Abstract:
Apparatus, systems and methods of 50 CFM exhaust and ventilation fans for bathrooms with grill covers having removable light lens covers, and flaps/ears that allow the housings to mount directly to joists and/or other structural members inside of a ceiling or inside of a wall. The housing can include a mounting plate having a motor with attached impeller thereon, wherein the mounting plate with motor and attached impeller and electrical connectors can be removed as a single unit from the housing for accessing and inspecting interior wire connections during inspection and for ease in replacing parts such as burned out motors overtime.

Description:
This invention is a Continuation-In-Part to U.S. Design patent application Ser. No. 29/401,838 filed Sep. 16, 2011, now U.S. Pat. No. Des. 678,497, which is incorporated by reference in its&#39; entirety. 
    
    
     FIELD OF INVENTION 
     This invention relates to ventilation exhaust fans, and in particular to apparatus, systems and methods of 50 CFM ventilation exhaust fans for bathrooms with lens covers and flaps/ears that allow the housings to mount directly to joists in a ceiling or wall. 
     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 exhaust fans, apparatus, systems and methods for use in bathrooms having flaps/ears on the housings and blowers that provides 50 (fifty) CFM (cubic feet of air per minute) of airflow. 
     A secondary objective of the present invention is to provide exhaust fans, apparatus, systems and methods for use in bathrooms, having lights where air flow does not pass into the light box so that moisture will not affect internal electrical components. 
     A third objective of the present invention is to provide exhaust fans, apparatus, systems and methods for use in bathrooms, where a motor and blower are mounted to a mounting plate, in order to allow for easy removal of the motor and blower for replacing parts and checking wires. 
     A fourth objective of the present invention is to provide exhaust fans, apparatus, systems and methods for use in bathrooms, where a motor and blower and mateable electrical connectors for the motor and a light are mounted to a mounting plate, in order to allow for easy removal of the motor and blower for replacing parts and checking wires. 
     A fifth objective of the present invention is to provide exhaust fans, apparatus, systems and methods for use in bathrooms, wherein electrical connections are inside of the box and not exposed to air and moisture outside of the box. 
     An exhaust fan embodiment can include a housing having closed side walls, an open top and open bottom, a blower wheel inside of the housing, a motor for running the blower wheel, a grill cover having vents for allowing air to be pulled into the housing by the blower wheel, a lens cover in the grill cover for covering a light source under the grill cover that is mounted in a light box, wherein the motor powered blower pulls air through the vents of the grill around the light box and not into the light box, in order to be exhausted from the housing. 
     The motor can be a 50 (fifty) CFM (cubic feet per minute) generating motor. 
     The housing can include external flaps attached to an exterior of the housing for mounting the housings directly to structural supports within a ceiling. The external flaps can include keyhole slots for allowing the housings to be flush mounted to the structural supports by fasteners being inserted into and locked with the keyhole slots. The flaps can include a base plate fastened to an external side corner of the housing, and flap plate attached at an angle to the base plate, the flap plate having a fastening opening for mounting the housing to a joist. The flaps can also have a hinge for allowing the flap plate to swing relative to the base plate. 
     The housing can include a removable mounting plate having the motor and the blower wheel pre-attached thereto, wherein the mounting plate with the motor and blower wheel are removable as a single piece from the inside of the housing. The removable mounting plate can include a central opening for extending the motor down therethrough. The mounting plate can include a bracket for attaching mateable electrical connectors for the light source and the motor, to the removable mounting plate. 
     The fan can also include a curved plate member to airflow and minimizes excess noise from air being moved from the blower wheel. 
     The lens cover can include a depressible and releaseable fastener for allowing the lens cover to be latched onto the grill cover by depressing a portion of the lens cover, and for allowing the lens cover to be removed by depressing the portion of the lens cover. 
