Abstract:
An all season fan with heated circulating blades which includes a heating elements mounted in slots defined in the rear surface of the fan blades for heating of air blown outwardly therefrom. Resilient biasing devices such as a bow springs are mounted in the fan blades extending over the slots to retain the heating elements in the slots. Electrically conductive ball bearings are included to facilitate rotation of the fan blade and hub while simultaneously providing electrical power to the heating elements during fan rotation. At least two bearings each individually maintain separate electrically conductive abutment respect to two separate conductive rings mounted in an insulating insert within the fan hub. Each ring is electrically conductive with respect to one end of each heating element for heating thereof during fan rotation.

Description:
[0001]     This application for patent is a continuation-in-part of U.S. patent application Ser. No. 10/734,973 filed Dec. 15, 2003, on a Heat Fan, currently pending. All priority rights including filing date priority are hereby formally claimed. and the parent application is hereby incorporated by reference herein for all purposes. 
     
    
     BACKGROUND OF THE INVENTION  
       [0002]     1. Field of the Invention  
         [0003]     Typically electric fans have been used to circulate air flow for cooling otherwise ambient environments. Other heaters have been used to provide supplementary heat in various areas by forcing air flow through heating elements wherein the air is warmed by the heater as it is forced to move through the heating elements. The present construction allows usage of a fan design for cooling or heating during all seasons. It is difficult to provide such constructions which are usable with fans that can oscillate, particularly pedestal fans, which are more useful in providing air circulation than stationary fans or blowers. Some electrically heated devices have been used to heat areas by placing a swivel fan in front of the heated element but this results in limited air circulation throughout the area. The construction of the present invention of heat fan provides cost effective means for circulation of heated air which is usable in many different environmental areas and applications. It has enhanced heating and air circulation capabilities which is usable in almost any ambient environment. It includes a unique means of transferring electrical power through the fan hub bearing to the heating element positioned on the rear surface of the fan blades.  
         [0004]     2. Description of the Prior Art  
         [0005]     Many patents have been granted on devices for moving and heating air simultaneously including fans and blowers and the like such as U.S. Pat. No. 1,737,912 patented Dec. 3, 1929 to F. T. Bogard and assigned to E. H. Christian on a “Rotary Heating Device”; and U.S. Pat. No. 1,784,528 patented Dec. 9, 1930 to O. F. Lidke et al and assigned to Lee A. Yoder on an “Electric Heating Apparatus”; and U.S. Pat. No. 2,110,621 patented Mar. 8, 1938 to I. H. Cohen and assigned to Thermal Units Manufacturing Company”; and U.S. Pat. No. 5,230,606 patented Jul. 27, 1993 to K. Fu on an “Electric Fan With Hot Air/Col.d Air Dual-Model Control”; and French Patent No. 942,017; and Italian Patent 464906; and British Patent Application GB 2 172 935 A, inventor S. Liaw on “A Cool And Warm Electric Fan”; and European Patent Application EP 0 964 211 A2; inventor M. Pigozzi on an “Electrically Heated Fan”.  
       SUMMARY OF THE INVENTION  
       [0006]     Temperature control by use of a unique heated fan is a primary advantage of the present invention. Control of air flow and temperature of the surrounding environment is made possible. Operation of the fan will gradually increase the temperature of surrounding air to reach the desirable temperature. The all season heat fan design of the present invention has been found to be particularly useful when used with a fan including an oscillating feature because it will provide better circulatiion of heated air than possible by any previous fan designs. Its unique construction and function is possible because of the particular designing of the fan and hub which allows the delivering of electrical current through sealed metal ball bearings to heating elements at least partially embedded in the fan blades.  
         [0007]     The fan can rotate and deliver electric current to the heating elements at the same time. One of the advantages of the present invention is in the delivering of electric current through the metal ball bearings to the heating elements on the blades during powered rotation of the fan. This construction is particularly advanced in its simplicity, cost and effectiveness. Proper safety precautions have been included in this design to comply with requirement set forth by Underwriter&#39;s Laboratory. This fan may be used for all seasons by the inclusion of a thermostat for adjusting the supplying of electrical power to the heating element such that when heating is not necessary, the fan can be used a conventional fan.  
         [0008]     The drive of the fan of the present invention is included in a housing which includes a front plate extending thereover. Preferably two electrical conductors extend outwardly through this plate and carry electrical current to be made available for heating of the heating elements. Heating elements are positioned in slots preferably defined on the rear surface of the fan to facilitate heating of air blown thereby. The individual fan blades are mounted in a fan hub and extend outwardly therefrom angularly to facilitate the movement of air therefrom.  
