Variable Height Installation Mechanism

This application claims priority under 35 U.S.C. § 119(e) to U.S. patent application Ser. No. 17/706,676, filed Mar. 29, 2022 and U.S. Provisional Application Ser. No. 63/167,253, filed Mar. 29, 2021, which is expressly incorporated by reference herein.

The present disclosure relates to a ventilation unit, and particularly to a ventilation unit including an installation system. More particularly, the present disclosure relates to a ventilation unit having an installation system with a plurality of fasteners that secure the ventilation unit to surrounding structures.

According to the present disclosure, a ventilation unit includes a housing including a plurality of walls defining an interior space. The ventilation unit may further include a temporary mount coupled to the housing and configured to at least temporarily couple the housing to the structure so that a user installing the housing on the structure can use both hands to install a plurality of primary mounts without having to hold the housing.

In some embodiments, the temporary mount includes an attachment flange configured to secure to the housing in a fixed position, an arm extending from the attachment flange, and a plurality of retainers that extend away from the arm on an opposite end of the arm from the attachment flange. In some embodiments, an upper end of each retainer extends above a top wall of the housing and engages a portion of the housing to provide a pivot point for each of the retainers as the ventilation system is installed. In some embodiments, the temporary mount further includes a first release lever coupled to the first retainer and a second release lever coupled to the second retainer.

In some embodiments, the plurality of retainers includes a first retainer and a second retainer that cooperate to provide variable-height, temporary attachment means to the structure. In some embodiments, the first retainer includes a first bottom edge and a first sloped upper edge and the second retainer includes a second bottom edge and a second sloped upper edge, and wherein the first bottom edge is located closer to the arm than the second bottom edge. In some embodiments, the first retainer extends to a first width from the arm and the second retainer extends to a second width from the arm, the second width being greater than the first width.

In some embodiments, the temporary mount includes an attachment flange configured to secure to the housing in a fixed position, a first arm extending from the attachment flange, a second arm coupled to the extending from the attachment flange, a first retainer coupled to the first arm, and a second retainer coupled to the second arm.

According to another aspect of the present disclosure, a ventilation unit includes a housing and an installation system. The housing includes a plurality of walls defining an interior space. The installation system is configured to retain the housing to a structure. In some embodiments, the installation system includes a plurality of primary mounts and a temporary mount coupled to the housing and configured to at least temporarily couple the housing to the structure so that a user installing the housing on the structure can use both hands to install the plurality of primary mounts without having to hold the housing.

In some embodiments, the temporary mount includes an attachment flange configured to secure to the housing in a fixed position, an arm extending from the attachment flange, and a plurality of retainers that extend away from the arm on an opposite end of the arm from the attachment flange. In some embodiments, the attachment flange is mounted to an interior surface of the housing such that the attachment flange and the arm are located within an interior space defined by the housing, and wherein the housing is formed to include a plurality of slots and each retainer passes through a corresponding slot included in the plurality of slots from the interior space to outside the interior space.

In some embodiments, an upper end of each retainer extends above a top wall of the housing outside the interior space and engages a portion of the housing to provide a pivot point for each of the retainers as the ventilation system is installed. In some embodiments, the arm is configured to flex and at least one of the plurality of retainers is configured to withdraw into the interior space as the ventilation system is installed on the structure.

In some embodiments, the plurality of retainers includes a first retainer and a second retainer that cooperate to provide variable-height, temporary attachment means to the structure, and wherein the first retainer includes a first bottom edge and a first sloped upper edge and the second retainer includes a second bottom edge and a second sloped upper edge, and wherein the first bottom edge is located closer to the arm than the second bottom edge. In some embodiments, the first retainer extends to a first width from the arm and the second retainer extends to a second width from the arm, the second width being greater than the first width.

In some embodiments, the temporary mount includes an attachment flange configured to secure to the housing in a fixed position, a first arm extending from the attachment flange, a second arm coupled to the extending from the attachment flange, a first retainer coupled to the first arm, and a second retainer coupled to the second arm.

