Slide on flush mount bracket with captive fastners

Devices, apparatus, mechanisms, systems and methods for flush mounted fans such as hugger fans for easy mounting by pre-attaching a bracket on a motor to a ceiling mounted plate by a hook, the plate having noise isolation pads. Raised alignment tabs and female receptacles on the ceiling plate and motor bracket for easily aligning the bracket to the ceiling plate, along with captive fasteners to attach the motor bracket to the ceiling plate. The alignment tabs allow the installer to position the bracket to the plate by sliding the bracket against the plate so that captive fasteners on the bracket adjacent to the alignment tabs are aligned with fastener holes on the plate. Finally, the installer can easily screw the captive fasteners into the holes for an easy to install, secure and wobble free installation between the motor bracket and the ceiling plate.

FIELD OF INVENTION

This invention relates to ceiling fans, and in particular to devices, mechanisms, apparatus, systems, and methods for mounting flush mount fans to ceilings using captive fasteners, alignment tabs and rubber isolation pads to reduce noise.

BACKGROUND AND PRIOR ART

Ceiling fan installations is often difficult since installers will need to have their hands raised above their head while supporting heavy components such as the ceiling fan blades, motor, motor housing, and the like. Installations often will take place with the installer being perched on a ladder which also adds to the requirement of the installer having to maintain their balance while doing the installation.

For flush mounted fans, such as hugger fans, the housings covering the ceiling fan motor must be fastened often by fasteners, such as but not limited screws, and the like, into a ceiling mounted plate. The combination of having to hold a screw driver over one's head with loose screw fasteners while supporting a motor housing with or without a heavy motor is tedious and time consuming. Furthermore, it is potentially dangerous if the housing with or without the motor happens to fall.

Furthermore, the screw type fasteners will tend to fall out during installation which causes the installer to have to repeat the attempts to mount the fan. Falling screws will often become lost so that additional screw type fasteners must be used, which adds additional time and material expense to the installation of the fan.

Additionally, the current screw type fasteners being used between the motor bracket and ceiling plate are often not secure connections which can loosen and result in a fan that can wobble during operation.

Still furthermore, the traditional practice of directly attaching metal plates with metal screw type fasteners, can create undesirable noise effects, when the ceiling fan is running in both forward and rearward directions.

SUMMARY OF THE INVENTION

A primary objective of the present invention is to provide devices, mechanisms, apparatus, systems, and methods for mounting flush mount fans to ceilings using captive fasteners, alignment tabs and rubber isolation pads to reduce noise.

A secondary objective of the present invention is to provide devices, mechanisms, apparatus, systems, and methods of mounting a ceiling fan motor housing to a ceiling attached plate that eliminates using loose fasteners such as screws, and the like.

A third objective of the present invention is to provide devices, mechanisms, apparatus, systems, and methods of mounting a ceiling fan motor housing to a ceiling attached plate that substantially reduces the installation time of mounting a ceiling fan motor.

A fourth objective of the present invention is to devices, mechanisms, apparatus, systems, and methods of mounting a ceiling fan motor housing to a ceiling attached plate that is easier, quicker and more safe to install than traditional methods of using fasteners to mount a ceiling fan motor.

A fifth objective of the present invention is to provide devices, mechanisms, apparatus, systems, and methods of mounting a ceiling fan motor housing to a ceiling attached plate by easily aligning ceiling fan motor mount plate onto the ceiling attached plate and screwing the captive fasteners in place.

A seventh objective of the present invention is to provide devices, mechanisms, apparatus, systems, and methods of mounting a ceiling fan motor housing to a ceiling attached plate that allows for an easier and more secure installation.

An eighth objective of the present invention is to provide devices, mechanisms, apparatus, systems, and methods of mounting a ceiling fan motor housing to a ceiling attached plate having alignment tabs that align with the motor bracket to create a secure, wobble free connection.

A ninth objective of the present invention is to provide devices, mechanisms, apparatus, systems, and methods of mounting a ceiling fan motor housing to a ceiling attached plate having pre-installed captive fasteners, such as screws in the motor bracket for easier installation.

An embodiment system for flush mounting a ceiling fan motor to a ceiling plate, can include a plate mounted to a ceiling having a plurality of fastener holes, and a bracket attached to a ceiling fan motor, the bracket having a plurality of captive fasteners, wherein aligning the captive fasteners with the fastener holes, allows for attaching the bracket to the plate by rotating the captive fasteners into the fastener holes.