         [0009]     Electrical communication between the two electrical conductors and the heating element is provided by including ball bearings mounted on the ends of the electrical conductors. These ball bearings are positioned in contact with respect to rings mounted inside of the fan hub. To facilitate electrical isolation a hub insert member preferably formed of an electrically insulating material such as silicone or rubber or thermoplastic is mounted within the fan hub with a first and second ring member of metallic conducting material mounted therein spaced apart from one another. A ball bearing is positioned on the end of each electrical conductor and in abutment with respect to the inside diameter of one of the rings to maintain electrical contact therewith. The individual heating elements mounted positioned in the slot on the fan blade surface extend through the hub and through the hub insert into electrical communication with respect to the two rings. In a preferred embodiment as shown in the present invention springs are positioned between the first and second ends of each heating element and the rings adjacent to which they are positioned to maintain contact therebetween during fan rotation. These springs will be in abutment with respect to the respective ends of the heating elements as well as being in contact with the outside surface of the respective rings for the purpose of maintaining full electrical flow between the heating elements and the respective electrical conductors at all times and especially during operation of the drive motor and the resulting rotation of the fan blades.  
         [0010]     The heating elements are maintained in the slots by positioning of holding members thereover preferably in the form of bow springs which are secured by a bow securement device such as a screw or the like directly into the fan blade itself. Preferably a single attachment point is included which allows the bow spring to be rotated away from the slot to facilitate replacement and/or maintenance of the heating elements positioned therein more easily.  
         [0011]     The present invention will preferably include a safety kill switch which will be operative to terminate all electrical power to the apparatus of the present invention responsive to the fan device being in any position other than upright. In this manner, if the unit is tipped or falls on its side, then no danger will exist because power supplied to the fan and to the heating elements will e automatically terminated. Such a safety kill switch can be most easily positioned in the base of a pedestal version of this fan apparatus.  
         [0012]     It is an object of the present invention to provide an all season heat fan apparatus which simplifies means for heating air within a predefined environment.  
         [0013]     It is an object of the present invention to provide an all season heat fan apparatus which provides electrical power to heating elements mounted in a fan blade which extends through bearings mounted inside of the fan hub.  
         [0014]     It is an object of the present invention to provide an all season heat fan apparatus which is easy and convenient to use.  
         [0015]     It is an object of the present invention to provide an all season heat fan apparatus which has minimal maintenance requirements.  
         [0016]     It is an object of the present invention to provide an all season heat fan apparatus which can be used with a pedestal fan or any other different type of fan design.  
         [0017]     It is an object of the present invention to provide an all season heat fan apparatus which can be utilized with fans of greatly varying different sizes and during many different temperatures and all seasons.  
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0018]     While the invention is particularly pointed out and distincly claimed in the concluding portions herein, a preferred embodiment is set forth in the following detailed description which may be best understood when read in connection with the accompanying drawings, in which:  
         [0019]      FIG. 1  is a side cross-sectional view of an embodiment of the all season heat fan of the present invention;  
         [0020]      FIG. 2  is a perspective illustration of an embodiment of an all season heat fan of the present apparatus showing the electrical conductors and collets and bearings extending outwardly from the front plate of the housing assembly;  
         [0021]      FIG. 3  is a front plan view of an embodiment of a fan plate usable with the present invention;  
         [0022]      FIG. 4  is a rear plan view of an embodiment of a fan plate usable with the present invention;  
         [0023]      FIG. 5  is an exploded illustration of the intersection between an embodiment of the heating element of the present invention and the adjacent ring member with the spring means positioned therebetween for maintaining contact;  
         [0024]      FIG. 6  is an assembly view of an embodiment of the hub assembly of the present invention showing the hub, hub cap and driveshaft mounting tube thereof;  
         [0025]      FIG. 7  is an exploded view showing the exterior of the hub assembly with mounting brackets extending outwardly therefrom and the hub insert member with slots defined therein for holding two metallic rings spaced apart from one another;  
         [0026]      FIG. 8  is an assembly view of the hub assembly shown vertically oriented with respect to the hub cap and driveshaft mounting tube as well as the hub insert member;  
         [0027]      FIG. 9  is a perspective illustration showing the manner of attachment of an embodiment of the fan hub of the present invention through the fan mounting brackets to the fan blades while maintaining electrical contact therebetween through the springs;  
         [0028]      FIG. 10  is a cross-sectional illustration of an embodiment of the fan blade showing the slot defined therein with the heating member positioned therein and a bow spring secured to the fan with an arcuate section thereof extending over the heating member for holding it in place within the slot;  
         [0029]      FIG. 11  shows an embodiment of the fan mounting bracket of the present invention;  
         [0030]      FIG. 12  is an assembly drawing of the line of electrical communication between the power input line and the first ball bearing means extending through the electrical conductor and collet assembly;  
         [0031]      FIG. 13  is a front plan view of an embodiment of the present invention illustrating a control box for facilitating control of various modes of operation of the present invention; and  
         [0032]      FIG. 14  is a side plan view of the embodiment shown in  FIG. 13 . 