     A ceiling mounted exhaust fan, can include a housing having closed side walls, an open top and open bottom, a motor attached to an impeller, and a mount plate member with an opening therethrough, the plate member having edge portions mounted inside of the housing so that the motor when mounted to the plate member allows for the motor to extend through the opening in the mount member, wherein the mount with mounted motor and attached impeller are removable as a single unit from the housing. 
     The motor can be a 50 (fifty) CFM (cubic feet per minute) generating motor. 
     The fan can include a bracket for attaching mateable electrical connectors for the light source and the motor, to the removable mounting plate 
     The fan housing can include a sealed light box, a light source mounted in the light box, and a removable lens cover overlaying the light source. 
     The housing can include external flaps attached to an exterior of the housing for mounting the housings directly to structural members inside of a ceiling. The flaps can include a base plate fastened to an external side corner of the housing, and a flap plate attached at an angle to the base plate, the flap plate having a fastening opening for mounting the housing to a joist. 
     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 perspective view of a 50 CFM bath fan housing with lens cover, grill, light box, light, motor, blower, mount, electrical connectors, deflector, and outlet. 
         FIG. 2  is another exploded view of the 50 CFM bath fan housing of  FIG. 1  without the lens cover, grill, light box and lights. 
         FIG. 3  is another exploded view of the 50 CFM bath fan housing of  FIG. 1  with light, light box, motor, mount, electrical connectors. 
         FIG. 4  is another exploded view of the 50 CFM bath fan housing of  FIG. 1  with assembled motor and blower and springs mounted to the removable mount plate. 
         FIG. 5  is a perspective assembled view of the 50 CFM bath fan housing of  FIG. 1  with partial cut-away. 
         FIG. 6  is a cross-sectional view of the assembled 50 CFM bath fan housing of  FIG. 5 . 
         FIG. 7  is a perspective top view of the assembled 50 CFM bath fan housing of  FIG. 5  with lens cover, grill and light box removed. 
         FIG. 8  is a top view of  FIG. 7  of the assembled 50 CFM bath fan housing with lens cover, grill and light box removed. 
         FIG. 9  is a top view of the assembled 50 CFM bath fan housing of  FIG. 5  without the lens cover. 
         FIG. 10A  is a perspective view of the bottom of the lens cover from the bath fan of  FIG. 1 . 
         FIG. 10B  is a side view of the lens cover of  FIG. 10A . 
         FIG. 10C  is an end view of the lens cover of  FIG. 10B  along arrow  10 C. 
         FIG. 11A  shows a prong used under the lens cover about to be attached to the assembled receptacle fastener of  FIG. 9 . 
         FIG. 11B  shows the prong being inserted into the receptacle fastener of  FIG. 11A . 
         FIG. 11C  shows the prong locking into the receptacle fastener of  FIG. 11B . 
         FIG. 11D  shows the prong locked into the receptacle fastener of  FIG. 11C . 
         FIG. 11E  shows the prong being pushed down again to start the release of the prong. 
         FIG. 11F  shows the prong being pushed out of the receptacle of  FIG. 11E . 
         FIG. 12  is a top view of the assembled 50 CFM bath fan housing of  FIG. 5  with lens cover. 
         FIG. 13  is a side perspective view of the assembled 50 CFM bath fan housing of  FIG. 5 . 
         FIG. 14  is another side perspective view of the assembled bath fan housing of  FIG. 5 . 
         FIG. 15  is a side view of an installed 50 CFM bath fan housing of  FIG. 5  showing airflow. 
     
    
    
     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. 
     50 CFM Bath Exhaust Fans with Flaps/Ears. 
     A list of the components for  FIGS. 1-15  will now be described.