According to another aspect of the present disclosure, a ventilation unit includes a housing and a mount. The housing may include a plurality of walls defining an interior space. The mount is coupled to the housing and is configured to at least temporarily couple the housing to a structure.

In some embodiments, the mount includes a first end fixed to one wall included in the plurality of walls and a second end spaced apart from the first end and movable relative to the housing. In some embodiments, the mount includes at least one retainer coupled to the second end and, during installation, the mount is configured to change from an undeformed position in which an end of the retainer is spaced from the housing a first distance and a deformed position in which the end of the retainer is spaced apart from the housing a second distance less than the first distance.

In some embodiments, the mount includes an attachment flange at the first end and configured to secure to the housing in a fixed position, an arm extending from the attachment flange, and a plurality of retainers that extend away from the arm on the second end of the arm spaced apart from the attachment flange. In some embodiments, the attachment flange is mounted to an interior surface of the housing such that the attachment flange and the arm are located within an interior space defined by the housing, and wherein the housing is formed to include a plurality of slots and each retainer passes through a corresponding slot included in the plurality of slots from the interior space to outside the interior space.

In some embodiments, the plurality of retainers includes a first retainer and a second retainer that cooperate to provide variable-height, attachment means to the structure, and wherein the first retainer includes a first bottom edge and a first sloped upper edge and the second retainer includes a second bottom edge and a second sloped upper edge, and wherein the first bottom edge is located closer to the arm than the second bottom edge.

Additional features of the present disclosure will become apparent to those skilled in the art upon consideration of illustrative embodiments exemplifying the best mode of carrying out the disclosure as presently perceived.

A ventilation unitincludes a housingas shown in. In the illustrative embodiment, the housingis a range hoodthat is configured to be mounted above a stove top, however, in other embodiments, the housingmay be a part of a different type of ventilation unit such as a bathroom fan located above a ceiling or within a wall of a building (not shown). A blower or fan (not shown) may be coupled to the housingeither directly or via a duct to draw air through the housingfor ventilation purposes. One or more filters and/or grilles (not shown) may also be coupled to the housing.

The ventilation unitfurther includes an installation systemthat mounts the housingto one or more structures such as a cabinet(see), ceiling joist(s), framing, or any other suitable structure of the building or fixture coupled to the building, for example. The installation systemincludes a plurality of primary mountsand a pair of temporary mountscoupled to the housing. The plurality of primary mountsare illustratively embodied as fasteners (i.e. screws, nails, bolts, studs, etc.) which extend through corresponding openingsformed in the housingand into the structure to which the housingis mounted (in this case a cabinet). The pair of temporary mountsare configured to engages portions of the structure to which the housingis mounted to temporarily hold the housingat or near a fully-installed position so that the person installing the housingis free to use both hands while installing the primary mounts. Thus, if a single person is installing the ventilation unit, the person does not have to hold the ventilation unitin position relative to the structure while simultaneously installing the primary mounts.

Only one temporary mountis shown in, however, it should be appreciated that a substantially similar temporary mountmay also be coupled to an opposite side of the housingfrom what is shown in. Each temporary mountincludes an attachment flangeconfigured to be coupled to the housing. An armhas a first end and a second end. The first end of the armextends from the attachment flange. A plurality of retainers(or at least one retainer) extends from the second end of the arm. The attachment flangeis configured to be fixed to an inside wall of the housingby one or more fasteners. The arminterconnects the attachment flangeand the plurality of retainers. Each of the plurality of retainersis configured to extend through a corresponding openingdefined in the housingto reside outside of an interior spacedefined by the housing. The plurality of retainersare configured to engage the structure to which the housingis mounted to temporarily hold the housingin place prior to full installation.