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT  
       [0033]     The present invention covers a unique configuration for an all season heating fan device, which is usable during all times of the year when cooling is desired like in the summer or when heating is desired like in the winter. The unit will include a housing  10  for the positioning of a drive means  12  such as a motor or the like therewithin. A front plate  14  will extend over the opening in the housing  10  with the driveshaft  72  of drive motor  12  extending outwardly therefrom and being freely rotatable responsive to powering of the drive means.  
         [0034]     The fan construction will include a fan hub  24  with a hub cap  74  extending over the front opening thereof and allowing a driveshaft mounting tube  76  to be positioned therewithin and extending rearwardly toward the housing  10  and in alignment with the driveshaft  72 . Preferably driveshaft  72  will engage the driveshaft mounting tube  76  in such a manner as to power rotation thereof. Driveshaft mounting tube  76  and hub cap  74  and fan hub  24  will be securely mounted with respect to one another such that powered rotation of the driveshaft  72  will cause powered rotation of the fan hub  24 . The individual fan blades  32  of the fan  30  will be mounted to the fan hub  24  through fan mounting brackets  58 . Each fan mounting bracket  58  will include fan mounting holes  82  defined therein to facilitate the fixed securement of the fan blades  32  with respect to the fan hub  24 . Preferably the individual fan blades  32  will be mounted at an angle  60  relative to the rotational direction of movement of the fan  30  to facilitate movement of air thereby and to facilitat heating of air when caused by rotation of the fan.  
         [0035]     An important aspect of the present invention is in the means of communicating electrical current to the heating element means  40 . These heating elements  40  will preferably be mounted within slots  38  defined in the rear fan surface  36  which is positioned oppositely from the front surface  34 . Each heating element will include a first heating end  42  and a second heating end  44 .  
         [0036]     Electrical power flow from the stationary housing  10  to the heating elements  40  which are rotating with the fan  30  is through electrical conductors  16  and  18 . A first electrical conductor  16  and a second electrical conductor  18  are mounted in collets defined in the front plate  14  of housing  10 . A first collet assembly  55  is mounted in front plate  14  with the first electrical conductor  16  extending therethrough. Similarly a second collet assembly  56  is mounted in the front plate  14  of the housing  10  with the second electrical conductor  18  extending outwardly therethrough. Each of the first and second collet assemblies  55  and  56  are made of an electrically insulating material to isolate the first and second electrical conductors  16  and  18  from the front plate  14  and are positioned apart from one another to achieve electrical isolation between the first and second electrical conductors  16  and  18  to prevent shorting.  
         [0037]     The first electrical conductor  16  and the second electrical conductor  18  extend outwardly from the point of mounting in the front plate  14  toward and into the fan hub  24 . Preferably each of the electrical conductors will include a ball bearing means mounted in electrical communication on the outer portion thereof. In the preferred embodiment shown in  FIG. 1 a  first ball bearing means  20  will be mounted to the first electrical conductor  16  near the outermost end thereof within the fan hub  24  at a position inside of an abutment with respect to a first ring member  26  mounted within fan hub  24 . In a similar manner a second ball bearing means  22  will be mounted on the second electrical conductor  18  at a position farther away from the front plate  14  than the first ball bearing means  20  in abutment with the inside surface of a second ring member  28 .  
