Abstract:
A connection device for attaching a downrod to a fan motor assembly of a ceiling fan assembly. The device includes a flange with an aperture defined therein such that a receptacle for receiving a downrod is formed in the flange. The device further includes a sleeve assembly which surrounds at least a portion of the flange, and is capable of projecting into the aperture of the flange. The sleeve assembly can be operated and adjusted to allow a downrod to be inserted and retained in the receptacle bordered by the flange.

Description:
FIELD OF THE INVENTION  
         [0001]    The present invention relates to a device for connecting a ceiling fan motor assembly to a downrod.  
         BACKGROUND OF THE INVENTION  
         [0002]    A downrod is generally used to hang a ceiling fan motor from a position overhead. In general, a first end of the downrod is mounted to a position on a ceiling, and the ceiling fan motor is attached to the second end of the downrod which hangs from the ceiling. Thus, the fan motor is suspended by the second end of the downrod.  
           [0003]    Conventionally, the fan motor is attached to the downrod by a combination of screws and pins that lock the downrod into an insert assembly provided on a surface of the fan motor. More specifically, each of the downrod and the insert assembly on the fan motor in which the downrod will be inserted, are provided with corresponding holes which align when the second end of the downrod is positioned in the insert assembly in a predetermined manner. Accordingly, pins and screws can be inserted through the aligned holes of each of the downrod and the insert assembly in order to lock the fan motor onto the hanging downrod.  
           [0004]    However, conventional devices for attaching a fan motor to a downrod present difficulty whenever it is necessary to install or remove the fan motor from the downrod. Because corresponding holes of the insert assembly on the fan motor and the downrod must be aligned in order for pins and screws to be inserted through each of the downrod and the insert assembly, the fan motor must be suspended and adjusted until the holes of the downrod and the holes of the insert assembly are aligned. Thus, great effort is required to suspend the fan motor assembly when aligning the insert assembly with the downrod before the fan motor can be secured to the downrod.  
         BRIEF SUMMARY OF THE INVENTION  
         [0005]    Accordingly, the present invention provides a connection assembly for a fan that facilitates the connection of a downrod to a fan motor of a ceiling fan assembly.  
           [0006]    In one aspect of the invention, a device for connecting a downrod to a fan motor assembly comprises a flange having an aperture defined therein, wherein the aperture in the flange is capable of receiving the downrod, and a sleeve assembly surrounding at least a portion of the flange, wherein a portion of the sleeve assembly projects into the aperture when the sleeve assembly is in a first position and retracts from the aperture when the sleeve assembly is in a second position.  
           [0007]    In another aspect of the invention, a connection assembly for a fan comprises a downrod having a first end and a second end, a flange provided on a surface of a fan motor assembly, wherein the flange has an aperture defined therein that is capable of receiving the first end of the downrod, and a sleeve assembly surrounding at least a portion of the flange, wherein the first end of the downrod can be retained in the flange when the sleeve assembly is in a first position and the first end of the downrod can be released from said flange when the sleeve assembly is in a second position.  
           [0008]    In yet another aspect of the present invention, a method of making a connection device for a fan comprises the steps of providing a flange having an aperture defined therein on a surface of a fan motor, wherein the aperture is capable of receiving a downrod, and positioning a sleeve assembly surrounding at least a portion of the flange, wherein a portion of the sleeve assembly projects into the aperture when the sleeve assembly is in a first position and retracts from the aperture when the sleeve assembly is in a second position.  
           [0009]    In a further aspect of the present invention, a sleeve assembly comprises an actuator sleeve, a biasing member, and an adjusting sleeve, wherein the actuator sleeve and the biasing member each surround a portion of the flange, and the adjusting sleeve is provided between the flange and the actuator sleeve.  
           [0010]    In yet another aspect of the invention, a projection is provided in a connector and a slot is provided in a downrod, wherein the slot is capable of receiving the tab. Accordingly, the downrod is restricted from rotation while inserted in the connector. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0011]    Other advantages and features of the invention will become more apparent with reference to the following detailed description of the presently preferred embodiment thereof in connection with the accompanying drawings, wherein like reference numbers have been applied to like elements, in which:  
         [0012]    [0012]FIG. 1 illustrates a fan assembly according to the one embodiment of the invention;  
         [0013]    [0013]FIG. 2 illustrates a connection assembly according to the present embodiment of the invention;  
         [0014]    [0014]FIG. 3 illustrates a cross-sectional view of the connection assembly according to the present embodiment of the invention;  
         [0015]    [0015]FIG. 4 illustrates a cross-sectional view of the connection assembly according to the present embodiment of the invention; and  
         [0016]    [0016]FIG. 5 illustrates a cross-sectional view of the connection assembly according to the present embodiment of the invention.  
