Patent Publication Number: US-2007095339-A1

Title: Non-metallic vent cap

Description:
BACKGROUND OF THE INVENTION  
      1. Field of the Invention  
      The present invention generally relates to components of a vent system for heating appliances, and more particularly relates to vent cap structures suited for exhausting combustion products and intaking fresh air for the heating appliance.  
      2. Related Art  
      Exterior intake and/or exhaust venting systems are generally known for use in buildings and other such structures. Such vents can be used for a variety of venting purposes, for example, to vent fireplaces, furnaces, water heaters, boilers, dryers, exhaust fans, and a many other such appliances and devices. Some such vents are primarily exhaust vents while others are primarily intake vents, and still others include structure that allows them to function as both intake and exhaust vents.  
      In one example, chimneyless gas fireplaces often include intake/exhaust venting units that are mounted on the outside of an exterior wall that provide a through-the-wall connection to a double walled collinear ducting of the gas fireplace. The double walled collinear ducting includes an inner duct that serves as an outtake port for exhaust fumes, and an outer duct that serves as an intake port for ambient combustion air. The venting units generally include an inner and an outer duct. Further, the double walled ducting is connected to a series of bases that have deflectors and heat shields. The venting unit has a series of venting apertures with a vent cap attached thereto. The vent cap is utilized to cover both the air intake and the combustion product exhaust.  
      Regardless of the specific structure or use of the vent, most venting systems generally include a functional vent cap that covers the intake and exhaust portions of the vent. However, many of the existing vent caps are not aesthetically pleasing, may get hot due to high temperature exhaust gases, and are exposed to the ambient atmosphere and therefore may be damaged. An example venting unit that includes a functional vent cap and vent covers is shown and described in U.S. Pat. No. 6,484,712.  
     SUMMARY OF THE INVENTION  
      The present invention relates to vent assemblies that provide proper fluid flow into and out of respective intake and exhaust apertures of a vent, and minimize the flow of fluids exhausted from the exhaust aperture back into the intake aperture. The vent assembly comprises at least one non-metallic member or at least one member that includes non-metallic materials such as a compression molded ceramic fiber and a binder material.  
      One aspect of the invention relates to a vent assembly that includes a base, an intake duct, an exhaust duct, and a cap assembly. The base includes a vertically oriented, outward facing primary surface and defines a duct aperture that extends through the outward facing primary surface. The base includes a metallic material. The intake duct is coupled to the base within the duct aperture, and the exhaust duct is oriented coaxially within the intake duct. An end of the exhaust duct extends distally beyond an end of the intake duct. The cap assembly includes first, second, and third members that each include a non-metallic material. The first member includes an intake aperture aligned with the duct aperture of the base and is sized to substantially cover the outward facing primary surface. The second member includes an exhaust aperture sized to receive the exhaust duct. The third member is positioned distally beyond an distal end of the exhaust duct in a flow path of exhaust gases exiting the exhaust duct.  
      Another aspect of the invention relates to a vent assembly that includes a base member, an intake duct, an exhaust duct, and a vent cap assembly. The base member is configured for mounting to a wall structure. The intake duct is coupled to the base member. The exhaust duct extends coaxially through the intake duct and extends distally beyond an open end of the intake duct. The vent cap assembly is configured to mount to the base member and the intake and exhaust ducts and includes a plurality of non-metallic structures configured to direct away from each other fluids entering and exiting the intake and exhaust ducts.  
      A further aspect of the invention relates to a method of mounting a venting assembly to a vertically oriented surface. The method includes mounting a base plate to the vertically oriented surface, the base plate defining a vent aperture, mounting an intake duct to the base plate within the vent aperture, and positioning an exhaust duct within the intake duct with an open end of the exhaust duct extending distally beyond an open end of the intake duct. The method further includes detachably mounting a vent cap assembly to the base plate wherein the vent cap assembly includes at least one cap member that comprise a non-metallic material. The vent cap assembly is configured to direct intake air into the intake duct and direct exhaust gases out of the exhaust duct and away from the open end of the intake duct.  