       1 . 50 CFM embodiment     10 . grill lens (lens cover)     12 . free end (push down end) with male prong     14 . sidewall     15 . top of lens     16 . sidewall     18 . hinged end     20 . grill     22 . side vents     25 . central opening     26 . hinge slot     28 . side vents     29 . inwardly protruding tabs attach to springs     30 . light source (bulb)     40 . light box.     42 . bent edge     48 . bent edge     50 . spring (2)     52 . outer end     55 . apex end     58 . outer end     60 . light box bracket     62 . footer end     63 . fastening slot(s)     68 . footer end     70 . wire buckle fixed plate     80 . motor mounting plate     82 . bent side edges     85 . central opening     84 . inwardly protruding flanges     90 . motor     92 . power line to motor     94 . side flanges     100 . impeller (blower)     110 . wind deflector     120 . housing     121 . ledge clip(s)     122 . first flap-ear     123 . keyhole slot     125 . open top     126 . rectangular outlet opening     127 . upper edges about open top     128 . second flap-ear     129 . keyhole slot     130 . male plug 2-pin (2)     140 . plug plate     150 . female plug 2-pin (2)     160 . outlet     168 . opening in outlet     170 . damper     180 . lamp socket     182 . power line to socket     300 . Grill lens connecting block chip (depressible engageable and releasable fastener)     310 . inside part with bendable prong arms     312 . bendable prong arms     320 . outside box     322 . top end with enlarged edges     340 . internal spring     400 . male prong with enlarged head     410 . shaft     420 . enlarged head   

       FIG. 1  is an exploded perspective view  1  of a 50 CFM bath fan housing  120  with lens cover  10 , grill  20 , light box  40 , light  30 , motor  90 , blower  100 , mount plate  80 , electrical connectors  130 ,  140 ,  150 , wind deflector, outlet  160  and damper  170 .  FIG. 2  is another exploded view  1  of the 50 CFM bath fan housing  120  of  FIG. 1  without the lens cover  10 , grill  20 , light box  40  and light  30 .  FIG. 3  is another exploded view of the 50 CFM bath fan housing  120  of  FIG. 1  with light, light box  40 , motor  90 , mount plate  80 , and electrical connectors  130 - 150 .  FIG. 4  is another exploded view  1  of the 50 CFM bath fan housing  120  of  FIG. 1  with assembled motor  90  and blower  100  and springs  50  mounted to the removable mount plate  80 . 
     Referring to  FIGS. 1-4 , the bath fan housing  120  can have a rectangular metal box configuration with closed sidewalls and closed bottom that are pre-fastened together by rivets, and the like, with an open top. For example, five metal pre-formed plates can be riveted together to form the open top box. Extending from outer edges of at least one sidewall of the box  120  can be ear-flap type flanges  122 ,  128 , each with slots  123 ,  129 , such as keyhole slots, that allow the housing  120  to be mounted to structural supports, such as but not limited to joists, and the like above a ceiling in a bathroom (which is shown in relation to  FIG. 15 ). Extending from one of the sidewalls of the housing  120  can be an air exhaust outlet  160 , which can include a pivotally mounted damper  170 . The exhaust outlet  160  can have a male protruding end  162  attached to a rectangular outlet opening  126  of the housing  120 . The pivotal outlet damper  170  can be attached to the exterior opening  168  of the outlet  160   
     A curved metal type wind deflector  110 , can be mounted by fasteners, such as but not limited to rivets, screws, and the like, to either or both the floor and/or interior sidewall(s) inside of the housing  120 . The curved deflector  110 , such as a curved metal plate, can direct air from the rotating blower  100  to be directed toward the outlet  160 . The curved plate  110  can be used to both guide the airflow and minimizes excess noise. 
     The motor  90  that can be used in these bath fans can be an electrical motor that can rotate and generate air at 50 CFM. The electrical motor  90  can have a rotating axle portion  95  having an end that fits into a central portion  105  of a blower wheel (impeller)  100 . The impeller  100  can have a disc shaped base  105  with blades perpendicular to and extending outward from a midportion therefrom in a cylindrical configuration. 