The plate can include the plurality of the fastener holes adjacent to a perimeter edge of the plate, and the plurality of captive fasteners is adjacent to a perimeter of the bracket.

The system can include alignment tabs and receptacles for aligning the bracket with the plate so that the captive fasteners are aligned with the fastener holes.

The alignment tabs can include raised portions adjacent to the captive fasteners on an upper surface of the bracket, which are mateable with indentation portions underneath the plate.

The alignment tabs can be underneath the plate, which are mateable with the female receptacles are on the upper surface of the bracket,

The system can include a hook on the plate and a hanging slot on the bracket for allowing the bracket to hang from the ceiling mounted plate.

The system can include a hook on the bracket and a hanging slot on the plate for allowing the bracket to hang from the ceiling mounted plate.

The captive fasteners can include screws. The captive fasteners can be bolts.

The system can include an isolation pad on the ceiling mounted plate for providing noise isolation between the plate and a ceiling attachment point for decreasing noise when operating the ceiling fan.

The plate can include keyhole slots for mounting the plate to the ceiling attachment point, with the isolation pad about the keyhole slots.

A method of flush mounting a ceiling fan motor to a ceiling mounted plate, can include the steps of providing a plate mounted to a ceiling having a plurality of fastener holes, providing a motor bracket with a plurality of captive fasteners, aligning the motor bracket to the plate so that the captive fasteners are aligned to the fastener holes, and attaching the motor bracket to the ceiling mounted plate by rotating the captive fasteners into the fastener holes.

The method can include the step of hooking the motor bracket to the ceiling mounted plate with a hook and a slot.

The step of providing the motor bracket with the plurality of captive fasteners, can include the step of providing screws as the captive fasteners.

The step of providing the motor bracket with the plurality of captive fasteners, can include the step of providing bolts as the captive fasteners.

The aligning step can include the steps of providing alignment tabs an upper surface of the motor bracket, and providing mateable alignment receptacles underneath the ceiling mounted plate; and aligning the tabs into respective receptacles.

The aligning step can include the step of sliding the bracket against the plate to align the bracket captive fasteners with the fastener holes.

The aligning step can include the steps of providing alignment tabs on a lower surface of the ceiling plate, and providing mateable alignment receptacles on the bracket.

The aligning step can include the step of sliding the bracket against the plate to align the bracket captive fasteners with the fastener holes.

The method can include the steps of providing keyhole slots in the ceiling plate and providing an isolation pads about the keyhole slots to decrease nose when the ceiling mounted plate is attached to a ceiling attachment fastener.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

A list of the components will now be described.2ceiling5downwardly protruding fasteners from ceiling junction box10ceiling mount plate12alignment receptacles(indentations) for raised tabs13through-hole(s) for captive fastener(s)14downwardly protruding rim edge15hook16keyhole slot(s) to attach to heads of fasteners in a ceiling mount17noise isolation pads18central opening for power lines(electrical conductors)20motor bracket21horizontal rim22raised alignment tabs to fit into receptacles(indentions)23captive fastener(s)(such as pre-installed screws, bolts, and the like)25. slot for hanging hook30remote receiver control in motor bracket40motor extending below motor bracket50motor housing

FIG. 1Ais a bottom view of a novel ceiling mount plate10.FIG. 1Bis a top view of the ceiling mount plate10ofFIG. 1A.

FIG. 2Ais an upper perspective view of a novel bracket20with remote control receiver30and a motor40mounted thereon.FIG. 2Bis a top view of the motor mount bracket20inside remote control receiver ofFIG. 2A.

FIG. 3is a side cross-sectional view of the ceiling mount plate10ofFIGS. 1A-1B, attached to a ceiling2by fasteners5extending below a conventional junction box in the ceiling.

FIG. 4is a cross-sectional view of the motor bracket20ofFIGS. 2A-2Bhooked to the ceiling plate10ofFIG. 3to start the attachment process.

FIG. 5Ais an upper perspective view of the ceiling mount plate10of the preceding figures with motor bracket20attached underneath.FIG. 5Bis a bottom perspective view of the ceiling mount plate10with attached motor bracket20ofFIG. 5A.FIG. 5Cis another bottom perspective view of the ceiling mount plate10with attached motor bracket20ofFIG. 5B.FIG. 5Dis an enlarged view of a captive fastener23in the motor bracket20attached to the ceiling mount plate10ofFIG. 5D.