     
    
     DETAILED DESCRIPTION OF THE INVENTION  
       [0017]    Turning to the drawings, a fan assembly  100  is illustrated in FIG. 1 according to one embodiment of the present invention. As shown, fan assembly  100  includes a connection assembly  101  provided on a motor assembly  102 . Fan assembly  100  further includes, a fan blade  103 , and a blade arm  104  for attaching fan blade  103  to motor assembly  102 .  
         [0018]    [0018]FIG. 2 illustrates the portions of connection assembly  101  in detail. In particular, FIG. 2 illustrates a downrod  201  and a connector  202 , each of which will be described in detail hereinafter.  
         [0019]    According to the present embodiment, connector  202  includes a flange  203 , which extends upwardly, away from motor assembly  102 . As shown, flange  203  defines the outer boundaries of an aperture  202   a , which runs in a lengthwise direction from a surface  102   a  of motor assembly  102  upwardly through flange  203 .  
         [0020]    Connector  202  also includes a sleeve assembly  204  which is formed by an actuator sleeve  204   a , a biasing member  204   b , and a plurality of spherical members  204   c forming an adjusting sleeve. In accordance with the present embodiment, actuator sleeve  204   a  is a solid ring that is provided in engagement with biasing member  204   b , which is in contact with surface  102   a  of motor assembly  102 . As shown in FIG. 2, actuator sleeve  204   a  is in an uppermost position when biasing member  204   b  is in a relaxed, or fully expanded state; however, actuator sleeve  204   a  is capable of traveling along flange  203  in a direction parallel to the length of flange  203  and aperture  202   a . Accordingly, biasing member  204   b  can be compressed according to the amount of travel and the position of actuator sleeve  204   a.    
         [0021]    Although the present embodiment will be described with reference to an adjusting sleeve formed by a plurality of spherical members  204   c , the adjusting sleeve can be of any known configuration, including a single ring, or a plurality of c-shaped rings. Similarly, although actuator sleeve  204   a  will be described with reference to a ring assembly which can be displaced by a sliding motion, actuator sleeve  204   a  can be of any configuration, including a threaded member. Likewise, biasing member  204   b  is not limited to the coil spring type illustrated, and any substitute, including an elastomeric sleeve, can be used without departing from the scope of the invention.  
         [0022]    In the present embodiment, the plurality of spherical members  204   c  are positioned between actuator sleeve  204   a  and flange  203 . As shown, actuator sleeve  204   a is in contact with each spherical member  204   c  such that each spherical member  204   c  is held against flange  203  and projects into aperture  202   a  through openings  203   a  defined in the wall of flange  203 . Further, when actuator sleeve  204   a  is in an uppermost position, as illustrated in FIG. 2, a chamber  205  is provided between actuator sleeve  204   a  and flange  203 , and above the plurality of spherical members  204   c.    
         [0023]    [0023]FIG. 2 also illustrates a projection  206 , provided in connector  202 , to project from flange  203  inwardly into aperture  202   a  and outwardly to a position between flange  203  and sleeve assembly  204 . Also, according to the present embodiment, actuator sleeve  204   a  is provided with a guide  206   a , in which projection  206  projects. According to the present embodiment, guide  206   a  is an elongated aperture having a length in a direction that is generally perpendicular to a plane of surface  102   a  that is greater than a length in a direction that is generally parallel to the plane of surface  102   a . As will be explained, the combination of projection  206  and guide  206   a  aid in controlling the amount of travel in actuator assembly  204 . The present description of projection  206  is merely exemplary, and it is understood that projection  206  can be formed by any configuration or shape, and similarly, guide  206   a  can be any shape that is capable of accommodating projection  206 .  
         [0024]    [0024]FIG. 2 further illustrates downrod  201  which is generally a tubular member having a first end  207  and a second end  208  with an aperture  201   a  defined therein in a lengthwise direction of downrod  201 , i.e., from first end  207  to second end  208 , or vice versa. Downrod  201  is further characterized by an indentation  209 , which, according to the present embodiment, is an indented ring around the outside of downrod  201  in the vicinity of first end  207 . Downrod  201  also includes a slot  210 , which begins at a position that is below indentation  209  and extends to the edge of first end  207 . In one embodiment of the invention, aperture  201   a  in downrod  201  and aperture  202   a  in flange  203  are used to contain electrical wiring to fan motor assembly  102 . Although downrod  201  is illustrated and described herein according to a preferred embodiment, downrod  201  can be of any length, size, and shape, as would be appreciated by those skilled in the art.  
