welded  1202  together.  
         [0022]     Still referring to  FIG. 2 , the flanges  172 ,  182  extend in-part substantially perpendicular to the respective side walls  170 ,  180  to which the flanges  172 ,  182  are coupled through a respective hinge  190 ,  192 . For example, as seen in  FIG. 2 , a flange  172  is coupled to one leaf of hinge  190  and the other side of hinge  190  is coupled to the bottom of side wall  170 . As also seen in  FIG. 2 , a flange  182  is coupled to one leaf of hinge  192  and the other side of hinge  192  is coupled to the bottom of side wall  180 . In an exemplary embodiment, each hinge  190 ,  192  extends over substantially the entire length of the edge formed by a side and its corresponding flange. The flanges  172 ,  182  serve to strengthen and support the side walls  170 ,  180 . In an exemplary embodiment, one leaf of hinge  190  is spot welded to flange  172  and the other leaf of hinge  190  is spot welded to side wall  170 . Additionally, one leaf of hinge  192  is spot welded to flange  182  and the other leaf of hinge  192  is spot welded to side wall  180 . In a preferred embodiment, the perforated material used to form the side walls  170 ,  180  and flanges  172 ,  182  is expanded eighteen (18) gauge AISI 304 or 304L stainless steel or galvaneal coated carbon steel mesh. Other suitable material may also be used.  
         [0023]     Each side edge  1170  of side wall  170  is coupled to a leaf  194  of a hinge  1195  ( FIG. 1 ) that, in a preferred embodiment, extends substantially along the length of the side edge  1170  of side wall  170 . Each side edge  1180  of side wall  180  is coupled to a leaf  196  of a hinge  1195  that extends substantially along the length of the side edge  1180  of side wall  180 . In an exemplary embodiment a leaf  194 ,  196  is spot welded to a respective side wall  170 ,  180 . In an exemplary embodiment, the distance between hinge centers on each side of a side wall  170 ,  180  is thirteen and three-eighths inches (13⅜″).  
         [0024]     Referring to  FIG. 2 , the sides walls  170 ,  180  and flanges  172 ,  182  of the cage  110  are derived from flat, perforated metal portions; e.g. expanded metal or metal mesh. In an exemplary embodiment, to form a substantially square shaped cage  110 , each side wall  170 ,  180  is formed from an approximately nine by thirteen inch (9″×13″) piece of expanded metal. Additionally, each flange  172  is formed from an approximately four by twelve inch (4″×12″) piece of expanded metal and each flange  182  is formed from an approximately four by thirteen inch (4″×13″) piece of expanded metal. In an exemplary embodiment, each hinge  190 ,  192  is approximately twelve inches (12″) and placed substantially centered on each respective side edge. In a preferred embodiment, hinge  190  is oriented so that side wall  170  is folded over the top of a plane substantially formed by the flanges  172 ,  182  and hinge  192  is oriented so that side wall  180  is folded under the bottom of a plane substantially formed by the flanges  172 ,  182 . These dimensions are provided to illustrate an exemplary embodiment of the invention. The invention may be constructed with other suitable dimensions. In a preferred embodiment, the diamond shaped mesh used to construct the side walls  170 ,  180  is oriented with a long dimension of the diamond in a horizontal direction. Such orientation results in the smoother points of the diamonds exposed at the top  1196 ,  1194  of the side walls  170 ,  180 . Similarly, the diamond shaped mesh used to construct the flanges  172 ,  182  is oriented with a long dimension of the diamond in a direction substantially parallel to the long sides of the respective flanges. Such orientation results in the smoother points of the diamonds exposed at the interior edge of the flanges  172 ,  182 . Reducing the sharp ends can reduce the likelihood that a worker, e.g., a chimney installer or chimney sweep, or a tool used by a worker, gets snagged on an exposed top  1196 ,  1194  or on an interior edge of flange  172 ,  182 . In a preferred embodiment, five-eighths inch (⅝″) apertured mesh is used.  
         [0025]     Each leaf  192 ,  194  is configured such that when side walls  170 ,  180  are positioned to form an edge, the knuckles  1191  of associated leafs  192  and  194  are interleaved and a pin  160  ( FIG. 1 ) is inserted to form a hinge. In an exemplary embodiment, leaves  192  and  194  are configured such that the top edges  1196 ,  1194  of side walls  170 ,  180  are at substantially the same height. Although the invention is described with reference to each side wall  170 ,  180  being adapted to be coupled to a neighboring side wall  180 ,  170  by interleaving knuckles  1191  with the neighboring side  180 ,  170  and securing with the insertion of a pin  160  down substantially the length of the combined knuckles  1191 , the invention is not so limited. For example, neighboring sides  170 ,  180  can be secured with the use of locking tabs.  