      Another aspect of the invention relates to a method of manufacturing a vent assembly, wherein the vent assembly includes a base member and a vent cap assembly. The vent cap assembly includes at least first and second vent cap members. The method includes coupling the vent cap members together with at least one first fastener that extends from the first vent cap member and into engagement with the second vent cap member, and coupling the vent cap assembly to the base member with at least one second fastener that extends through the first vent cap member into engagement with the base member.  
      The above summary of the present invention is not intended to describe each disclosed embodiment or every implementation of the present invention. In particular, the example embodiments described below in relation to the Figures are the application of the present invention to a heating appliance vent system, whereas other fields may be applicable to fulfill the purposes and intents of the present invention. Figures in the detailed description that follow more particularly exemplify certain embodiments of the invention. While certain embodiments will be illustrated and describe embodiments of the invention, the invention is not limited to use in such embodiments.  
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
      The invention may be more completely understood in consideration of the following detailed description of various embodiments of the invention in connection with the accompanying drawings, in which:  
       FIG. 1  is a perspective view of one example vent assembly according to principals of the present invention;  
       FIG. 2  is an exploded perspective view of the vent assembly as shown in  FIG. 1 ;  
       FIG. 3  is a side view of the vent assembly shown in  FIG. 1 ;  
       FIG. 4  is a front view of the vent assembly shown in  FIG. 1 ;  
       FIG. 5  is a cross sectional view taken along cross section indicators  5 - 5  in  FIG. 4 ;  
       FIG. 6  is a cross sectional view taken along cross section indicators  6 - 6  shown in  FIG. 4 ;  
       FIG. 7  is an exploded perspective view of a base assembly portion of the vent assembly shown in  FIG. 1 ;  
       FIG. 8  is a rear view of a first cap member of the vent assembly shown in  FIG. 1 ;  
       FIG. 9  is a rear view of a second cap member of the vent assembly shown in  FIG. 1 ; and  
       FIG. 10  is a rear view of a third cap member of the vent assembly shown in  FIG. 1 . 
    
    
      While the invention is amenable to various modifications and alternate forms, specifics thereof have been shown by way of example and the drawings, and will be described in detail. It should be understood, however, that the intention is not to limit the invention to the particular embodiments described. On the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention.  
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT  
      The present invention generally relates to vent systems, vent assemblies and related methods of venting and assembling vent systems and vent assembly components. One aspect of the invention relates to the use of non-metallic materials with a vent assembly, in particular, portions of a vent cap or vent cover of a vent assembly that are exposed for viewing.  
      The vent systems and assemblies are typically associated with heating appliances that require at least one of a source of inlet air and an exhaust outlet. The example systems and methods described herein include an exhaust member configured to exhaust combustion products away from the heating appliance through an exhaust portion of the vent assembly, and an intake member configured to provide a source of intake air to the heating appliance. The exhaust and intake members are preferably coaxially oriented with the exhaust member extending within the intake member. This coaxial arrangement (sometimes referred to as a B-vent arrangement) provides cooling of exhaust gases in the exhaust member via heat transfer with the intake air flowing through the intake member. Other embodiments can provide different arrangements of the exhaust and intake members relative to each other, or provide exhaust or intake functions rather than both functions.  
      The use of metallic materials for components of a vent assembly is common. Metallic materials can have certain drawbacks related to, for example, safety issues (e.g., related to exposed heated surfaces of the vent assembly), aesthetics and appearance, and replaceability of components. The use of non-metallic materials for at least some of the components of a vent assembly address some or all of the drawbacks of metallic vent assemblies. For example, some non-metallic materials such as the compression molded ceramic materials disclosed in U.S. Published Patent Application No. 2003/0049575, which patent application is incorporated herein by reference in its entirety, possess heat dissipating properties that result in improved safety.  