         [0025]    According to the present embodiment, an inner diameter of flange  203  corresponds with an outer diameter of downrod  201 , such that downrod  201  can be inserted into flange  203 . The stages of this operation will be now explained with reference to FIGS.  3 - 5 .  
         [0026]    [0026]FIG. 3 illustrates a cross-sectional view of connection assembly  101  with downrod  201  and connector  202  in a separated state, i.e., before downrod  201  is inserted into connector  202 . According to FIG. 3, biasing member  204   b  is in a relaxed, or expanded state, and accordingly, actuator sleeve  204   a  is in an uppermost position, with respect to surface  102   a . As can be seen, actuator sleeve  204   a  is positioned to engage spherical members  204   c  whenever actuator sleeve  204   a  is in an upwardmost position with respect to surface  102   a.    
         [0027]    As shown, actuator sleeve  204   a  narrows at an upper edge thereof forming chamber  205  between flange  203  and actuator sleeve  204   a  when actuator sleeve  204   a  is in the upwardmost position. However, when in the upwardmost position, actuator sleeve  204   a  is formed such that a portion of actuator sleeve  204   a  engages spherical members  204   c . Accordingly, when actuator sleeve  204   a  is in an upwardmost position with respect to surface  102   a , each spherical member  204   c  is held fixedly in opening  203   a.    
         [0028]    According to the configuration previously described with respect to FIG. 3, the plurality of spherical members  204   c  project into aperture  202   a  in flange  203 . The plurality of spherical members  204   c  projecting into aperture  202   a  form a ring in flange  203  that has an effective diameter that is less than the outer diameter of downrod  201 . Thus, although downrod  201  may be inserted into a portion of connector  202  above the ring formed by the plurality of spherical members  204   c , downrod  201  cannot be fully inserted into connector  202  because downrod  201  is unable to slide past the ring formed by the plurality of spherical members  204   c.    
         [0029]    [0029]FIG. 4 illustrates connection assembly  101 , wherein downrod  201  is partially inserted in connector  202 . As shown, biasing member  204   b  is in a compressed state, and is displaced in a direction toward surface  102   a  of motor assembly  102 . Correspondingly, actuator sleeve  204   a  is also displaced to a downwardmost position, in a direction toward surface  102   a . Thus, chamber  205 , which was formed between actuator sleeve  204   a  and flange  203 , is displaced downwardly in a direction toward surface  102   a , such that the new position of chamber  205  corresponds with the position of the plurality of spherical members  204   c . More specifically, spherical members  204   c  are released from their positions in openings  203   a  by the movement of actuator sleeve  204   a  in the direction toward surface  102   a , and thus, each of the spherical members  204   c  retract into chamber  205 . As shown, in the present embodiment, chamber  205  provides sufficient spacing to accommodate the plurality of spherical members  204   c , and therefore, spherical members  204   c  do not project into aperture  202   a . Thus, the effective inner diameter of flange  203  becomes equal throughout the length of aperture  202   a , and in particular, the effective inner diameter of flange  203  is now sufficient for downrod  201  to be inserted fully into flange  203 . Accordingly, downrod  201  can be inserted into connector  202  past the position of the ring previously formed by the plurality of spherical members  204   c , as FIG. 4 shows.  
         [0030]    [0030]FIG. 4 also illustrates one of the functions of projection  206 , according to one embodiment of the present invention. In particular, projection  206  is formed to mate with slot  210  provided in first end  207  of downrod  201 . Therefore, in order for first end  207  of downrod  201  to be fully inserted into connector  202 , projection  206  and slot  210  must be aligned, as shown in FIG. 4, when first end  207  of downrod  201  is being inserted into connector  201 . Thus, projection  206  and slot  210  provide a guide for installing downrod  201  into connector  202 .  
