Abstract:
A range hood having a grease collecting motor housing and integrated grease tray and fan grill. The motor housing intake openings are defined by circular walls projecting vertically into the motor housing that act to prevent grease from passing back through the air intakes. Condensed liquids within the housing are directed to drain holes in the lower surface of the housing for transport out of the range hood. The tray (with attached grill) is releasable connectable to the housing through the air inlet in the range hood lower panel. The tray may be removed without removal of the lower panel of the range hood.

Description:
FIELD OF THE INVENTION 
     This invention relates to range hoods, and more particularly to the collection and disposal of grease accumulated within, and to access to, the motor housing. 
     BACKGROUND OF THE INVENTION 
     Range hoods are used above cooking surfaces to remove grease, common odors and hazardous gases created during the cooking process. Typically, range hoods have a pair of motors horizontally installed in a motor housing within the hood body. Each motor drives a fan. The fans suck air from the cooking area below and force it through the motor housing to ventilation piping. 
     As the vaporized grease contained in the entrained air travels through the motor housing, some of it condenses on the inside walls of the housing from where the shaping of the walls and floor of the housing directs the grease to a circular grease catcher mounted below each fan opening. Grease catchers are known in the art as illustrated in U.S. Pat. Nos. 6,216,686 B1 and 5,537,988. 
     Grease catchers are also adapted to capture any grease that drips off the fan blades when the motors are turned off. Typically, the grease catcher has radial inner and outer trays with a wall separating them. The wall extends vertically so as to be almost flush with the lower edge of the outer circumference of the fan. In this way air being drawn in by the fans is compelled to enter the motor housing rather than the hood body. The wall therefore acts to control the air currents of the range hood. 
     The grease catchers are usually provided with an inclined base or floor, so as to direct accumulated grease to a hole in the floor. A hose is attached to the hole to convey the grease to a grease receptacle outside the range hood. 
     The motor housing and grease catchers are mounted within the hood body. Openings in the lower surface of the hood body are positioned so as to match those of the motor housing. Typically the lower surface of the hood body is removably fitted into the main hood body. A protective grill is attached to the outside of each opening in the hood body so as to prevent the insertion of body parts when the fan is in operation. 
     One disadvantage of the foregoing system of motor housing and grease catchers is that in order to clean the interior of the range hood, a user must first remove the lower surface of the hood body, following which the grease catcher must then be removed. This can be quite awkward and is difficult for those without the strength to hold the weight of the lower surface. 
     Furthermore, because the grease catchers extend below the motor housing, the size of the hood body must be sufficient to accommodate them. The cost of materials for the production of the range hood is therefore high. The resulting range hood also takes up a large amount of space, both when installed, and when being stored or shipped, such that storage and shipping costs are high. 
     Furthermore, in order to increase the suction power of the range hood either the size of the fan must be increased or its speed of rotation. Both changes have undesirable consequences. To increase the size of the fan, the range hood would also have to increase in size, leading to the deficiencies outlined above. Increased rotation would cause increased noise, which is not desirable. 
     It is therefore an object of an embodiment of the present invention to provide a range hood in which the grease is captured within the confines of the motor housing such that the size of the range hood may be decreased in relation to a range hood with the grease catcher of the prior art. 
     It is a further object of the present invention to provide a range hood in which the lower surface need not be removed in order to clean the inside of the motor housing. 
     It is a further object of an embodiment of the present invention to provide a range hood, which has increased suction power over prior art range hoods of the same size. 
     It is a further object of an embodiment of the present invention to provide a range hood that has the same suction power as similar sized range hoods according to the prior art, but that produces less noise. 
     Various aspects of the invention address these objects, but not all aspects of the invention necessarily address all such objects simultaneously. Other objects of the invention will be apparent from the description that follows. 
     SUMMARY OF THE INVENTION 
     The invention is directed to a motor housing and tray assembly for use in a range hood. According to the invention, the motor housing acts as a grease catcher. Intake openings in the lower surface of the housing are formed by walls that project into the interior of the housing. An extension extends from the wall into the opening and in a downward direction so as to form a gap between the extension and the wall. The housing is shaped so as to direct any accumulated liquid within the housing, such as grease, towards a drainage hole in the lower surface of the housing where the liquid is directed out of the range hood. The walls prevent any liquid from passing back through the opening. 