         [0026]     In an exemplary embodiment, a fastening stud  310  is attached to each side wall  170  at the top  1196 . As seen in  FIG. 2  (and in  FIG. 1 ) each stud  310  is resistance welded to a placement pad  312 , which in turn is welded to a respective side wall  170 . The studs  310  are positioned on the side walls  170  to correspond to the openings, e.g., holes,  146  in the lid  140  ( FIG. 3 ). In a preferred embodiment, the placement pad  312  is a three (3) inch by one and a half (1½) inch triangle of twenty four gauge stainless steel and is fastened to the exterior of each respective side  170 .  
         [0027]     The lid  140  is shown in greater detail in  FIG. 3 . The lid  140  is preferably sufficiently configured to prevent weather elements such as rain, snow or the like, from directly downwardly accessing a chimney flue. The lid  140  has a central flat area  142  and four sloped eaves  144 . The eaves  144  are sloped top to bottom which minimizes the congregation of elements on the top side of the lid  140  and prevents elements from directly rolling off of the top side of the lid  140  into a chimney flue or the cage  110 . In a preferred embodiment, the lid  140  is formed of twenty-four (24) gauge stainless steel or galvaneal coated carbon steel. The perimeter of the lid  140  has a one hundred and eighty degree (180) rollover that is three-eighths (⅜) of an inch, where the roll is formed towards the underside of lid  140 . Each eave  144  is a three (3) inch overhang that is sloped at a forty-five (45) degree downward angle. The lid  140  also has two (2) openings  146 , i.e., holes, that are used to secure the lid  140  onto the cage  110 .  
         [0028]     After a lid  140  is placed over the chimney cage  110  and the fastening studs  310  protrude through holes  146 , wing nuts  149  ( FIG. 1 ) are screwed onto fastening studs  310  to secure the lid  140  to the chimney cage  110 . It is preferable that a washer  148  is placed over the fastening stud  310  and between the top of the lid  140  and the bottom of the wing nut  149 .  
         [0029]     A securing mechanism  130  secures the chimney cage  110  to a flue  50 . As seen in  FIG. 4 ( a ), a securing mechanism  130  is approximately “C shaped” having sides  403 ,  405 , and  407  and a flange  401 . The flange  401  extends roughly perpendicular from side  403  in the direction of side  407 . In a preferred embodiment flange  401  has one side  402  ( FIG. 4 ( b )) that is approximately concave shaped which can aid the securing mechanism  130  in grasping a surface of a flue  50 . The side  405  has a hole  413  through which a mounting stud  135  is extended away from the surface of side  405 . In an exemplary embodiment, the mounting stud  135  extends three eighths of an inch (⅜″) from the surface  405  and is secured to the side  405  by a right angle weld stud  411 . Side  407  has a hole  408  through which a securing screw  134  ( FIG. 1 ), e.g., having a pointed end, is used to fasten the securing mechanism  130  to a flue  50 . On the interior surface of side  408  is a nut  409 ; the aperture of nut  409  is aligned with hole  408 , both of which are adapted to receive the screw  134 . In an exemplary embodiment, the nut  409  is slab welded to the inside surface of side  408 . In an exemplary embodiment, flange  401  is one half inch (½″) in length, side  403  is one and nine-sixteenth inches (1 9/16″) in length, side  405  is one and fifteen-sixteenth inches (1 15/16″) in length, and side  409  is one and one-sixteenth inches (1 1/16″) in length, and the sides and flange are one and three-eighths inches (1⅜″) in width. Longer lengths of side  403  can increase the flexibility of the securing mechanism  130  and consequently decrease the strength of the securing mechanism  130 . These dimensions are provided to illustrate an exemplary embodiment of the invention. The invention may be constructed with other suitable dimensions.  
         [0030]     The size and shape of a flue  50  may vary. For the chimney cap  100  to be effective, ideally the aperture of the flue  50  fits within the bottom of the cage  110 .  