In the depicted embodiment, the plurality of retainersincludes a first retainerand a second retainerto provide temporary installation of the housingat two different heights. In this way, the housingmay be temporarily held in place for subsequent, full installation with primary mountsno matter the size, form, or dimensions of the structure to which the housingis installed. For example, the cabinetmay include a vertical side walland a bottom wallas shown in. The second retainermay be used in this situation to rest on top of the bottom wallof the cabinetand temporarily hold the housingat or near a full-installation position relative to the cabinet. Depending on a thickness of the bottom wall, the first retainermay be used to temporality hold the housingin place instead of the second retainer. The plurality of retainersmay further include additional retainers with portions between the first retainerand the second retainerfor retaining the housingat additional heights relative to the structure.

In another example, the cabinetincludes only the vertical side wallas shown inwithout a bottom wall. A separate attachment bracketmay be installed on the inside of the vertical side wall. The first retaineris configured to engage the attachment bracketto temporarily hold the housingin place relative to the cabinetprior to full installation with primary mounts. The separate attachment bracketmay alternatively be located on the structure such that the second retaineris configured to engage and rest on the attachment bracketto temporarily hold the housingin place relative to the cabinetprior to full installation.

The armis configured to flex as the housingis being installed, as depicted in. Each of the retainers,includes a sloped upper edge,and a generally horizontal bottom edge,. The sloped upper edges,are configured to engage the bottom wallor the attachment bracketwhile the housingis being installed and cause the armto flex inward and the retainersto retract into the interiorout of the way of the bottom wallof the cabinetor the attachment bracket. Once either the first retaineror the second retainer have cleared the bottom wallor the attachment bracket, the armreturns to an at least partially undeformed position where one or both of the retainerstemporarily hold the housingduring subsequent full installation as discussed above.

In the illustrative embodiment, the armand the retainersare configured to twist relative to the housingas suggested in. One or both of the retainers,may further include a hook,that engages the housingto block a portion of the retainersfrom retracting into the interiorof the housingas shown in. The hooks,overlay a top wallof the housingand are arranged to lie outside of the interiorof the housing. Only a lower portion of each retainerretracts into the interiorof the housingas the armflexes. Thus, the top wallof the housingprovides a pivot pointabout which the retainerspivot as the armflexes. In some embodiments, the hooks,are omitted and the armand the retainers flex linearly relative to the housing.

The first retainerand the second retainerare spaced apart from one another along a lengthof the temporary mountas shown in. The first retaineris located closer to the attachment flangecompared to the second retainer. The bottom edgeof the first retaineris located closer to the armcompared to the bottom edgeof the second retainer. When the armand the retainersflex relative to the housingand the attachment flange, the bottom edgeof the second retainerretracts a greater distance compared to the bottom edgeof the first retainer. In some embodiments, the first and second retainers,may be located an equal distance from the attachment flangerelative to the lengthof the temporary mount.

The first retainerextends to a first widthfrom the armand the second retainerextends to a second widthfrom the armas shown in. The first widthis less than the second widthto account for the greater distance in which the second retainerwill retract when the armflexes. In some embodiments, the widths,may be equal.

Each of the retainers,further includes a release lever,as shown in. The release levers,extend from lower ends of each respective retainer,and are arranged to lie within the interiorof the housing. The release levers,may be engaged by a user to manually flex the armand the retainersthereby retracting the retainersinto the interiorand disengage the retainersfrom the bottom wall, attachment bracketor another structure to which the retainersare coupled so that the housingcan be separated or uninstalled from the cabinet.

In some embodiments, on the inner side of the housing, release levers,are provided (integral with the dual level snapping action arm), in order to allow the end user to unlatch the ventilation unitfrom the cabinetry, should a major overhaul of the unit be required. A twisting motion may occur when the first and second retainers,are triggered. The other extremity of the arm (i.e. attachment flange) is rigidly attached to the housingby two anchoring points, represented by two holes,(intended for rivetsor another suitable fastener).