     The motor  90  with attached impeller  100  can be mounted into a central opening  85  of a metal type mounting plate  80 , by flange edges  94  on the sides the motor  90  that attach to inwardly protruding flanges  84  on the mounting plate  80  using fasteners, such as but not limited to screws and bolts. Together, the motor  90  and impeller  100  are attached to the mounting plate  80  by the flanges  84  and  94  that can be easily attached and detached from one another by the removable fasteners (screws, bolts, and the like). Antivibration and anti-noise members, such as but not limited to rubber pads, and the like, can be sandwiched between the mounting flanges  84 ,  94 . 
     When attached the impeller  100  with motor  90  can extend through the middle opening  85  of the mounting plate  80 . The mounting plate  80  can have bent side edges  82  which allow the mounting plate  80  with mounted motor  90  and impeller  100  to be attached to interior sidewalls of the housing  120  by various removable type fasteners, such as screws and bolts, and the like. The bent edges  82  can also sit on plural ledge clip(s)  121  arranged about an interior perimeter edge inside of the housing  120 . 
     In a preferred embodiment, the impeller  100  and motor  90  are preattached to the mounting plate  80  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 more easily attach and visually inspect electrical connections ( 130 ,  140 ,  150 ) by being able to insert and remove this one-piece assembly of components. Additionally, removing the combined plate  80  mounted motor  90  and impeller  100  allows for replacement of parts, such as a burned out motor to be more easily accomplished after the fan has been installed. 
     Additionally, the outer bent ends  52 ,  58  of the springs  50  can be located between the motor  90  and the perimeter of the opening  85 , so that the expanding outer ends  52 ,  58  catch about the lip edge of the opening  85  in the mounting plate  80 . The springs (spring clips)  50  can have an apex portion  55  that attach to inwardly protruding members  29  on the inside walls of the grill cover  20 , so that the springs  50  attach the grill cover  20  to the housing  120 . 
     The pair of spring clips  50  can springably hold the grill cover  20  to cover the top opening  125  of the blower housing  120 . The pair of grill clips  50  can each be scissor clips each having an apex  55  that can attach to an inner protruding portion  29  ( FIG. 4 ) along a sidewall of the grill cover  20 . The cover  20  can be attached by pressing together the leg ends  52 ,  58  of the clips  50  ( FIG. 1 ), so that the bottom bent edges  52 ,  58  can be inserted to catch inside edges under the opening  85  of the mounting plate  80  within the housing  120 . 
       FIG. 5  is a perspective assembled view of the 50 CFM bath fan housing  120  of  FIG. 1  with partial cut-away.  FIG. 6  is a cross-sectional view of the assembled 50 CFM bath fan housing  120  of  FIG. 5 .  FIG. 7  is a perspective top view of the assembled 50 CFM bath fan housing  120  of  FIG. 5  with lens cover  10 , grill  20  and light box  40  removed.  FIG. 8  is a top view of  FIG. 7  of the assembled 50 CFM bath fan housing  120  with lens cover  10 , grill  20  and light box  40  removed.  FIG. 9  is a top view of the assembled 50 CFM bath fan housing  120  of  FIG. 5  without the lens cover  10 . 
     Referring to  FIGS. 1-9 , an inverted U-shaped bracket  60  with footer ends  62 ,  68  can be mounted to surface portions of the mounting plate  80  by removable fasteners, such as but not limited to screws, bolts, and the like. A bottom floor portion of a metal type light box  40  can be mounted to a mid portion  65  of the light box bracket  60  by fasteners, such as screws, bolts, and the like. The inside of the light box  60  can be closed so that no air can pass through the bottom or sidewalls of the inside of the light box  60 . As such, any moisture in the air will not be pulled into the light box to affect any of the electrical components in the box. A lamp socket  180  can be mounted inside of the light box  60  and have a light source  30 , such as a bulb  30  attached to the socket  180 . The light box  140  can have bent flange edges  142 ,  148  that can also be attached to upper edges  127  of the housing  120  by fasteners, such as screws, bolts, and the like. 
