Ceiling fan hanger assembly

A ceiling fan hanger assembly includes a mount plate and a downrod having an inner and an outer portion. The inner and outer portions of the downrod are slidably engaged and can be fastened together to extend or shorten the length of the downrod.

BACKGROUND

Ceiling fans are used to generate airflow within a space or area, often used for cooling or temperature regulation. Ceiling fans can be used in industrial, commercial or other suitable environments to circulate air to maintain proper temperature regulation. Often, the ceiling fan is suspended from the ceiling of a building structure, or other structural elements of the building structure at the ceiling, such as beams or girders for example.

Suspension of the ceiling fan includes mounting a portion of the ceiling fan, such as a mounting bracket, to the ceiling or building structural elements. The remainder of the ceiling fan is then coupled to the mounting bracket and suspended within the area at an appropriate height from the floor. Often, determining the appropriate height can be challenging for an installer. Furthermore, if the ceiling or building structure is provided at an angle, the suspension of the ceiling fan must account for such an angle.

BRIEF DESCRIPTION

In one aspect, the disclosure relates to a ceiling fan assembly comprising a ceiling mount structure, a motor assembly having a rotating blade hub, and an adjustable downrod assembly connecting the motor assembly to the ceiling mount structure, the adjustable downrod assembly comprising an upper rod connected to the ceiling mount structure, a lower rod connected to the motor assembly and configured to telescopingly slide relative to the upper rod, and at least two fasteners positioned around the periphery of one of the upper or lower rods and configured to secure the upper rod to the lower rod.

In another aspect, the disclosure relates to a ceiling fan assembly comprising a ceiling mount structure, a motor assembly having a rotating blade hub, and a downrod assembly comprising a telescoping rod having a hollow interior connecting the motor assembly to the ceiling mount structure and at least two fasteners positioned around the periphery of the telescoping rod to secure the telescoping rod in a fixed position.

DETAILED DESCRIPTION

The description herein is directed to systems, methods, and other devices related to a ceiling fan. More specifically, the description relates to a ceiling fan downrod assembly for suspending a ceiling fan. The ceiling fan downrod assembly provides for an adjustable length of the downrod for the ceiling fan to hang or suspend from a structure. The ceiling fan downrod assembly further provides for simplification of adjustment of assembly and installation, as the ceiling fan downrod assembly can facilitate installation of the ceiling fan at the desired height.

FIG.1illustrates a top perspective view of a ceiling fan10including a ceiling fan hanger assembly12for mounting to a ceiling (not shown) or a structure. The ceiling fan includes a downrod14, a motor assembly16, a set of blade holders18, and a set of blades20. An adapter assembly30can couple the downrod14to the motor assembly16, and can include an adapter plate32provided at the end of the downrod14configured to mount to the motor assembly16, a motor shaft (not shown), or any other attachment member configured to suspend the motor assembly16from the downrod14. In one example, a set of fasteners34can be utilized to couple the adapter plate32to the motor assembly16.

The motor assembly16can include a housing40. A set of blade hubs42can be provided on the housing40. The set of blade hubs42can be configured to receive and couple to the set of blade holders18, which can be used to couple the blades20to the motor assembly16for rotatably driving the blades20. The motor assembly16can house a motor (not shown) such as a permanent magnet type motor including a stator and a rotor in one non-limiting example. A supply of power can be used to drive the rotor about the stator to rotate the motor housing40, and thereby rotating the blades20coupled to the motor housing40via the blade holders18. A safety cable120and an electrical wire130can be threaded through the ceiling fan hanger assembly12and the downrod14.

Referring now toFIG.2A, the ceiling mount structure or ceiling fan hanger assembly12includes a mount plate50, a connector bracket70, and a downrod mount90. The mount plate50includes a set of apertures60. While the set of apertures60are shown herein as including eight apertures, with two apertures in each corner, any suitable number and arrangement of apertures60is contemplated, as may be suitable for manufacture, structural integrity of the mount plate, or overall weight reduction. The mount plate50includes a cable opening63near the center of the mount plate50. The connector bracket70provides for connecting the mount plate50to the downrod mount90via rounded fasteners65. The downrod mount90can have a bottom wall92with an opening. A removable bushing96can be included in the opening.