         [0031]    Further, as can also be seen in FIG. 4, guide  206   a , formed in actuator sleeve  204   a also interacts with projection  206 . More specifically, projection  206  projects into guide  206   a  in actuator sleeve  204   a  such that the amount of travel of actuator sleeve  204   a  in a direction parallel to flange  203  is limited by the length of guide  206   a . Accordingly, when actuator sleeve  204   a  is displaced in one direction, the movement of actuator sleeve  204   a  is halted when projection  206  encounters an uppermost wall of guide  206   a . Similarly, when actuator sleeve  204   a  is displaced in a second direction, which is opposite to the first direction, the movement of actuator sleeve  204   a  is halted when projection  206  encounters a lowermost wall of guide  206   a . Thus, projection  206  can be positioned in guide  206   a when actuator sleeve  204   a  is displaced upwardly and downwardly with respect to surface  102   a , and further, the combination of guide  206   a  and projection  206  can control the amount of upward and downward displacement of actuator sleeve  204   a.    
         [0032]    [0032]FIG. 5 illustrates connection assembly  101  with downrod  201  fully inserted in connector  202 . According to FIG. 5, biasing member  204   b  is returned to a relaxed, or expanded position, and correspondingly, actuator sleeve  204   a  is returned to an uppermost position, as in FIG. 3. Similarly, the plurality of spherical members  204   c  are re-positioned in openings  203   a  in flange  203  such that each spherical member  204  projects into aperture  202   a.    
         [0033]    Further, the projected portions of each spherical member  204   c  is now at least partially housed in indentation  209  of downrod  201 . More specifically, according to the present embodiment, indentation  209  has a predetermined shape which corresponds with a shape of the ring formed by spherical members  204   c . In other words, in the present embodiment, indentation  209  has a contour of a curve in order to receive each spherical member  204   c  that projects through opening  203   a  of flange  203 . Thus, when downrod  201  is fully inserted into connector  201 , and actuator sleeve  204   a  and biasing member  204   b  are released to return to a relaxed and upperwardmost position, each spherical member  204   c  is re-positioned in opening  203   a  in flange  203 , and correspondingly, each spherical member  204   c  engages indentation  209  in downrod  201  in order to retain, or lock, downrod  201  in flange  203  such that downrod  201  is substantially restrained from movement in a direction parallel to a length of flange  203  . Thus, when downrod  201  is inserted into connector  202 , the engagement of the plurality of spherical members  204   c  with indentation  209  in downrod  201 , aid in locking downrod  201  into connector  202 . Further, the force of actuator sleeve  204   a  against the adjusting sleeve formed by the plurality of spherical members  204   c  also prevents the adjusting sleeve from releasing downrod  201 .  
         [0034]    Additionally, as shown in FIG. 5, projection  206  is inserted into slot  210  of downrod  201 . Thus, projection  206  also aids in locking downrod  201  into connector  202 , and in particular, aids in preventing downrod  201  from rotating while positioned in connector  202 .  
         [0035]    In order to release downrod  201  from the position illustrated in FIG. 5, it is only necessary to move sleeve assembly  204  to the position shown in FIG. 4, wherein the plurality of spherical members  204   c  do not project into aperture  202   a , and more specifically, do not interfere with the movement of downrod  201 . Thus, downrod  201  can be removed from flange  203  of connector  202  because downrod  201  is free to move in a direction parallel to the length of flange  203 .  
         [0036]    In a construction of the presently preferred embodiment of connection assembly  101 , flange  203  can be formed with aperture  202   a  having a predetermined diameter corresponding to a diameter of downrod  201 , which is also formed to mate with flange  203 . Flange  203  can be provided on surface  102   a  of motor assembly  102  by any suitable manner including, welding, or a one-piece construction with motor assembly  102 . In a similar manner, projection  206  can be provided in flange  203 . Thereafter, sleeve assembly  204  can be positioned to surround flange  203  as previously described. Alternatively, flange  203  and sleeve assembly  204  can be formed integrally, then positioned on surface  102   a.    
         [0037]    Although the present invention has been described with reference to a presently preferred embodiment, it will be appreciated by those skilled in the art that various modifications, alternatives, variations, and substitution of parts and elements, may be made without departing from the spirit of the invention. For example, indentation  209  provided in downrod  201  is not limited to a curved contour as described, but rather, can be of any shape capable of mating with the sleeve assembly  204 . Similarly, projection  206 , downrod slot  210 , and guide  206   a  can be of any configuration which are capable of mating with each other. Furthermore, connection connector  202  can be constructed with actuator sleeve  204   a  against surface  102   a  and biasing member  204   b  provided thereon, such that the operation described above, in the present embodiment is reversed. Thus, the present application is intended to cover such modifications, alternatives, variations and elements as fall within the scope of the appended claims.