Abstract:
Outdoor high velocity wall and pedestal mounted fans, devices, apparatus, systems and methods of operation. The fans can have water resistant motor housings with at most one rear wall located opening for allowing a power cord to pass therethrough. The switches and pull chains are connected to the fan only through the bottom of the motor housing. The bottom of the motor housing can have a drainage hole for allowing excess moisture to drain therefrom. The motor housing can be stainless steel. Additionally, the motor housing can have a powder coat finish on all parts to reduce corrosion. The motor can be an oversized inverted outdoor rated oscillating motor having improved gear mechanisms for big torques and reduces heat rise during fan operation. The fan can operate under hot and cold temperature extremes as well as during wet and dry environmental conditions.

Description:
This invention is a Continuation-In-Part of U.S. Patent Application 29/261,391 filed Jun. 13, 2006, and this invention claims the benefit of priority to U.S. Provisional Patent Application Ser. No. 60/834,520 filed Jul. 31, 2006. 

   FIELD OF INVENTION 
   This invention relates to fans, in particular to high velocity wall and floor fans for outdoor use, and related devices, systems and methods of operation. 
   BACKGROUND AND PRIOR ART 
   Electrical fans have been in use for many years. There have been many designs in the field for 100 years on industrial, pedestal and wall fans. Traditional types of electrical fans that run off 120 volt power supplies have included pedestal based fans and mounted fans, where the motors are mounted adjacent to and generally behind the fan rotors. These traditional fans are well known for indoor use. 
   However, the traditional wall plug useable fans have housings with openings therethrough that do not allow for outdoor use. For example, traditional fans have open vents for allowing airflow therethrough to keep the motors cool. The traditional fan motors can easily overheat since the tendency is run undersized motors to reduce electricity demand, where the heating motors must be continuously vented to eliminate overheating effects that would result in damage to the fans, such as burn-out and potentially fires. 
   Traditional fans often use on/off type switches, such as oscillation switches, on the top of the housings and/or rotary switches having space around the switches which would attract gravity traveling moisture such as that from rainfall and dew effects into the fan housing and the electrical components therein. 
   Similarly, traditional fans have used pull chains located in the side of motor housings or in the top of the motor housings which also attract gravity traveling moisture such as that from rainfall and dew effects into the fan housing and the electrical components therein. 
   Thus these fans cannot be used outdoors or in wet damp environments since the motor housings allow for moisture to enter through vents, and openings in the housings. Thus, traditional wall and pedestal mounted fans are not useful in outdoor settings such as in backyards, around pools, in gazebos, and the like. 
   Still furthermore, traditional fans will have closed bottoms in their motor housings which will tend to allow for moisture to accumulate inside and potentially damage the motor and electrical components inside the housing. 
   Additionally, the traditional fans have included metal housings and parts that tend to rust and deteriorate over time and cannot be used in outdoor and wet environments. Traditional service coatings on the housings do not prevent rust and corrosion damage. Additionally, the vented side openings allow for the internal metal components to also rust and corrode over time and create a short lifespan for the fans. 
   Alternatively, many traditional electrical fans use materials such as plastic with or without metal for their exterior, where the plastic is not durable and eventually crumbles and fails under continuous exposure to outdoor exposure. 
   In addition, traditional fans often are recommended to only be operated under mild conditions such as that found in continuously air conditioned environments. Hot and cold temperatures and continuous temperature changes will also cause traditional fans to eventually fail by exposure to the outdoor variable conditions. 
   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 high velocity wall and floor fans, devices, systems and methods of operation for outdoor use. 
   A secondary objective of the present invention is to provide high velocity wall and floor fans, devices, systems and methods of operation for outdoor use, being sealed on the top and around switch openings and wire openings in the motor housing. 
   A third objective of the present invention is to provide high velocity wall and floor fans, devices, systems and methods of operation for outdoor use, having completely sealed motor housings except for small-narrow hole on the top back end shield that lets the wires into the housing. 
   A fourth objective of the present invention is to provide high velocity wall and floor fans, devices, systems and methods of operation for outdoor use, having small drainage hole(s) only on the bottom of the motor housing to allow for any moisture to safely drain away from the motor housing. 