The downrod14can be a telescoping rod including at least an upper rod102and a lower rod112. The upper rod102can be hollow with an interior101. The upper rod102can be formed as a tube with a round shape or any shape having edges and corners, in non-limiting examples. The upper rod102can include a first end104and a second end106, with a wall103extending therebetween. A set of outer openings108can be spaced along the upper rod102. The set of outer openings108can be spaced linearly along the length of the upper rod102, however alternative spacing patterns are contemplated, such as a spiral pattern. In one non-limiting example the set of outer openings108can be spaced on opposite sides of the upper rod102. Additionally, and alternatively, the set of outer openings108can be circumferentially spaced about the upper rod102.

The downrod14can include a lower rod112. The lower rod112can be hollow with an interior111. The lower rod112can be formed as a tube with shape complementary to the shape of upper rod102. As illustrated, the lower rod112has a smaller diameter than the upper rod102and is sized to fit concentrically within the upper rod102. The lower rod112can include a upper end114and a lower end116, with a wall113extending therebetween. The lower end116of the lower rod112can be connected to the adapter plate32and configured to mount to the motor assembly16. It should be recognized that in other non-limiting examples, the lower rod112can have a larger diameter than the upper rod102for telescoping engagement.

A set of inner openings118can be included in the lower rod112. The set of inner openings118can be arranged at or near the upper end114. As shown, the set of inner openings118includes two openings, however it is contemplated that the set of inner openings118can include any number of openings. The spacing of the set of inner openings118can match the spacing of the set of outer openings108. The set of inner openings118can be spaced linearly along the length of the lower rod112, however it should be appreciated that other spacings of the set of inner openings118can be utilized, such as circumferential spacing about the periphery of lower rod112, spiral, or offset spacing. The spacing, or distance between the sets of inner and outer openings108,118can be about 1 inch. Additionally, or alternatively, the spacing can be between about 2 inches and about 12 inches. The inner and outer openings108,118can receive a set of fasteners115. The diameter of each opening of the sets of inner and outer openings108,118can be about 0.5 inches. Alternatively, the openings108,118can have any diameter appropriate to the fastener115.

The safety cable120can extend unobstructed through the upper rod102and the lower rod112. At least one end of the safety cable120can include a clevis124. The electrical wire130can extend unobstructed through the upper rod102and the lower rod112. The safety cable120and the electrical wire130extend through the cable opening63in the mount plate50, through the center of the connector bracket70, and through the center of downrod mount90. At the lower end116, the safety cable120and the electrical wire130extend through the adapter plate32.

Turning now toFIG.2B, the downrod14can include at least one additional rod between the upper rod102and the lower rod112. For example, a middle or third rod122with openings128can be included in downrod14. The openings128can be spaced according to the spacing of openings108and118to receive fasteners115. The third rod122can have a diameter intermediate between the diameters of the upper rod102and the lower rod112. It should be appreciated that in other non-limiting examples, the upper rod102, third rod122, and lower rod112can have any combination of diameters that supports telescoping engagement. For example, the diameter of the third rod122can be smaller than the diameter of the lower rod112and larger than the diameter of the upper rod102.

Referring now toFIG.3, the mount plate50, connector bracket70and downrod mount90are shown in more detail. The mount plate50includes an upper surface52and a lower surface54. The mount plate50further includes a pair of plate extensions62. The mount plate50further includes a pair of flanges58. The pair of flanges58are formed as angled portions of the mount plate50, offset from the planar surface of the remainder of the mount plate50. As shown, the pair of flanges58angle in the direction of the lower surface54of the mount plate50, while other configurations are contemplated, such as angling toward the upper surface52.

The plate extensions62can be described as a pair of plate extensions62that are arranged parallel to one another, and can be shaped similar or identical to one another, while it is contemplated that the plate extensions62can be shaped differently from one another or oriented in a different arrangement. The plate extensions62can extend perpendicular from the lower surface54of the mount plate50. Each plate extension62can include an aperture64. The plate extensions62can be welded to the mount plate50, for example, or can be stamped as a part of the mount plate50and bent into the position as shown inFIG.3. The cable opening63in the mount plate50can be located between the plate extensions62.