The temporary mountmay snap to the housingin the following installation configurations: The second retainermember may be used for installations where the cabinet bottom wallis present after a cutout has been formed in the cabinetby the installer. The first retainermay be used for tighter installation configurations, where there is no cabinet bottom wallafter the cutout has been formed. In this case, a supplementary L-shaped bracketmay be installed to the cabinet, in order to allow the first retainerto engage the bracketand hold the housingto the cabinet.

Another embodiment of a temporary mount, in accordance with the present disclosure, is shown in. The temporary mountis similar to temporary mount. Accordingly, similar reference numbers in theseries are used to designate similar features between temporary mountand temporary mount. The disclosure of temporary mountis incorporated by reference herein for temporary mountexcept for the differences expressly described below.

Each temporary mountincludes an attachment flangeconfigured to be coupled to the housing. An armhas a first end and a second end. The first end of the armextends from the attachment flange. A plurality of retainersextends from the second end of the arm. The attachment flangeis configured to be fixed to an inside wall of the housingby one or more fasteners. The arminterconnects the attachment flangeand the plurality of retainers.

In the depicted embodiment, the plurality of retainersincludes a first retainerand a second retainerto provide temporary installation of the housingat two different heights. The armis configured to flex as the housingis being installed. Each of the retainers,includes main body,having a sloped upper edge,and a bottom edge,, and a nose,extend from a distal end of the main body,relative to the arm. The sloped upper edges,are configured to engage the bottom wallor the attachment bracketwhile the housingis being installed and cause the armto flex inward and the retainersto retract into the interiorout of the way of the bottom wallof the cabinetor the attachment bracket. Once either the first retaineror the second retainerhave cleared the bottom wallor the attachment bracket, the armreturns to an at least partially undeformed position where one or both of the retainerstemporarily hold the housingduring installation as discussed above. The noses,extend downwardly below each respective bottom surface,and are configured to engage the bottom wallor the bracketto retain the housingin place.

In the illustrative embodiment, the armand the retainersare configured to twist relative to the housingwhen the temporary mount flexes during installation. One or both of the retainers,may further include an upper end,that extends above a top wallof the housingand engages the housingto block a portion of the retainersfrom retracting into the interiorof the housingas shown in. The upper ends,are arranged to lie outside of the interiorof the housing. Only a lower portion of each retainerretracts into the interiorof the housingas the armflexes. Thus, the top wallof the housingprovides a pivot pointabout which the retainerspivot as the armflexes. In some embodiments, the upper ends,are omitted and the armand the retainers flex linearly relative to the housing.

The first retainerand the second retainerare spaced apart from one another along a length of the temporary mountas shown in. The first retaineris located further from the attachment flangecompared to the second retainer. The bottom edgeof the first retaineris located closer to the armcompared to the bottom edgeof the second retainer. When the armand the retainersflex relative to the housingand the attachment flange, the bottom edgeof the second retainerretracts a greater distance compared to the bottom edgeof the first retainer. In some embodiments, the first and second retainers,may be located an equal distance from the attachment flangerelative to the length of the temporary mount.

Each temporary mountmay be formed from a single piece of material (e.g. metal) or multiple pieces of material and is machined and/or deformed to provide the various features included in each temporary mount. In the embodiment depicted in, the temporary mountcomprises both a first arm′, and a second armthat extend from the attachment flangein side-by-side, parallel relation to one another as shown in. The first retainerextends from arm′ while the second retainerextends from the second arm. In this way, the first retainermay be movable relative to the second retainer.

Each of the retainers,further includes a release lever,. The release levers,extend from lower ends of each respective retainer,and are arranged to lie within the interiorof the housing. The release levers,may be engaged by a user to manually flex the arms,′ and the retainersthereby retracting the retainersinto the interiorto disengage the retainersfrom the bottom wall, attachment bracketor another structure to which the retainersare coupled so that the housingcan be separated or uninstalled from the cabinet. The release levercoupled to the second retainerextends at least partially over the other release leverso that movement of the release leverin a releasing direction will also move the other release leverto flex both of the retainersat the same time. The release levermay be independently moveable relative to release lever.