   A fifth objective of the present invention is to provide high velocity wall and floor fans, devices, systems and methods of operation for outdoor use, having on/off switches such as an oscillation control switch only on the bottom of the motor housing that also inhibits gravity traveling moisture from entering into the motor housing. 
   A sixth objective of the present invention is to provide high velocity wall and floor fans, devices, systems and methods of operation for outdoor use, having pull chains only on the bottom of the motor housing that also inhibits gravity traveling moisture from entering into the motor housing. 
   A seventh objective of the present invention is to provide high velocity wall and floor fans, devices, systems and methods of operation for outdoor use, that allows for long life protection from exposure to outdoor elements but also is tough enough to give good fan performance at different temperatures. 
   An eighth objective of the present invention is to provide high velocity wall and floor fans, devices, systems and methods of operation for outdoor use, that can use oversized motors to reduce heat rise. 
   A ninth objective of the present invention is to provide high velocity wall and floor fans, devices, systems and methods of operation for outdoor use, having an inverted outdoor rated oscillating motor. 
   A tenth objective of the present invention is to provide high velocity wall and floor fans, devices, systems and methods of operation for outdoor use, with an improved gear mechanism to give long life operation at big torques on the gear. 
   A eleventh objective of the present invention is to provide high velocity wall and floor fans, devices, systems and methods of operation for outdoor use, having components made out of stainless steel for durability and extended lifespan. 
   A twelfth objective of the present invention is to provide high velocity wall and floor fans, devices, systems and methods of operation for outdoor use, having a powder coat finish on all parts to reduce corrosion. 
   An thirteenth objective of the present invention is to provide high velocity wall and floor fans, devices, systems and methods of operation for outdoor use, that can effectively and continuously operate under different temperature conditions such as hot, cold, and variable conditions therebetween. 
   A fourteenth objective of the present invention is to provide high velocity wall and floor fans, devices, systems and methods of operation for outdoor use, that can effectively and continuously operate under extreme weather conditions such as during snow, icing conditions, humid conditions, dry conditions, and windy conditions such as that found during hurricanes, and the like. 
   A preferred embodiment of a high velocity fan for outdoor use, can include a plurality of blades, an electric motor supplied by electric power, for rotating the blades, and a waterproof housing about the motor for preventing moisture infiltration to the motor therein, the housing being waterproof with no exterior vents through the housing. 
   The motor housing can have a small opening in a rear wall of the housing for allowing an electrical power wire to sealingly pass therethrough. 
   The housing can further have at least one drainage opening underneath the front and/or the rear surface of the housing. 
   The housing can further have a power activation switch such as but not limited to a pull chain for the fan, and a mount for mounting the control switch underneath the housing. 
   The housing can further have an oscillating knob mounted underneath the housing, and gear linkage can be placed underneath the housing. 
   There are no openings into the housing along the top of the housing. 
   The housing and other components can be made from stainless steel. The housing can include and/or further have a powder coat finish thereon. 
   The invention can operate with an oversized motor such as but not limited to an inverted outdoor rated oscillating motor. 
   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 a front perspective view of a pedestal fan version of the invention. 
       FIG. 2  is a rear perspective view of the pedestal fan of  FIG. 1 . 
       FIG. 3  is an exploded view of the pedestal fan of  FIG. 1 . 
       FIG. 4  is an exploded view of the motor housing of the pedestal fan of  FIGS. 1-3 . 
       FIG. 5  is a front planar view of the pedestal fan of  FIG. 1 . 
       FIG. 6  is a right side view of the pedestal fan of  FIG. 1 . 
       FIG. 7  is a rear view of the pedestal fan of  FIG. 1 . 
       FIG. 8  is a top view of the pedestal fan of  FIG. 1 . 
       FIG. 9  is a bottom view of the pedestal fan of  FIG. 1 . 
       FIG. 10  is a front perspective view of a wall mounted fan version of the invention. 
       FIG. 11  is a rear perspective view of the wall mounted fan of  FIG. 10 . 
       FIG. 12  is an exploded view of the wall mounted fan of  FIG. 10 . 