The connector bracket70includes a set of four sidewalls74to define a square cross-sectional profile taken perpendicular to each of the sidewalls74, while any number of sidewalls is contemplated. Each sidewall74terminates at a top edge76and bottom edge78. Two opposing sidewalls74of the set of sidewalls74include a top tab80at least partially forming the top edge76. The two remaining opposing sidewalls74of the set of sidewalls can include a pair of bottom tabs81. The top tabs80are arranged such that two opposing sidewalls74each include a top tab80extending from the top edge76, and the remaining two opposing sidewalls74each include one bottom tab81extending from the bottom edge78. Each top tab80includes an upper opening82located adjacent to the top edge76. Each bottom tab81includes a lower opening84located adjacent the bottom edge78. The upper openings82can be spaced complementary to the apertures64on each plate extension62. As shown, the upper and lower openings82,84can be rounded, while any suitable shape is contemplated, such as polygonal in one non-limiting example.

The downrod mount90can include a bottom wall92sized to be larger than the diameter of the downrod14such that the bottom wall92extends radially wider than the remainder of the downrod14. A pair of downrod extensions94can extend from the bottom wall92opposite the downrod14. The downrod extensions94can be arranged parallel to one another, and can be substantially planar members. The downrod extensions94can be identical to one another, while it is contemplated that each extension can be unique or can be arranged non-parallel to one another. A set of downrod extension apertures98can be included in downrod mount90, where each downrod extension94includes at least one of the set of downrod extension apertures98. The apertures64, upper and lower openings82,84, and downrod extension apertures98can have a rounded or circular shape adapted to receive the rounded fasteners65.

The bottom wall92can include an opening with the removable bushing96aligned with the hollow interior101of the upper rod102. The bushing96can be sized complementary to the interior of the downrod14, and can be used to provide a smoother surface for items passing into the interior of the downrod14, such as electrical wiring, for example. The downrod mount90and the upper rod102of downrod14can be a one-piece assembly, such as cast or formed integral with one another, and can be a monolithic or unitary structure, while it is contemplated that the downrod mount90affixes to the downrod14, such as by welding, for example.

Referring now toFIG.4, the downrod14is shown in a collapsed configuration, according to an aspect disclosed herein. The mount plate50, connector bracket70, and downrod mount90are pivotably connected with rounded fasteners65. The first end104of the upper rod102can be fixed to the ceiling fan hanger assembly12at the downrod mount90. In one non-limiting example, the bushing96can extend into the interior101of the upper rod102. The lower rod112can be secured inside upper rod102with a set of fasteners115positioned around the periphery of one of the upper rod102or lower rod112. In one non-limiting example, the set of fastener115can include screw-nut pairs, however it should be appreciated that any kind of reasonable fastener can be used such as set screws.

In the collapsed configuration, the upper rod102and lower rod112are positioned such that the upper-most openings of the set of openings108of the upper rod102are aligned with the openings118of the lower rod112. The upper-most openings of the set of openings108are those nearest the first end104and nearest the ceiling fan hanger assembly12. The set of fasteners115can be inserted through the upper-most openings of the set of openings108into the set of openings118. Additionally, and alternatively, the set of fasteners115can be set screws that extend through the set of openings108and press against the wall113of the lower rod112to secure the upper and lower rods102,112together. In one non-limiting example, the openings118in the lower rod112can be threaded such that the fasteners115can protrude through the upper rod102and screw into the lower rod112to hold the upper and lower rods102,112in place. The fasteners115do not protrude all the way through the interior of the lower rod112to allow cables and/or wiring such as safety cable120and electrical wire130to move freely within the interior111. In other words, the fasteners115do not span the width of the hollow interior of the rods102,112. In the collapsed configuration, the downrod14is shortest in length.

Turning now toFIG.5, the downrod14is shown in an intermediate expanded configuration, where the upper rod102and the lower rod112are secured together with fasteners115in intermediate openings of the sets of openings108and the set of openings118. In other words, the intermediate openings are any of the set of openings108that are not the upper-most openings or the lower-most openings along upper rod102. It should be appreciated that the upper and lower rods102,112can be secured together by fasteners115in any combination of the sets of outer and inner openings108,118. For example, the downrod14can be in a fully extended configuration when fasteners115are placed in the lower-most openings of the set of openings108and the set of openings118. In the fully-extended configuration, the downrod14is in its longest configuration.