FIG. 6Ais a bottom view of the ceiling mount plate10with attached motor bracket20ofFIGS. 5A-5C.FIG. 6Bis a side view of the ceiling mount plate10with attached motor bracket20ofFIG. 6A.FIG. 6Cis an enlarged view of a captive fastener23in the motor bracket20about to be attached to the ceiling mount plate10ofFIG. 6A.

Referring toFIGS. 1A-6C, the invention can include a ceiling mount plate10, and a motor bracket20for flush mounting a ceiling fan, such as a hugger fan to a ceiling.

The ceiling mount plate10can be generally rectangular with curved outer edges with downwardly extending rim edges14, or disc shape with a raised mid-portion having noise isolation pads17on top of and/or below the mid-portion of the plate10. Noise isolation pads17can be attached to keyhole slots16.

Along an outer perimeter of the plate10can be a plurality of through-holes13within alignment receptacles12for use with the captive fasteners23which will be discussed in more detail later. About each of the fastener through-holes13can be indentations12underneath the plate10which can form female tab receptacles12for the raised tabs22on the motor bracket20. Underneath the plate10can be a single downwardly protruding hook15.

Noise isolation pads17, such as but not limited to rubber isolation pads, can be mounted to by sliding about keyhole slots16in the ceiling plate10.

The motor bracket20can have an upper ring portion forming a horizontal rim21with a plurality of captive fasteners23supported within upwardly raised alignment type alignment tabs22, which can have raised dimple and/or washer shapes. The captive fasteners23can include but are not limited to screws and bolts, having threaded ends with the screw heads exposed underneath the rim21of the bracket20. The motor bracket20can be attached to a motor40on a flush mountable ceiling fan.

For installation, the ceiling plate10can be pre-mounted to a ceiling2by sliding and locking the keyhole slots16to downwardly extending enlarged headed fasteners extending below an electrical junction type box. Central opening18can have wires that can protrude through the ceiling plate10. The noise isolation pads17can decrease any noise effects when the ceiling plate10is directly attached to metal such as screw or bolt heads5extending below the junction box.

The installer can initially hang the motor bracket20by positioning a through-hole (slot)25on an edge of the bracket20to the end of a downwardly extending hook15which is attached to the ceiling plate10. The installer can then make the electrical connections between the hanging motor bracket20and junction box wires passing through the opening18in the ceiling plate10.

Next, the installer can raise up the free end hanging portion of the motor bracket20, and slide the upper surface of the raised alignment tabs22of the bracket20over the bottom surface of the ceiling plate10until each of the alignment tabs22move into each of the female alignment receptacles12underneath the ceiling plate10. The alignment tabs22align the motor bracket20with the ceiling plate10to create a secure, wobble free connection.

Next, the installer can easily use a manual or power screwdriver or other tool to drive the captive fasteners(screws or bolts) into the through-holes13from the motor bracket20into the ceiling plate10so that the bracket20is securely attached to the ceiling plate10. The noise isolation pads17on the ceiling plate10can also be used between the ceiling plate10and portions of the bracket20wherein these parts abut each other to further decrease undesirable noise effects when running the ceiling fan.

FIG. 7is another side view of the ceiling mount plate10with attached motor bracket20ofFIG. 6Bwith a motor40attached to the mount bracket20.

FIG. 8is a side cross-sectional view of the ceiling mount plate10with attached motor bracket20and motor40ofFIG. 7with a canopy motor housing50attached thereon.

FIG. 9is a bottom view of another motor bracket20B flush mounted to a ceiling plate10.FIG. 10is a side cross-sectional side view ofFIG. 9showing the motor bracket20B mounted to the ceiling plate10.FIG. 11is an enlarged view of a captive fastener23in the motor bracket20about to be attached to the ceiling mount plate10ofFIG. 9. This embodiment can function and operate similar to the previously described ceiling plate10and motor mount bracket20.

While the invention is shown with the female tab receptacles in the ceiling plate, and the raised alignment tabs on the motor bracket, the invention can be used with the female tab receptacles on the rim of the motor mount bracket and the raised alignment tabs extending below the ceiling mount plate.

While the hook is shown on the ceiling plate, and hanging slot on the motor bracket, the hook can be on the motor bracket and the hanging slot on the ceiling plate.

Although the preferred embodiments show captive fasteners and alignment tabs and receptacles used with a ceiling fan motor bracket and ceiling plate, the invention can be used with other applications. For example, other components, such as but not limited to ceiling fan motor housings and/or shades and/or other components can also be fastened to ceiling plates and/or ceiling brackets, and the like with the novel invention features.