In another embodiment, the housingmay include a stopperthat extends across one or more of the slotsdefined in the housingand through which the retainersextend. The stopper is configured to block full retraction of the retainersinto the interiorof the housing(such as be catching the noseof the second retainer, as depicted in) and thereby prevent the retainersfrom being stuck against the housingin a retracted position.

Another embodiment of an attachment bracketthat can be used to at least temporarily mount the housingto the cabinetis shown in. The attachment bracketmay be coupled to an inside surface of a vertical cabinet walland can be oriented or structured in various ways to mount the housing within spaces between cabinets of varying widths as suggested in.

The attachment bracketincludes an attachment panel, a first mount flangecoupled to a first endof the attachment panel, and a second mount panelcoupled to a second, opposite second endof the attachment panelas shown in. The attachment panelis configured to be fixed to the inside surface of the vertical wallof the cabinet(or another structure) to mount the attachment bracketto the vertical wall. The first mount flangeand the second mount flangeeach extend away from the attachment panelat a generally 90 degree angle relative to the attachment panel. One or both of the first mount flangeand the second mount flangemay engage a retainer,during installation of the housingto at least temporarily hold the housingin place for subsequent full installation.

The attachment panelis formed to define a plurality of fastener openingsarranged at different locations along a lengthof the attachment panelas shown in. The plurality of fastener openingsare configured to receive a fastener (not shown) that extend into the vertical wallto secure the attachment bracketto the cabinet(or other structure). The plurality of fastener openingsare arranged to lie at longitudinal ends,of the attachment panel.

Some fastener openingsmay also be formed in a central areaof the attachment panel. In the illustrative embodiment, the attachment panelis also formed to include vertical cutoutsthat are arranged along a lineextending across a vertical width of the attachment panel. The vertical cutoutsprovide a frangible breakaway point where the attachment bracketcan be broken (i.e. by repetitive bending) to divide the attachment bracketinto a plurality of sections′,″. One or more sections′,″ can be installed on a vertical wallto fit structures having various depths. Each section′,″ includes first and second mount flanges,and fastener openingsat their respective longitudinal ends.

The first mount flangehas a first widthand the second mount flangehas a second widthas shown in. The first widthis less than the second widthso that either the first mount flangeor the second mount flangecan be used depending on spacing between the vertical walland the retainer,. For example, the attachment bracketcan be oriented so that the second mount flangeis on a bottom of the attachment bracketif a spacebetween a distal end of the retainer,and the vertical wallis relatively large as shown in. On the other hand, the attachment bracketcan be oriented so that the first mount flangeis on a bottom of the attachment bracketif a spacebetween the distal end of the retainer,and the vertical wallis relatively small as shown in.

The attachment paneldefines a plurality of horizontal aperturesthat extend along a horizontal linealong the lengthof the attachment panel. The horizontal aperturesare formed in the shape of an elongated oval each separated by a divider material section. Each divider material sectionhas a length that is less than a length of each horizontal apertureso that the attachment bracketcan be deformed along a pivot pointat the horizontal lineas shown in. Deforming the attachment panelabout pivot pointallows a user to increase the second widthby a distanceif spacing between the distal end of the retainer,and the mount flanges,is too large to reach either mount flange,and support the housing. In particular, if the attachment panelis deformed about the pivot line, the attachment paneldefines a proximal portionconfigured to be secured to the vertical walland an extended portionextending away from the vertical walllocating the second mount panelfurther away from the vertical wall.

Attachment panelmay also be defined to include one or more support aperturesthat receive a support(depicted as a bolt) as shown in. The support(s)are configured to transfer loads between the portion of the attachment bracketthat is deformed about pivot pointand the vertical wallto maintain the attachment bracketin its deformed position. Surfaces defining the support aperturesmay be threaded to interact with threads on each support. In some embodiments, the divider material sectionsmay have a strength sufficient to retain the attachment bracketin its deformed position while supporting the housingsuch that the supportand aperturescan be omitted.