Referring now toFIG.6, the sectional view of the assembled downrod14shows the arrangement of the upper and lower rods102,112with the set of fasteners115in the sets of outer and inner openings108,118. The sets of outer and inner openings108,118can be aligned to receive the set of fasteners115as pairs. The pairs of fasteners115can be positioned on opposite sides of the upper and lower rods102,112. In one non-limiting example, the set of fastener pairs do not extend through the center of the downrod14. In another non-limiting example, the inner opening can include a nut that receives a screw inserted through one of the set of outer openings. The upper rod102and lower rod112are secured together by fasteners in pairs arranged opposite one another. In other words, at least two screws can extend through the openings of the upper rod102and screw into the openings of the lower rod112to secure the upper and lower rods102,112relative to one another. The screw/nut can extend partially into the interior of the downrod14.

Additionally, and alternatively, as shown inFIG.7, the set of fasteners115can extend through the openings108of the upper rod102and compress against the wall113of lower rod112. The compression of the fastener can thus secure the upper and lower rods102,112relative to one another without the fasteners115extending into the interior of the downrod14. In another non-limiting example, the set of fasteners115can extend through the openings118of the lower rod112and compress against the wall103of upper rod102. The safety cable and the electrical wire can pass through the interior of the downrod14without contacting the set of fastener pairs.

In assembling the ceiling fan hanger assembly12, the connector bracket70can be inserted between the plate extensions62of the mount plate50. The upper openings82positioned in the tab80adjacent the top edge76of the connector bracket70are aligned adjacent to the apertures64in the plate extensions62. The rounded fasteners65can be provided through the aligned upper openings82and the apertures64to mount the connector bracket70to the mount plate50. In this way, the connector bracket70couples to the mount plate50at the plate extensions62at two opposing sidewalls74of the connector bracket70.

The downrod mount90of the downrod14can be positioned with the downrod extensions94on opposing sidewalls74of the connector bracket70, offset from and unoccupied by the plate extensions62already coupled to the connector bracket70. In this way, the downrod extensions94are positioned along the remaining, unoccupied sidewalls74of the connector bracket70, and between and perpendicular to the plate extensions62. The downrod extension apertures98in the downrod extensions94can align with the lower openings84in the connector bracket70positioned in the top tabs80along the bottom edge78. The rounded fasteners65can be provided through the aligned lower openings84and the downrod extension apertures98to mount the connector bracket70to the downrod mount90.

The mount plate50and the connector bracket70are pivotably connected through the fasteners65in the apertures64and upper openings82. Similarly, the connector bracket70and the downrod mount90are pivotably connected through the fasteners in the lower openings84and downrod extension apertures98. In this way, the downrod mount90, and therefore the downrod14and ultimately the remainder of the hanging ceiling fan10, can pivot relative to the connector bracket70.

The downrod14is connected at one end to the downrod mount90and at one end to the adapter plate32of the motor assembly16. The upper rod102is connected at the first end104at the bushing96, which can extend through the bottom wall92into the interior101of the upper rod102and form an interference fit.

The lower rod112can be slideable relative to the upper rod102in a telescoping manner. The upper and lower rods102,112can be arranged by sliding to have a specified length as desired by the user and fixed with fasteners115. The length of the downrod14can be adjusted by sliding the lower rod112within the upper rod102to a desired length, aligning the set of outer and inner openings108,118, and inserting the fasteners115.

The safety cable120and the electrical wire130can be threaded through the interior111of the lower rod112and also through the interior101of the upper rod102. The safety cable120can be secured to the motor assembly by any suitable means, such as by the clevis124with a clevis pin through a rod that is inserted in the center of the motor (not shown). The other end of the safety cable120can be secured to the structure by any reasonable means, such as cable clamps. During installation, the set of fastener pairs do not impede or interrupt the cable and/or the wire as it is being threaded through the interior of the lower tube allowing or easier installation of ceiling fan.

To the extent not already described, the different features and structures of the various embodiments of the present disclosure may be used in combination with each other as desired.