     A tray, defined by inner and outer walls, is shaped so that its outer wall may be inserted into the gap in the housing. The tray may have a fan grill attached to it to prevent any body parts from being inserted into any fan operating within the housing. The tray may be releasably connected to the housing by insertion through air inlets in the lower panel of the range hood body. An automatic shutoff switch acts to shut off power to the fans when a tray is disconnected from the housing. The removable lower panel need not be removed in order to remove the tray and clean the interior of the housing. 
     Alternatively, the fan grill may be attached to the air inlet in the lower panel of the hood body. In this embodiment, the lower panel must be removed in order to releasably connect the tray to the housing. 
     In one aspect, the invention comprises a motor housing and tray assembly for a range hood where the motor housing generally defines an enclosure and comprises an upper surface and a lower surface. The lower surface has at least one intake opening and at least one drain hole. The intake opening is defined by a wall depending from the lower surface and projecting into the interior of the enclosure. The tray comprises an opening, first and second tray walls extending around the opening, and a floor between the first and second tray walls. The tray is releasably connectable to the intake opening. 
     Alternative embodiments of the motor housing and tray assembly for a range hood comprise one or more of the following: 
     a. the wall of the intake opening of the motor housing of the invention has an extension extending toward the intake opening so as to define a gap between the extension and the wall of the intake opening; 
     b. at least a portion of the extension diverges from the wall of the intake opening to form a wedge surface; 
     c. the tray is releasably connectable to the intake opening by wedging the second tray wall into the gap; 
     d. the first tray wall is proximal to the tray opening and the second tray wall is distal from the tray opening in relation to the first tray wall. The second tray wall is shaped and dimensioned so as to be insertable within the intake opening so that at least a portion of the second tray wall is in abutment with at least a portion of the wall of the intake opening, forming a close fit; 
     e. a grill is connected to the first wall of the tray of the assembly; 
     f. the tray has a bottom surface, and when the second wall is inserted in the gap, at least a portion of the bottom surface of the tray lies in substantially the same plane as the lower surface; and 
     g. there are two intake openings, two trays and two drain holes. 
     In another embodiment, the assembly according to the invention comprises a range hood, motor housing and tray. The range hood generally defines an enclosure and comprises an upper panel and a lower panel. The lower panel has at least one air inlet. The motor housing is connectable to the range hood within the enclosure of the range hood, the motor housing generally defining a further enclosure and comprising an upper surface and a lower surface. The lower surface has at least one intake opening and at least one drain hole. A wall depending from the lower surface and projecting into the interior of the further enclosure defines the intake opening. The tray comprises an opening, a first tray wall extending around and proximal to the tray opening, a second tray wall distal from the tray opening in relation to the first tray wall, and a floor between the first and second tray walls. The second tray wall is shaped and dimensioned so as to be insertable within the gap, forming a close fit. Finally, the tray is releasably connectable to the intake opening. 
     Further aspects of alternative embodiments of the range hood, housing and tray assembly may comprise one or more of the following: 
     a. the air inlet is defined by a second wall depending from the lower panel and projecting into the interior of the range hood enclosure; 
     b. the air inlet and the intake opening are of identical shape, the air inlet being located directly below the intake opening; 
     c. the tray may be releasably inserted into the air inlet and connected to the intake opening; 
     d. a grill is connected to the first tray wall; 
     e. the housing is shaped so as to direct any liquid located within it to the drain hole; and 
     f. there are two intake openings, two air inlets, two trays and two drain holes. 
     Other aspects of the invention will be appreciated by reference to the detailed description of the preferred embodiment and to the claims that follow. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The invention will be described by reference to the detailed description of the preferred embodiment and to the drawings thereof in which: 
     FIG. 1 is a cross sectional view of a range hood according to the preferred embodiment of the invention; 
     FIG. 2 is an exploded perspective view of the range hood of FIG. 1; 
     FIG. 3 is an exploded cross sectional view of portions of the range hood of FIG. 1; 
     FIG. 4 is a perspective view of a motor housing according to the preferred embodiment of the invention; 
     FIG. 5 is a perspective view of the range hood of FIG. 1 in its assembled form; 
     FIG. 6 is a cross sectional view of an alternative embodiment of range hood according to the invention; 
     FIG. 7 is an exploded cross sectional view of portions of the range hood of FIG. 6; 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     The preferred embodiment of a range hood  100  with a motor housing and tray according to the invention is illustrated in FIG.  1 . The motor housing  110  itself doubles as a grease catcher. Tray  140 , which has an integral fan grill  138 , is releasably connectable to both the motor housing  110  and to lower panel  108  of the hood body  102  as discussed below. Both the housing  110  and the tray  140  will be described in greater detail below. 