       FIG. 13  is an exploded view of the motor housing of the fan of  FIGS. 10-12 . 
       FIG. 14  is a front planar view of the wall mounted fan of  FIG. 10 . 
       FIG. 15  is a right side view of the wall mounted fan of  FIG. 10   
       FIG. 16  is a rear view of the wall mounted fan of  FIG. 10 . 
       FIG. 17  is a top view of the wall mounted fan of  FIG. 10 . 
       FIG. 18  is a bottom view of the wall mounted fan of  FIG. 10 . 
   

   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. 
   A list of the components will now be described.
       1  Pedestal Fan Embodiment     10  Base     12  Flat outer base ring     13 . Fastener holes to mount base     14  middle domed base portion     16  cone base connector     18  lower tubular support     20  upper end of lower tubular support     25  rotatable tightening knob with internal protruding member To lock telescoping upper and lower tubular supports     30  upper tubular support     31  elongated oval opening for pivoting knob  35  in flat flange  32       32  flat flange connector on upper tubular support     33  through-holes for fasteners     35  pivoting position tightening knob     36  elongated oval through-hole for pivoting knob     37  fastener for pivoting knob     38  parallel flange plates     39  through-hole for pivoting fastener     50  grill cage for fan blades     52  grill section for mounting to motor housing  100       54  outer grill section     60  fan blades     100  water resistant motor housing     101  Hex nut     102  spring washer     103  front end plate     104  rubber ring     105  bearing     106  open ring     107  Rotor     107 P Axle pin on rotor     108  stator     109  cylindrical motor housing shell     110  open ring     111  bearing     112  wavy washer     113  rear endplate     114  hex head bolt     115  gear box     116  capacitor     117  washer     118  screw     119  washer     120  screw     121  cord clip     122  clam shell     123  screw     124  spring washer     125  elbow     126  pull chain     127  oscillating knob     128  screw     129  power cord     130  fob     131  driver     132  washer     133  screw     134  linkage     135  washer     136  washer     137  screw     138  screw     139  spring washer     140  cord clip     141  flag (parallel plates     142  washer     143  spring washer     144  screw     145  seal gasket     146  bearing     147  screw     148  washer     149  washer     150  bearing seat     151  bearing     152  washer     153  spring washer     154  screw     155  connecting plate for parallel flange plates  38 /flag  141       200  Wall Mounted Fan Embodiment     210  Wall connecting base plate     213 . Fasteners and mounting holes to mount base     214  mounting sleeve on base plate     215  upper opening in mounting sleeve     217  tightening knob to lock lower end  222  of mounting arm  220  to base plate     220  Step shaped mounting arm     222  lower end of mounting arm  220       228  upper end of mounting arm     232  flat flange connector on upper end of mounting arm     233  through-holes for fasteners     35  pivoting position tightening knob     36  through-hole for pivoting knob     37  fastener for pivoting knob     38  parallel flange plates     39  through-hole for pivoting fastener     250  grill cage for fan blades     252  grill section for mounting to motor housing  100       254  outer grill section     260  fan blades   

   Pedestal Fan Embodiment 
     FIG. 1  is a front perspective view of a pedestal fan version  1  of the invention.  FIG. 2  is a rear perspective view of the pedestal fan  1  of  FIG. 1 .  FIG. 3  is an exploded view of the pedestal fan  1  of  FIG. 1 .  FIG. 4  is an exploded view of the motor housing  100  of the pedestal fan  1  of  FIGS. 1-3 .  FIG. 5  is a front planar view of the pedestal fan  1  of  FIG. 1 .  FIG. 6  is a right side view of the pedestal fan  1  of  FIG. 1 .  FIG. 7  is a rear view of the pedestal fan  1  of  FIG. 1 .  FIG. 8  is a top view of the pedestal fan  1  of  FIG. 1 .  FIG. 9  is a bottom view of the pedestal fan  1  of  FIG. 1 . 