      Some non-metallic materials can be molded, caste, or otherwise formed or shaped to include details and features than improve aesthetics and appearance of a resulting product. The moldability of some types of non-metallic materials provide for flexibility in generating complex component shapes and structures that could be more difficult and costly to produce if using metallic materials. Some types of non-metallic materials are useful for providing desired surface finishes such as texture, color and grain that match the appearance of exposed structures that surround the vent assembly. For example, a vent cap or vent cover made in part from a non-material material such as the compression molded ceramic material mentioned above can be formed with a stucco style exposed surface that matches a stucco surface of the wall structure to which the vent cap/cover is mounted.  
      Referring now to  FIGS. 1-10 , an example vent assembly  10  includes a base  12 , an intake duct  14 , an exhaust duct  16 , and a vent cap assembly  18 . The vent cap assembly  18  includes first, second and third cap members  20 ,  22 ,  24 , first and second screens  26 ,  28 , and an exhaust duct base  30 . Preferably, at least one of the cap members  20 ,  22 ,  24  comprises a non-metallic material such as the compression molded ceramic material disclosed in U.S. Patent Application No. 2003/0049575. While the vent cap assembly  18  includes three separate cap members, other embodiments may have a similar resulting configuration by integrally forming two or more of the cap members  20 ,  22 ,  24  as a single piece.  
      Referring to  FIG. 2 , the base  12  includes a vent aperture  40 , a water flashing  42 , and an exposed outward facing surface  43 . The base  12  may be coupled as a sub-assembly  13  with the intake duct  14  and heat shield  32  (see  FIG. 7 ). The sub-assembly  13  is preferably mounted to an outside surface of a wall structure such as an exterior wall of a living structure (e.g., residential home or commercial building). The wall structure typically includes a hole having a diameter equal to the diameter of the heat shield  32 . When the base  12  is mounted against the wall structure, the intake duct  14  is positioned within the wall structure such that an inner open end  44  of the intake duct is in a position for attachment to further ducting extending within the living structure. Typically, the further ducting (not shown) is coupled to a heating appliance that requires intake of air drawn in through the intake duct  14 .  
      When mounting the base  12  to the wall structure, the base  12  may be permanently or semi-permanently mounted with fasteners, adhesives, or the like, thereby providing a mounting surface for the vent cap assembly  18 .  
      A outer open end  44  of the intake duct  44  terminates at a point distally beyond the outward facing surface  43  of the base  12 . The intake duct  14  may also include a flange  46  or other structure to help mount the intake duct  14  to the base  12  within the vent aperture  40 .  
      The exhaust duct  16  is coaxially mounted within the intake duct  14  as shown in  FIGS. 3, 5  and  6 . An inward open end  52  of the exhaust duct  16  extends axially beyond the inward open end  45  of the intake duct  14  to provide, for example, easier connection to further exhaust ducting that extends within the living structure. An outward open end  50  of the exhaust duct  16  extends distally beyond the outer open end  44  of the intake duct  14  so as to be positioned within the vent cap assembly  18  when the vent cap assembly is mounted to the base (see  FIGS. 5 and 6 ). The exhaust duct  16  may also include a flange member  54  at the outer open end  50  that can be used to help attach the exhaust duct  16  within the vent cap assembly  18 . The first cap member  20  includes an outward facing surface  60 , an intake vent aperture  62 , a water shield  64  formed across the top of the intake vent aperture  62 , and first and second sets of fastener apertures  66 ,  68 . The first cap member  20  is sized to substantially cover the outward facing surface  43  of the base  12  (see  FIG. 4 ).  
      In other embodiments, the first cap member  20  may be sized to overlap and completely conceal and/or cover all of the base  12  from view, in particular from a front view as shown in  FIG. 4 . In other embodiments, the first cap member  20  may have a smaller size such that portions of the base  12  are exposed. In such an embodiment, the exposed portions of base  12  can be covered by the exterior cover of the building structure such as siding, stucco, or the like to provide a more permanent mounting of the base  12  to the wall structure.  