         [0031]     The chimney cap  100  is compactly stored by folding the chimney cage  110  into a reasonably low profile folded condition. A pair of sides is folded over the top of a plane substantially formed by the flanges  172 ,  182  ( FIG. 2 ) and by folding the other pair of sides under the bottom of the plane substantially formed by the flanges  172 ,  182 . In a preferred embodiment, hinge  190  is such that the significant portion of the knuckles of hinge  190  is on the upper or top surfaces of side wall  170  and flange  172 . As such, side wall  170  is folded over the top of a plane substantially formed by the flanges  172 ,  182 . Hinge  192  is such that the significant portion of the knuckles of hinge  192  is on the lower or bottom surfaces of side wall  180  and flange  182 . As such, side wall  180  is folded under the bottom of a plane substantially formed by the flanges  172 ,  182 .  
         [0032]      FIG. 6 ( a ) shows a chimney cap  100  ready for storage or installation. As seen in  FIG. 6 ( a ), the side walls  170 ,  180  are folded over and/or under the floor of the cage  110 . In an exemplary embodiment, as seen in  FIG. 6 ( a ), the side walls  170 ,  180  are folded substantially over and/or under the floor of the cage  110  resulting in a reasonably flat, compact cage  110 . The height of the folded cap is less than 25% of the height of the assembled cap  100 . A lid  140  can be placed over the folded cage  110 . In an exemplary embodiment, the folded cage  110  fits substantially within a well  143  ( FIG. 3 ) formed by the underside of the lid  140 .  
         [0033]     A folded cage  110  with a lid  140  can be placed in a flat cardboard box  600  as seen in  FIG. 6 ( b ). Associated hardware, e.g., the four securing mechanisms  130 , the four pins  160  and other fasteners (e.g., four wing nuts  131 , four washers  132 , two wing nuts  149  and two washers  148 ), can be placed in the box  600  as well. In an exemplary embodiment the box  600  is not substantially bigger than the size of the folded cage  140  and lid  110 —the box  600  is approximately twenty inches long by twenty inches wide by two and one half inches tall (20″×20″×2.5″). The height of the box  600  is preferably less than 25% of the width of the box  600 . Thus the box  600  may have the size and shape of a conventional “pizza box” with its substantially square-shaped top and low profile. In an exemplary embodiment, the box  600  may also have a handle  603  for carrying the box. In an exemplary embodiment, the associated hardware is contained in a plastic bag (not shown), which would increase the likelihood the hardware will remain with the cap  100  when need for use later. This knock down chimney cage  110  design permits storage in a compact sized box  600  that reduces the need for storage space for the chimney cap  100  with all of its component parts as described above. In another aspect, a folded cage  110  with a lid  140  can be placed in a plastic bag rather than a flat, cardboard box. In an exemplary aspect, the plastic bag is see-through and slightly larger than the size of the folded cage  110  with a lid  140  with room to also contain the associated hardware.  
         [0034]     The chimney cap  100  is quickly set up for installation by removing the lid  140 , the cage  110  and component parts from the box  600 . The securing mechanisms  130  are secured to a chimney flue  50  with the screw  135  positioned in an upward direction. The screws  134  are tightened thereby firmly securing the securing mechanisms  130  to the flue  50  such that the mounting studs  135  extend in an upward direction. The chimney cage  110  is unfolded and configured into a box-like arrangement such that coinciding knuckles  1191  of leaves  194 ,  196  are interleaved. Pins  160  are placed into the opening of the knuckles  1191  and extend substantially the length of the leaves  194 ,  196  to form a hinge  1195  and mechanically couple the corresponding sides  170 ,  180  of the cage  110 . The cage  110  is placed appropriately over the aperture  45  of the flue  50 , such that mounting studs  135  protrude through openings of expanded metal in the bottom of cage  110 . Wing nuts  131  are screwed onto mounting studs  135  to secure the chimney cage  110  to the flue  50 . It is preferable that a washer  132  is placed over the securing stud  135  and between the top of the bottom of the cage  110  and the bottom of the wing nut  131 . A lid  140  is secured to the chimney cage  110  as described above. An additional advantage of the bottom of the cage  110  having a multitude of openings in the expanded metal is that the cage  110  can be easily re-oriented on the securing mechanisms  130  as the position and placement of the securing mechanisms  130  can differ on each flue  50 .  
         [0035]      FIG. 5  shows a perspective view of an assembled cap  100  installed on a flue  50 . As seen in  FIG. 5 , the lid  140  is secured to the top of the cage  110  and the cage  110  is secured to the flue  50 . The flue  50  may be any appropriate flue of a home, business, or industrial exhaust.  