The telescoping downrod14allows the user to suspend the ceiling fan10from the ceiling or structure at a specific desired height. The height can be adjusted if necessary in height intervals, or by any amount. The height adjustment intervals can be limited by the spacing of the openings108,118. Alternatively, if fasteners115are set screws, only one of openings108,118is needed as the set screw can fix the upper and lower rods together by compression. The fasteners do not contact or otherwise interfere with the safety cable and electrical wire running through the downrod14, reducing any abrasive contact and improving the longevity of the safety cable and electrical wire and the ceiling fan10.

The telescoping arrangement of the downrod allows the length of the downrod to be altered as needed during and after installation. For example, if a user wishes to move the ceiling fan to a different room having a different ceiling height, the downrod length can be changed accordingly by removing the fasteners, adjusting the telescoped length of the rods, and securing with the fasteners. Further, because the fasteners do not span across the whole width of the downrod, the safety cable and/or electric wires do not contact the fasteners. Thus, the safety cable and/or electric wires can freely move through the interior of the tubes uninterrupted and untouched.

Further aspects of the disclosure are defined by the following clauses:

A ceiling fan assembly comprising: a ceiling mount structure, a motor assembly having a rotating blade hub, and an adjustable downrod assembly connecting the motor assembly to the ceiling mount structure, the adjustable downrod assembly comprising: an upper rod connected to the ceiling mount structure, a lower rod connected to the motor assembly and configured to telescopingly slide relative to the upper rod, and at least two fasteners positioned around the periphery of one of the upper or lower rods and configured to secure the upper rod to the lower rod.

The ceiling fan assembly of any preceding clause, wherein the upper and lower rods are hollow.

The ceiling fan assembly of any preceding clause, further comprising a safety cable connected at one end to the motor assembly and extending unobstructed through the upper and lower rods.

The ceiling fan assembly of any preceding clause, further comprising an electrical wire connected at one end to the motor assembly and extending unobstructed through the upper and lower rods.

The ceiling fan assembly of any preceding clause, wherein the at least two fasteners comprise screws.

The ceiling fan assembly of any preceding clause, wherein the screws are set screws.

The ceiling fan assembly of any preceding clause, wherein the at least two set screws extend through one of the upper and lower rods and compress against the other of the upper and lower rods to secure the rods relative to one another.

The ceiling fan assembly of any preceding clause, wherein the at least two screws extend through one of the upper or lower rod and screw into the other of the upper or lower rod to secure the rods relative to one another.

The ceiling fan assembly of any preceding clause, wherein the at least two screws do not extend through a center of the upper and lower rods.

The ceiling fan assembly of any preceding clause, wherein the at least two fasteners are positioned on opposing sides of the one of the upper or lower rods.

The ceiling fan assembly of any preceding clause, wherein the at least two fasteners comprises 4 fasteners.

A ceiling fan assembly comprising: a ceiling mount structure, a motor assembly having a rotating blade hub, and a downrod assembly comprising a telescoping rod having a hollow interior connecting the motor assembly to the ceiling mount structure and at least two fasteners positioned around the periphery of the telescoping rod to secure the telescoping rod in a fixed position.

The ceiling fan assembly of any preceding clause, wherein the at least two fasteners do not extend into the hollow interior.

The ceiling fan assembly of any preceding clause, wherein the telescoping rod comprises a first rod and a second rod slideable relative to the first rod.

The ceiling fan assembly of any preceding clause, wherein the at least two fasteners do not extend through a center of the telescoping rod.

The ceiling fan assembly of any preceding clause, further comprising an electrical wire connected at one end to the motor assembly and extending unobstructed through the telescoping rod.

The ceiling fan assembly of any preceding clause, further comprising a safety cable connected at one end to the motor assembly and extending unobstructed through the telescoping rod.

The ceiling fan assembly of any preceding clause, wherein the at least two fasteners are positioned on opposing sides of the telescoping rod.

The ceiling fan assembly of any preceding clause, wherein the telescoping rod comprises a third rod slideable relative to the first rod and second rod.

The ceiling fan assembly of any preceding clause, wherein the at least two fasteners extend through two of the first rod, second rod, or third rod and secure the rods relative to one another.