     The housing  110  defines an enclosure and is mountable within the enclosure formed by the hood body generally indicated by the numeral  102 . A pair of motors  125  fit within the motor housing  110  and are attached to the upper surface of the hood body  102 . Fans  120  are attached to each of the motors  125  and secured by fan caps  129 . The motors  125  are positioned within the motor housing so that when the fans  125  are attached they are positioned above intake openings  112  (of the motor housing  110 ) and air inlets  109  (of the lower panel  108 ), shown in FIGS. 2 and 4. When activated, the motors  125  act to rotate the fans such that air is drawn through intake openings  112  and air inlets  109  and into the motor housing  110 . Air drawn into the motor housing is then forced out of ventilation holes in the upper surfaces of the housing  110  and hood body  102 . 
     The fans  120  and motors  125  are dimensioned so as to be removable from within the housing  110  through openings  112 . 
     As shown in FIG. 4, openings  112  in motor housing  110  have walls  130  depending and rising vertically from lower surface  108 . The diameter of the circles formed by walls  130  is roughly equal to the diameter of the intake openings  109 . An outwardly and downwardly projecting extension or lip  132  depends from wall  130 , so as to form a gap  134  between the lip  132  and wall  130 , as illustrated in FIG.  3 . Extension  132  may diverge from wall  130  such that gap  134  forms a wedge surface. 
     Fan grills  138 , illustrated in FIG. 5, are preferably made of metal and are designed to allow maximum airflow into motor housing  110 , while still preventing solid objects such as kitchen utensils or body parts from penetrating through the grill to fans  120 . 
     The tray  140  is circular and has inner wall  144 , concentric outer wall  142 , trough  146  and fan grill  138 , which is connected to inner wall  144 . Inner wall  144  is proximate to, and defines, an opening. Outer wall  142  is distal from the opening in relation to the inner wall  144 . Outer wall  142  is shaped and dimensioned to fit within gap  134  when tray  140  is connected with housing  110  so that a portion of outer wall  142  is in abutment with wall  130 . Preferably, the diameter of inner wall  144  is smaller than the diameter of lower fan edge  122 . The tray  140  is dimensioned such that when connected with the motor housing  140 , the top of inner wall  144  is just below the level of fan  120 , thereby directing air into the housing  110  by way of the fan  120 . 
     The lower panel  108  is removable from the remainder of main hood body  102 , as discussed in greater detail below. Lower panel  108  has a pair of air inlets  109  as shown in FIG.  2 . Air inlets  109  are defined by circular vertical walls  101 , which depend, and rise vertically from, lower surface  108 . The circular vertical walls  101  can vary in height between a minimum height and a maximum height. The minimum height is the height at which the circular vertical walls  101  will remain in contact with the tray  140  when it is connected to the housing  110  as described below. The maximum height is the height at which the top of the circular vertical walls  101  abuts the bottom of the housing  110  when the lower panel  108  is connected with hood body  102 . 
     Tray  140  is connected to the range hood  100  by inserting it through intake opening  109  in lower panel  108  and into intake opening  112  in the motor housing  110  until outer wall  142  is firmly in place within gap  134 . Tray  140  may be releasably connected to housing  110  by wedging outer wall  142  into gap  134 . Preferably, when tray  140  is connected to the housing  110 , outer wall  142  is also in contact with lower panel  108  and acts to seal any space that may exist between the housing and the lower panel thereby preventing air from entering into any undesired area within the range hood body  102 . However, it is contemplated that if circular vertical wall  101  is dimensioned so as to abut the bottom of housing  110  so as to form a seal when lower panel  108  is connected with the hood body  102 , then tray  140  may fit loosely within intake opening  109  while connected to said housing. A clip or other form of suitable restraint (not shown) accessible on the outside surface of the range hood is used to hold the tray in place. In this way, lower panel  108  need not be removed in order to access the interior of the motor housing  110 . A user need simply remove the tray in order to access the interior of the housing, for example, to remove the fans  120  and clean the interior of the motor housing. 