   Referring to  FIGS. 1-9 , pedestal fan  1  can include base  10  that can have a diameter of approximately 25 to approximately 28 inches, flat outer base ring  12  with fastener holes  13  that can mount the pedestal fan with fasteners, such as bolts and the like to other surfaces such as but not limited to concrete, pavement, wood decks, and the like. The base  10  can have a middle dome portion  14  with a cone shaped connector  16  which functions as a center piece to support lower tubular support  18 , the latter of which can have a diameter of approximately 2 to approximately 3 inches, and have a height of approximately 30 to approximately 36 inches. An enlarged upper end  20  of the lower tubular support  18  can have a ring shape with a rotatable tightening knob  25  with an internal protruding member which can lock against side walls of an upper tubular member  30 , that can have a diameter of approximately 1¾ to approximately 2¾ inches, the latter of which can also have an telescoping adjustable height of approximately 30 to 36 inches tall. The upper end of upper tubular support  30  can include a flat flange connector  32  with through-hole(s)  33  therethrough. 
   The motor housing  100  is attached to the flat flange  32  of the upper tubular support by parallel flange plates  38 , the latter of which fit over and about flat flange  32 . A knob  36  can fit into an elongated oval shaped through-hole  36  in the flange  32  and a like elongated oval shaped through-hole  31  in flat flange  32 . A bolt fastener  39  with mateable fastener can attach though circular openings  33 ,  39  in both the parallel flange plates  38  and flat flange  32 . The motor housing  100  with grill cage  50  can pivot about bolt fastener  39  that is within openings so that the grill cage  50  can be positioned to aim upward, horizontal or downward as desired. The knob  35  with fastener can be moved within elongated oval shaped through holes  31 ,  36 , and then rotated to locking the position of the grill cage  40  in the different positions. 
   Referring to  FIGS. 3 ,  4 ,  6  and  8 , the motor housing  100  can have a rotor  107  positioned inside of a stator  108  which fits into a right end of a cylindrical motor housing shell  109 . The front rotor pin  107 P can pass through open ring  106 , bearing  105  and rubber ring  104 , and the front end of motor housing shell  109  can be covered by a front end plate  103  so that the end of front rotor pin  107 P protrudes therefrom. Elongated hex head bolts  114  can attach the rear end plate  133  to the rear end of the motor housing shell  109  and also attach the front end plate  103  to the front end of the motor housing shell  109  with hex nuts  101  that can lock against spring washers  102  against the outer surface of the front end plate  103 . 
   Rear rotor pin  107 B can pass through open ring  110 , bearing  111 , wavy washer  112 , and rear end of motor housing shell  109  can be capped by rear endplate  113  so that rear rotor pin  107 B can protrude rearwardly from rear end plate  113  of motor housing shell  109 . Rearwardly extending rear rotor pin  107 B can pass into gear box  115  that can have a capacitor  116  mounted thereon by mounting screws  118  and washers  117 . The gear box  115  can be mounted to the outside of rear end plate  113  by screws  119  and washers  118 . Capping the outside of rear end plate  113  can be a dome shaped clam shell  122  that can be held in place by screw  137  with threaded shaft passing through washers  135 ,  136  one end of linkage  134 , driver  131  which is attached through an opening underneath clam shell  122  and into the bottom protruding tip of gear box  115 . A driver  131  spaces the end of linkage  134  to be spaced below the clam shell  122 . The driver  131  can be held in place by an outer screw  133  that attaches with a washer to abut against the downwardly protruding tip of gear box  115 . 
   In the novel invention, the gear clutch components were redesigned from a normal position on the top of a fan motor to the unique new location of underneath to provide wet proof operation. The linkage  134  was developed to be corrosive resistant under the motor housing  109  and the oscillating knob  127  is located downward to prevent water intrusion from rain. 
   The motor housing  100  is kept oriented relative to the tubular support stand components  18 ,  30  by the linkage  134 . A downwardly protruding support rod  109 T that is fixably attached to the lower surface of the motor housing shell  109  passes through seal gasket  145 , bearing  146  and into an upper opening in bearing seat  150 . An upwardly protruding screw  154  with spring washer  153  and washer  154  attaches a lower bearing  151  to the bottom of protruding support rod  109 T An inner end of linkage  134  attaches to an upper end edge of bearing seat  150  by a screw  147  with washers  148 ,  149 . An oscillating knob  127  has an upper end that fits into a small through-hole in the bottom of the clam shell  122  and into the gear box  115 . 