     Light power line  182  and motor power line  92  connect to respective male plugs  130  which are mateably attached to female plugs  150 , where the male and female connectors  130 ,  150  can be mounted inside of the housing  120  by a plug plate  140 . The plug plate  140  can be attached to an opening in the motor plate  80  by fasteners, such as rivets, screws, bolts, and the like. As previously described, the combined one piece motor/impeller/mount assembly (mounted to plate  80 ) allows inspectors, such as home inspectors, and the like, to be able to more easily attach and visually inspect electrical connections ( 130 ,  140 ,  150 ) by being able to insert and remove this one-piece assembly of components. 
     The wire buckle fixed plate  70 , shown in  FIGS. 1 ,  2 ,  7  and  8  can be a metal plate to cover the wiring connections  130 ,  140 ,  150 , and can be held by fasteners, such as screws and the like, to either or both an inner wall of the housing  120  or to the mounting plate  80 . Plate  70  can have openings, such as rectangular openings, for the male  130  and female plug connections that supply power to the motor  90  and the light  30 . 
     The grill cover  20  can include grill vents  22 ,  28  on both sides of a central opening  25  with the light box  40  is beneath, and in which a lens cover  10  covers the opening  25 . 
       FIG. 10  is a perspective view of the bottom of the lens cover  10  used in the bath fan  1  of  FIG. 1 .  FIG. 11A  is a side view of the lens cover  10  of  FIG. 10 .  FIG. 11B  is an end view of the lens cover  10  of  FIG. 11A  along arrow  11 B. 
       FIG. 11A  shows a prong used  400  under the lens cover  10  about to be attached to the assembled receptacle fastener  300  of  FIG. 9 .  FIG. 11B  shows the prong  400  being inserted into the receptacle fastener  300  of  FIG. 11A .  FIG. 11C  shows the prong  400  locking into the receptacle fastener  300  of  FIG. 11B .  FIG. 11D  shows the prong  400  locked into the receptacle fastener  300  of  FIG. 11C .  FIG. 11E  shows the prong  400  being pushed down again to start the release of the prong  400  from the receptacle  300 .  FIG. 11F  shows the prong  400  being pushed out of the receptacle  300  of  FIG. 11E . 
     The lens cover  10  with prong  400  and receptical  300  can be similar to the lens cover having prong and receptical used in the assignees copending application Ser. No. 13/269,171 filed Oct. 7, 2011, by the same inventor and assignee, which is incorporated by reference. This lens cover  10  can also include depressibly releaseable fasteners that include a male prong member  400  having a shaft  410  and an enlarged head  420  that fasten into a receptical  300  as in the co-pending application. 
     The lens cover can include an outwardly protruding hinge end  18 , and an opposite push down end  12  having the downwardly extending male prong  400  (depressible fastener). The lens cover  20  can include sidewalls  14 ,  16  with a top translucent surface  15  that allows light to pass therethrough. The hinge end  18  of the lens cover  10  can insert into and pivot relative to the hinge slot  26  in an end portion of the central opening  25  of the grill cover  20 . 
     Referring to  FIGS. 1-11F , to attach the light cover  10 , to the grill cover  20 , the unhinged end  12  of the outside of the light cover  10  is first pushed toward the grill cover  20 , so that the prong  400  is first pushed (or depressed) into the bendable arms  312 . This causes the bendable arms  312  to be catch the enlarged prong head  420  while the arms  312  are being pushed into the upper end  322  of the box  320  which partially compresses spring  340 . Once the inner part  310  is inside the box  320 , the inner part  310  is latched in place. To release the light cover  10 , the opposite side of the light cover  10  is pushed toward the housing  120 , this causes the inner part  310  to push down again on spring  340 , which then releases the latching of the inner part  310 . The expanding spring  340  causes the inner part  310  to be pushed to a raised position, with the bendable arms  312  outside the upper end  322  of the box  320 , where the arms  312  expand from one another releasing the enlarged prong head(s)  420 , and the light cover  10  is then free to pivot open (relative to a hinged end)  18  to allow access to change out the light sources inside of the grill cover  20 . 