      The water shield  64  extends outwardly away from the outward facing surface a distance approximately equal to a width of the inflow opening defined by the second cap member  22  (described in further detail below). The water shield  64  helps to prevent water from flowing into an interior defined by the vent cap assembly  18  the water shield  64  defines a generally curved structure such that any precipitation falling vertically onto a top surface of the water shield  64  is directed laterally to one of the sides of the venting assembly  10  and away from entering into the intake vent  14  via the vent opening  62 .  
      The second set of fastener apertures  68  are sized to receive the second set of fasteners  36 , which are used to positively attach the first cap member  20  to the base  12 . When the vent cap assembly  18  is assembled together, securing the first cap member to the base  12  results in positive attachment of the entire vent cap assembly  18  to the base  12  and thereby attachment to the wall structure to which the base  12  is also mounted.  
      The second cap member  22  includes an outward facing surface  70 , an exhaust vent aperture  72 , a plurality of connecting members  74  that define a plurality of inflow openings  76 , and fastener apertures  78 . The exhaust vent aperture  72  is sized to receive the exhaust duct  16  with the open end  50  of the exhaust duct being positioned flush mounted with the outward facing surface  70  or extending distally beyond the outward facing surface  70  as shown in  FIGS. 5 and 6 . The exhaust duct  16  is mounted with a positive connection to the second cap member by coupling the exhaust duct base  30  against the flange  54  of the exhaust duct and then securing the exhaust duct base  30  to the outward facing surface  70  of the second cap member  22  with, for example, fasteners or adhesives.  
      The connecting members  74  act as, for example, dividers, standoff members or separators that space apart the second cap member  22  from the first cap member  20 . A spacing between the first and second cap members  20 ,  22  is preferred in order for air to flow into the intake duct  14  via the intake aperture  62  of the first vent cap member when the vent cap assembly  18  is assembled together. The connecting member  74 , while shown in this embodiment integrally formed with the structure of the second cap member  22  that defines the outward facing surface  70 , other embodiments may include a connecting member that is separate and distinct. In other examples, the connecting members may be integrally formed with the first cap member  20 . Furthermore, while four connecting members  74  are shown in the present embodiment, other embodiments may include fewer or more than four connecting members while providing separation of the first and second cap members  20 ,  22 .  
      The fastener apertures  78  extend through the connecting members  74  such that the first set of fasteners  34  can pass through the apertures  78 . The apertures  78  align with the first set of fastener apertures  66  in the first cap member  20  so that the fasteners  34  can pass through the apertures  68 , through the apertures  78 , and be connected to the third cap member  24  (discussed in further detail below) for assembly of the first, second and third cap members  20 ,  22 ,  24  as a subassembly of the venting assembly  10 .  
      The third cap member  24  includes an outward facing surface  80 , a plurality of connecting members  82 , a plurality of outflow openings  84  defined between the connecting members  82 , and a plurality of fastener receivers  86  defined within the connecting members  82  (see  FIG. 9 ). The connecting members  82  provide spacing and separation between the second and third cap members  22 ,  24 . Separation between the second and third cap members  22 ,  24  or at least some openings or apertures should be defined within the second or third cap members  22 ,  24  to provide a flow path for exhaust gases leaving the exhaust duct  16  via the outward open end  50 . In this embodiment, the connecting members  82  define the plurality of outward flow openings  84  around a circumference of the third cap member  24  to provide such a flow path. In other embodiments, the connecting members  82  extend from the outward facing surface  70  of the second cap member rather than from the third cap member  24  as shown in the Figures. In still further embodiments, the connecting members  82  may be separate and distinct members that are coupled between the second and third cap members. In still further embodiments, the second and third cap members are integrally formed as a single piece rather than the two separate pieces illustrated in the figures.  
      The fastener receivers  86  defined in the connecting members  82  are exposed in a rearward direction so as to receive the fasteners  34  that have been extended through the first and second cap members. In other embodiments, fasteners may be, for example, co-molded into the first, second, or third cap members  20 ,  22 ,  24  to provide the desired coupling function of the various cap members.  