   The pull down and push up oscillating knob  127  can have two positions, one that keeps the fan in fixed orientation, and another pulled down position that allows the fan to oscillate (rotate in a horizontal plane) that is perpendicular to the support state members  18 ,  30 . 
   The gear mechanism has been designed to give long life operation at big torques on the gear. The gear box  115  has been constructed with steel and brass since the oscillating feature created higher than normal wear and tear on all the parts and gears in the gear box  115 . This construction allows for the parts to not break and wear out over normal operating conditions. 
   The oscillating switch and mechanism are places on the underside of a completely sealed motor to prevent water from entering the motor. 
   The invention can use a large ¼ hp motor instead of the ⅛ hp motor that has been used on prior art type fans. Low, medium and high speed amps are approximately 1.58, approximately 1.68 and approximately 1.91 amps respectfully. The watts for the ⅛ hp motor for low, medium and high speeds are approximately 134, approximately 200 and approximately 295 watts respectfully. 
   The motor can be built with more steel and copper to dissipate the heat since it is a totally enclosed drip proof system. 
   A power activation switch for the novel fan  1  can be done by a pull chain  126  that is mounted through a small through-hole in the bottom of the clam shell  122  having an elbow  125  mounted therein. The pull chain is drip proof and will not allow water inside like most rotary switches. 
   The switch can use copper parts inside to minimize corrosion and the pull chain  126  goes through a drip proof pull chain elbow  125  to prevent rain or hose spray from entering the unit. The chain pull  126  can be a stainless steel chain to prevent corrosion. The bottom of the pull chain  126  can have a fob  130  that can be easily handled by an operator, and the upper end of the chain  126  can connect into the gear box  115 . Pulling down on the pull chain  126  by the fob  130  can turn the fan on, pulling down a second time can switch the fan into a slow rotational speed while pulling another time can go to a higher operating speed or turn off the fan. 
   Electrical power can be supplied to the fan by a power cord  129  having an upper end that passes through a sealable cord clip  121  that is in a small opening in the bottom of shell casing  122 . 
   The plug and SJT wire is sealed at the housing and clamped to the oscillating ball bearing bracket to prevent fatigue in the wire during oscillations. 
   The plug cord  129  with three SJT (Service Junior Thermoplastic) wire construction attaches to the Bearing sleeve  150  with a cord clip  140  and spring washer  139  to provide enough flex in the power cord  129  to prevent failure after approximately 100,000 plus hours of operation. This arrangement of components is substantially different conventional units which have the power cord down directly, which leads to pinched cord that could cause the power cord to fail quickly. 
   Optional front small drainage hole  180  and/or optional rear small drainage hole  170  can be located adjacent to the front end and/or rear end of the motor housing shell so that any excess moisture inside the motor housing can safely drain away from the motor. 
   The motor housing  100  is attached to the flag  141  (parallel flange plates  38 ) by screws  144 , spring washers  143  and washers  142  that attach a connecting plate  155  to the bottom of the bearing seat  150 . The motor housing  100  attaches to the tubular support members  30  and  18  as previously described. 
   All of the exterior components such as the motor housing  100  and pedestal stand components  10 ,  18  and  30  as well as the interior components of the motor housing and grill and fan blades can be formed from stainless steel and the like. 
   These components can further have a powder coat finish to reduce corrosion, and other damage that can be caused by hot, cold, wet and dry environmental conditions. 
   We developed a 3_M coating that is a very durable paint system well advanced over the durable powder coat systems used in the industry. The metal parts can be pre-coated using a special technique to allow the heavy duty powder coat to stick permanently without leaving any holes or exposed edges that could lead to corrosion of the steel parts. 