       FIGS. 11A-11D  show the steps to lock the prong  400  to the receptacle fastener  300 .  FIG. 11A  shows a prong  400  used under the lens cover  20  about to be attached to the assembled receptacle fastener  300  of  FIG. 9 . The prong  400  can have a shaft  410  and an enlarged head  420 . The bendable arms  312  can have lower ends attached to top edges of the inner part  310  and have upper inwardly protruding hook ends 
       FIG. 11B  shows the prong  400  being inserted into the receptacle fastener  300  of  FIG. 11A , where the enlarged head  420  starts to expand the upper hook ends of bendable prongs  312  until the upper hook ends hook about the enlarged head  420  of the prong  400 . 
       FIG. 11C  shows the prong  400  locking into the receptacle fastener  300  of  FIG. 11B , where the hooked prong head  420  is continued to be pushed into the box  320  so that the spring  340  under the inner part  320  starts to compress inside of the box  320 .  FIG. 11D  shows the prong  400  locked into the receptacle fastener  300  of  FIG. 11C . Here, the prong arms  312  are wrapped about the head  420  so that the entire head  420  and substantially most of the arms  312  are inside the upper open end of the box  320 . At this point the light cover  10  is fully attached to grill cover  20 . 
       FIGS. 11E-11F  show the steps to release a light cover  10  from the grill cover  20   FIG. 11E  shows the prong  400  being pushed down again to start the release of the prong  400 . By pushing down the prong  400 , the inner spring  340  compresses again.  FIG. 11F  shows the prong  400  being pushed out of the receptacle  300  of  FIG. 11E  by the spring  340  pushing up against the bottom of inside part  310 . 
       FIG. 12  is a top view of the assembled 50 CFM bath fan housing  1  of  FIG. 5  with lens cover  10  attached to and covering the light box and light source.  FIG. 13  is a side perspective view of the assembled 50 CFM bath fan housing  1  of  FIG. 5 .  FIG. 14  is another side perspective view of the assembled bath fan housing  1  of  FIG. 5 . 
       FIG. 15  is a side view of an installed 50 CFM bath fan housing  1  with the ear flanges  122 ,  128  attached to joists, J, or other structural supports above a ceiling, C, by enlarged headed fasteners (not shown) be locked into the openings, such as circular openings or keyhole slots  123 ,  129  in the ear flanges  122 ,  128  on the housing  120 . 
     Once a fastener is screwed tight the outer leg side with the ears can be flush against the joist, J and will not move. The ear flaps allow for flush mounting the bath fans  1  to the joists in less steps and using less parts than other types of mount members such as telescoping members, and the like. The flap ears can be rigid L shaped members. Alternatively, the flap ears can have a hinge between the housing mount leg, and the perpendicular extending ear leg portion, so that the flap ears are more versatile when mounting the housing inside of the ceiling. 
       FIG. 15  shows airflow passing into the box  120  by arrow I, and exhausting from the outlet  160  of the housing  120  by arrows O. The vents  22 ,  28  allow for incoming air, I, being pulled by rotating blower  100 , to pass around the light box  40 , so that no incoming air passes into the light box  40  to affect the light sources and electrical connections inside of the light box  40 . 
     Although the invention uses a light cover and light, the invention can be practiced without a light cover and light. 
     While the preferred embodiment describes a 50 CFM fan, the invention can be practiced with a 60 CFM, 70 CFM, and 90 CFM motor and the like. 
     Although the preferred embodiments describe the housings to be attached directly to joists in ceilings, the invention can apply to attaching the housings to structural members in walls, and other structural members behind ceilings and/or walls. 
     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.