      An advantage of providing separate cap members in the vent cap assembly  18  is to enable positioning of the first and second screens  26 ,  28  in the space defined between the first and second cap members and between the second and third cap members, respectively. In other embodiments, the screens  26 ,  28  may be co-molded or otherwise formed within one or more of the cap members. In still further embodiments, wherein two or more of the cap members are integrally formed as a single piece, the screens may be properly positioned during the process of molding those cap members as a single piece. The screens  26 ,  28  preferably overlap the openings  76 ,  84  defined in the second and third cap members  22 ,  24  to prevent objects (e.g., animals and insects) from entering the intake and exhaust vents.  
      In one embodiment, the first, second and third cap members  20 ,  22 ,  24  each comprise substantially a non-metallic material such as the compression molded ceramic material described above. In some embodiments, the cap members  20 ,  22 ,  24  may include a combination of different non-metallic materials. In other embodiments, metallic features may be co-molded or otherwise integrated into one or more of the cap members.  
      One advantage of the vent cap assembly  18  is that it substantially conceals all metallic features of the venting assembly  10 . In fact, the only metal features that are viewable in the front view of  FIG. 4  is the water flashing  42 , a top portion of the base  12  (which would typically be covered by a decorative surface member—e.g., siding, brick, stucco, etc.), and heads of the fasteners  36 . Even in the side view of  FIG. 3 , the only additional metal objects that are viewable are portions of the screens  26 ,  28 . Thus, the vent cap assembly  18  can provide a more aesthetically pleasing design that blends into the décor of its surroundings (e.g., decorative design or appearance of the wall structure to which the vent assembly  10  is mounted).  
      Another benefit of using non-metallic material for some or all of the vent cap assembly components is the added safety some non-metallic materials provide. For example, the compression molded ceramic material described above can maintain a relatively safe surface temperature even after extended periods of heated gases being applied to a non-exposed, opposite surface of the cap assembly.  
      While the present embodiment includes a separate base member to which the intake duct and heat shield are mounted, other embodiments may be possible that do not include such a base member. For example, the intake duct  14  and heat shield  32  may be connected directly to the first cap member of the vent cap assembly  18  and the first cap member  20  is coupled directly to the wall structure for mounting of the venting assembly to a horizontal vent. In other embodiments, the base may be integrally formed into one of the cap members. In still further embodiments, one or more of the cap members  20 ,  22 ,  24  may be replaced with a metallic member. For example, the first cap member  20  may be completely eliminated or replaced by a water shield that is coupled to the base  12 , whereas the second and third cap members  22 ,  24  are connected directly to the base  12 . All of these and other embodiments, configurations, and arrangements may be possible.  
      One advantage of the embodiment disclosed with reference to  FIGS. 1-10  is the ability to easily replace the vent cap assembly portion  18  for any desired reason. Because the base  12  is mounted to a wall structure with a more permanent mounting configuration, the vent cap assembly  18  can be replaced for any number of reasons. For example, a new vent cap assembly can provide a new look and feel for the vent assembly (e.g., a design or pattern being added to the exposed outward facing surface  80  of the third cap member), or be used to replace broken or damaged components of the vent cap assembly  18 .  
      Another aspect of the disclosed embodiments relates to a method of assembling portions of the venting assembly so as to conceal metal objects such as fasteners that are used to assemble components of the venting assembly. In one example, the vent cap assembly  18  is coupled together using fasteners that extend from a back side of the first cap member wherein they are concealed from view, through the second cap member  22  and into engagement with the third cap member  24 . In this way, a single set of fasteners can be used to couple all of the cap members together. A fasteners may also be used to concurrently capture the screens in proper position covering the inflow and outflow openings  76 ,  84 .  
      The present invention should not be considered limited to the particular examples or materials described above, but rather should be understood to cover all aspects of the invention as fairly set out in the attached claims. Various modifications, equivalent processes, as well as numerous structures to which the present invention may be applicable will be readily apparent to those of skill in the art to which the present invention is directed upon review of the instant specification.