   Referring to  FIGS. 3-4 , front rotor pin  107 P can be connected to the middle hub portion of three form blades  60 , and held in place by fasteners such as nuts, and the like. Blades  60  can be pre-formed blades formed from metal such as but not limited to aluminum, galvanized metal, and the like, and preferably be one piece. The blades  60  can have diameters of approximately 24 inches across, and 30 inches across as well as smaller and larger sizes as needed and can be housed in a grill cage  50  that has a rear grill section  52  that can be mounted to the front plate  103  by conventional fasteners such as screws, washers and nuts, and the like. An outer grill section  54  can snapably attach to the rear grill section and cover the blades  60  therein. 
   Wall Mounted Fan Embodiment 
     FIG. 10  is a front perspective view of a wall mounted fan version  200  of the invention.  FIG. 11  is a rear perspective view of the wall mounted fan  200  of  FIG. 10 .  FIG. 12  is an exploded view of the wall mounted fan  200  of  FIG. 10 .  FIG. 13  is an exploded view of the motor housing  100  of the fan  200  of  FIGS. 10-12 .  FIG. 14  is a front planar view of the wall mounted fan  200  of  FIG. 10 .  FIG. 15  is a right side view of the wall mounted fan  200  of  FIG. 10   FIG. 16  is a rear view of the wall mounted fan  200  of  FIG. 10 .  FIG. 17  is a top view of the wall mounted fan  200  of  FIG. 10 .  FIG. 18  is a bottom view of the wall mounted fan  200  of  FIG. 10 . 
   Referring to  FIGS. 10-18 , the wall mounted fan  200  can include a wall connecting base plate  210  that can have a triangular configuration with through-holes  213  that can be used for conventional fasteners such as screws and washers to attach the fan  200  to an outdoor wall on a building, structure, and the like. On the front of the base plate  210  can be a vertically oriented sleeve  214  having an opening  215  in an upper end for allowing the lower end  222  of a step shaped arm  220  to fit into. The step shaped arm can be pipe shaped and can have a length of approximately 1 to approximately 2 feet, and have a diameter of approximately 1 to approximately 2 inches. The lower end  222  of arm  220  can be cylindrical in order to allow for some rotation within socket opening  215 . A rotatable knob  217  having an inner protruding portion can abut against the sides of end  222  to lock the position of the step shaped arm  2220  relative to the wall connected base plate  210 . 
   Referring to  FIG. 12  and  FIG. 3  of the previous embodiment, the upper end  228  of step shaped support arm  220  can be attached to a flat flange connector  232  with through-hole(s)  233  therethrough. The motor housing  100  is attached to the flat flange  232  of the upper tubular support by parallel flange plates  38 , the latter of which fit over and about flat flange  32  which is described in more detail in reference to the pedestal mounted fan described above. 
   As described in the previous embodiment, the knob  36  can fit into an elongated oval shaped through-hole  36  in the flange  32  and a like elongated oval shaped through-hole  31  in flat flange  32 . A bolt fastener  39  with mateable fastener can attach though circular openings  33 ,  39  in both the parallel flange plates  38  and flat flange  32 . The motor housing  100  with grill cage  50  can pivot about bolt fastener  39  that is within openings so that the grill cage  50  can be positioned to aim upward, horizontal or downward as desired. The knob  35  with fastener can be moved within elongated oval shaped through holes  31 ,  36 , and then rotated to locking the position of the grill cage  40  in the different positions. 
     FIG. 13  describes the motor housing  100  and can use the same components that are described in reference to the motor housing  100  shown in  FIG. 4 . 
   Referring to  FIGS. 12-18 , front rotor pin  107 P can be connected to the middle hub portion of three form blades  260 , and held in place by fasteners such as nuts, and the like. Blades  260  can be pre-formed blades formed from metal such as but not limited to aluminum, galvanized metal, and the like, and preferably be one piece. The blades  60  can have diameters of approximately 24 inches across, and 30 inches across as well as smaller and larger sizes as needed and can be housed in a grill cage  250  that has a rear grill section  252  that can be mounted to the front plate  103  by conventional fasteners such as screws, washers and nuts, and the like. An outer grill section  254  can snapably attach to the rear grill section and cover the blades  260  therein. 
   Although the preferred embodiments describe applications for using the novel motor housing and related components in a pedestal fan and a wall mounted fan, the invention can be used in other applications, and the like. 
   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.