         [0036]      FIG. 7  shows a chimney cap  700  according to another exemplary embodiment of the present invention which includes a cage  710  and a lid  740 . Chimney cap  700  differs from cap  100  in that cap  700  is substantially more rectangularly shaped, e.g., sides  780  are substantially longer than sides  770 .  
         [0037]      FIG. 8  shows the chimney cap  100  of  FIGS. 1-6  in another aspect. In this aspect a mounting strongback  820  and bracket  830  are shown in place of securing mechanisms  130  to secure a cage  110  to a flue  50 . The strongback  820  is a slotted metal portion with a channel  823  and a hole  821 . The strongback  820  is placed channel side down across the bottom of a cage  110 , substantially in the middle of the cage  110  both in terms of length and width, effectively ‘bridging’ a flange  172  on one side with a flange  172  on the opposite side of the cage  110 . In a preferred embodiment, the strongback  820  is formed from twelve gauge stainless steel, is twelve inches (12″) long, having a channel  823  one inch (1″) across with one half (½″) side walls of the channel  823  and is welded to flanges  172 .  
         [0038]     FIGS.  9  ( a )-( c ) show a portion the bracket  830  of  FIG. 8  in greater detail. As seen in FIGS.  9 ( a ) and ( b ), a securing mechanism  830  is shown to be a V-type bracket assembly. The securing mechanism  830  has a V-shaped bracket  856  comprising a rod  850  coupled to one end of a metal portion  881  which is coupled on the other end of metal portion  881  to two metal portions  882 . Metal portion  882  has two legs  891 ,  892  and in a preferred embodiment metal portion  882  is bent resulting in an acute angle between legs  891 ,  892  of 30 degrees. The other end of metal portion  881  is sandwiched between metal portions  891 . As seen in  FIG. 9 ( c ), a coupling nut  854  is attached by its exterior at each end of the metal portion  882  such that the hole of each nut  854  is substantially five (5) degrees  857  off parallel, in a radial direction, to metal portion  882 . Two threaded rods  852  ( FIG. 8 ) are threaded into a respective coupling nut  854 . A wing nut  862  is threaded onto the rod  850  above a washer  872  and is used to secure the cage  110  through the strongback  820  to the flue  50 .  
         [0039]     In a preferred embodiment, the bracket  856  is constructed of twelve gauge stainless steel and is at a transverse angle from the plane perpendicular to the rod  850 . The threaded rods  852  are at least six (6) inches in length and the threaded rod  850  is at least four (4) inches in length. Rod  850  is two and one-half inches long (2½″) and three-eighths in diameter. Metal portion  881  is four and one-half inches (4½″) by one inch (1″). Metal  882  is four and one-half inches (4½″) by one inch (1″) with the bend between leg  891  and leg  892  at two and one-half inches (2½″). Although described with reference to a bracket assembly  830 , other types of securing mechanisms can be used. For example, a securing mechanism can be used like that described in Daniels U.S. patent application Ser. No. 10/634,753.  
         [0040]     The cage  110  is adapted to be disposed with a portion of its bottom to be within a flue  50  which is within a chimney  51 . The securing mechanism  830  secures the cage  110  to the flue  50 .  
         [0041]     Therefore, a chimney cap of the present invention is provided that is compactly stored and easily set up for use and installation. The use of folding sides increases the compact storage capabilities. The compacted cap reduces the amount of storage space (e.g., for wholesalers, distributors, retailers, installers) required for the cap. Additionally, because part of the cost of shipping a product is based on the dimensions of the shipping box, the compact design of the chimney cap reduces shipping costs, particularly when shipped by air. The use of easily coupled corners of a cage, e.g., through the insertion of pins into the interleaved knuckles, permits the cage to be field installable by an installer or homeowner who doesn&#39;t have to perform significant work, such as welding during set up, to couple the sides.  
         [0042]     While the invention has been described and illustrated with reference to specific exemplary embodiments, it should be understood that many modifications and substitutions can be made without departing from the spirit and scope of the invention. Although the embodiments discussed above describe preferred angles, size, shape, and specific numbers of sides, bends, fasteners, etc. the present invention is not so limited. For example, the dimensions are provided to illustrate an exemplary embodiment of the invention. The invention may be constructed with other suitable dimensions. Accordingly, the invention is not to be considered as limited by the foregoing description but is only limited by the scope of the claims.