     The range hood  100  is equipped with an automatic shutoff switch. Shutoff switches are known in the art and are used as a safety feature to cut off power to the motors  125  when no protective grill is in place to prevent access to the fans  120 . Preferably, the shutoff switch is releasably attached to the housing  110 . However, it is contemplated that the shutoff switch could be positioned elsewhere, including to lower panel  108 . Any position is satisfactory provided that there is a shutoff switch for each intake opening and provided that the shutoff switch acts to cut the power to the fans when a tray and fan grill are not connected, or not properly connected, to the range hood. 
     Fan tip grease catcher  150  is releasably attachable to the lowest portion of the fan grill  138  and acts to catch any grease or other liquid that may drip from the lowest portion of the fan grill  138 . 
     Motor housing  110  is shaped such that any accumulated grease or liquid that condenses on its inner surface is directed towards drain holes  124  in motor housing  110 . Holes  124  are therefore located at the lowest point of lower surface  118 . As seen in FIG.  1  and FIG. 3, a hose  128  is attached to each of holes  124 . Accumulated grease and liquids travel through hoses  128  by way of gravity to an external grease cup  126 . Wall  130  (best seen in FIG. 3) acts as a barrier to any condensed grease or other liquid which accumulates in the interior of the motor housing, preventing it from dripping through opening  112 . Typically only a very small amount of grease drips from a fan  120  as most is dispersed by means of the centripetal force of the rotating fan. Any grease or liquid that does drip from the fan when it is no longer rotating tends to drip from lower fan edge  122  and is captured in trough  146 . As very little grease accumulates in trough  146 , it need only be cleaned periodically during regular maintenance of the range hood and need only have minimal depth. 
     By altering the motor housing so that it acts as a grease catcher itself, the need for the large grease catchers of the prior art is negated and the overall size of the range hood in comparison to those of the prior art may be decreased. This more streamlined range hood is able to intake the same cubic feet per minute (cfm) of air of a larger range hood while taking up less space. Additionally, a smaller size translates into lower material costs in the construction of the range hood and additional savings in shipping and storing costs. 
     Alternatively, if the size of the range hood is maintained, then a larger motor housing, motor and fan can be used as compared to the range hoods of the prior art, occupying space previously occupied by grease catchers of the prior art. By increasing the size of the fans, a greater intake of air may be achieved while running at the same rpm as a range hood with smaller fans. Hence a more powerful range hood may be designed without having to increase the size of the range hood. Additionally, the same cfm could be generated at lower rpm, thereby making a quieter range hood. 
     An alternative embodiment of the invention is shown in FIGS. 6-7. Those aspects of the alternative embodiment that are identical to aspects of the preferred embodiment have identical reference numbers. 
     The lower panel  208  and the tray  240  of range hood  200  differ from those described above. In this embodiment, fan grill  238  is connected to lower panel  208 . Preferably this connection is fixed such that grill  238  is not easily detached from lower panel  208 . Tray  240  has outer wall  242 , inner wall  244  and trough  246 . Outer wall  242  fits within gap  134  when tray  240  is connected with motor housing  110 . A clip or any suitable restraint (not shown) may be used to hold tray  240  in place with the motor housing  110 . Tray  240  is dimensioned such that the diameter of inner wall  244  is smaller than the diameter of the lower fan edge  122 . Furthermore, inner wall  244  is dimensioned such that when tray  240  is connected with motor housing  110 , the top of inner wall  244  is just below the level of fan  120 , thereby acting to direct the inflow of air into the motor housing  110 . 
     Lower panel  208  is releasably connectable to hood body  202 . In order to connect or remove tray  240 , the lower panel  208  must first be removed. An automatic shutoff swich, as described above acts to cut off power when the lower panel  208  is disconnected from the hood body. Air inlets are defined by circular vertical walls  209 , which are dimensioned so that when lower panel  208  is connected to the hood body, circular vertical walls  209  abut trays  240 . This flush fit between components ensures that air is just drawn into the motor housing and does not travel into the remainder of the hood body. 
     It will be appreciated by those skilled in the art that the preferred and alternative embodiments have been described in some detail but that certain modifications may be practiced without departing from the principles of the invention.