         [0038]     The first and second ring members  26  and  28  are both preferably mounted within the fan hub  24  by being positioned within a hub insert member  54 . Hub insert member  54  is preferably positioned within the fan hub  24  and includes the first and second ring members  26  and  28  mounted therein electrically insulated from one another and electrically insulated from the fan hub  24  itself. The fan hub  24  will preferably be formed of an electrically insulating material such as silicone, rubber, thermoplastic or any other electrically insulating material in order to facilitate electrical isolation of the power flow path to the heating means  40  on each fan blade  32 . In the embodiment shown in  FIG. 1  the first ring member  26  will be positioned closer to the housing  10  than the second ring member  28  in order to be properly aligned with the first and second ball bearing means  20  and  22 . Also it is preferable that the portion of the first electrical conductor  16  and the second electrical conductor  18  be further electrically insulated by placing a vinyl exterior insulation sheathing  80  extending thereover between the respective collet assembly and the respective ball bearings.  
         [0039]     The means of positioning of the heating means  40  on the rear fan surface  36  is an important consideration of the present invention. Preferably the rear fan surface  36  will define at least one slot  38  extending thereover into which the heating element  40  can be positioned. The heating element  40  can be a round or oval design but will be positionable within the slot  38  for facilitating holding of the heating element in place on the desired area of the rear fan surface  36 . A holding member  46  will be included for the purpose of retaining the heating element members  40  in the slots  38 . These holding members preferably comprise individual bow spring members  48  which are securable through a bow securement means such as a screw  50  directly to the rear fan surface  36  securing of the holding members  46  in place. Preferably each bow spring member  48  or holding member  46  includes an arcuate bow section  52  extending over the adjacently positioned heating element  40  while it is positioned within the slot  38  for the purpose of retaining it as desired. The use of a single screw as the bow securement means  50  has the advantage of allowing the bow spring member  48  to be rotated away from the position extending over the slot  38  to facilitate replacement and/or maintenance of the heating elements  40  which tend to need replacement over long terms of usage.  
         [0040]     Another important consideration in the present invention is in the maintaining of electrical contact between the first heating end  42  and the outside surface of the first ring member  26  and also maintaining contact between the second heating end  44  and the second ring member  28 . The maintaining of this contact to continuously supply heat to the heating elements is achieved by the configuration shown in  FIG. 5 . The first heating end  42  will include a first spring means  62  which is in engagement with the outer surface of the first ring member  26  will simultaneously being biased into engagement with the first heating end  42  of heating element  40 . In some configurations the heating element  40  will include an electrical wire extending therefrom which further facilitates the maintenance of electrical contact therebetween. The flexibly resilient biasing of the first spring means  62  will facilitate continuous maintenance of contact between the external surface of the first ring member  26  and the first heating end  42  of heating means  40  despite any movement that may occur during rotation of the fan. A similar construction is utilized for the inner section between the second heating end  44  of heating element  40  and outside surface of the second ring member  28  by the inclusion of a second spring means  64 . Both the first spring means and the second spring means are shown in  FIG. 9 .  
         [0041]     To isolate the heating means  40  from the fan hub  24  the fan hub can define first heating element aperture  66  and second heating element apertures  68  therein. These apertures are defined in the fan hub  24  and are defined in the hub insert member  54  to allow the heating means  40  to extend therethrough as shown best in  FIG. 5  to a position where the spring means will be immediately adjacent to the end of the heating tube and will be in contact with the outer surface of the ring member  26  and/or  28 . To further isolate the heating element  40  from the fan hub  24  a ceramic or other electrically insulating tube  78  can be positioned within the first heating element apertures  66  and also within each of the second heating element apertures  68 .  
         [0042]     A control box housing  90  is preferably included in the present invention with a thermostat  91  positioned thereadjacent or therewithin. Control box  90  will hold the means of operating of the fan or heating apparatus. A preferred configuration is shown in  FIGS. 13 and 14 . A main power switch  92  is operative to allow or prevent electrical power from being supplied to both the fan and the heating elements thereof. Switch button  94  provides and on/off power switch for the fan. Buttons  95 ,  96  and  97  provide low, medium, and high speed fan rotation speed, respectively. Also, indicator lights are preferably included. Light  98  in this preferred embodiment is the indicator light for showing power is being supplied to the unit and light  99  is the indicator light for showing that the heating elements are operational. This control box housing is preferably mounted in the vertical stand of the pedestal fan embodiment, but is usable with many different fan configurations which includes the noval aspects of the present invention. A safety kill switch is also preferably included which will stop all power to the fan or to the heating elements if the fan is in any orientation other than being upright.  
         [0043]     While particular embodiments of this invention have been shown in the drawings and described above, it will be apparent that many changes may be made in the form, arrangement and positioning of the various elements of the combination. In consideration thereof, it should be understood that preferred embodiments of this invention disclosed herein are intended to be illustrative only and not intended to limit the scope of the invention.