Patent Publication Number: US-6709238-B2

Title: Two-piece safety mechanism for ceiling fans

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates to a two-piece safety mechanism for use with ceiling fans. A first cable attaches to a ceiling fan, and a second cable attaches to a ceiling support. The first and second cables have first and second connectors, respectively, which releaseably attach to form a continuous cable that retains the ceiling fan in close proximity to a ceiling support if the fan&#39;s normal mounting apparatus should fail. 
     2. Description of the Prior Art 
     A conventional ceiling fan consists of a motor suspended from a ceiling with radially extending fan blades operably associated with the motor. A cylindrical body, or downrod, is secured to the motor on one end. On the opposing end, the downrod includes a hanger ball. The hanger ball is generally secured to a mounting bracket, and the mounting bracket is secured to a support from a ceiling support. Therefore, the downrod, hanger ball, and mounting bracket work in conjunction to hang the fan from the ceiling support. Electrical wiring from the fan is generally attached to an electrical box in the ceiling. It is known in the art that such ceiling mounted fans may be subject to falling for various reasons. 
     A ceiling fan may fall if it is installed improperly. The mounting bracket must be properly secured to the ceiling support. Furthermore, the support must be capable of holding the fan. If not, the fan may fall, damaging the fan or other property, or even causing personal injury. Even if the ceiling support can hold the weight of the fan, the mounting bracket may fail. 
     In addition, many fans are manufactured with metric bolts, screws or corresponding threads. However, some electrical boxes, especially those manufactured in the United States, have standard threads. When a metric component is fastened to a standard component, a proper fit is not achieved and the attachment may pull free. 
     Ceiling fans may also fall if faulty or defective materials are used in the fan components. Many mounting brackets manufactured today are largely composed of zinc. When casting zinc brackets, the zinc must not contain impurities. Impurities in a cast zinc mounting bracket may cause brittleness over time and break. Although zinc brackets today may be cast properly, faulty mounting brackets are always a possibility so long as zinc is used in their manufacture. 
     In addition, ceiling fans are sometimes unbalanced. An unbalanced fan continuously rocks back and forth. The constant, repetitive rocking motion can loosen electrical or mounting connections, cause metal fatigue, and ultimately cause the fan to fall. 
     To curb the installation of faulty ceiling fans that are prone to falling, and the installation of poorly secured electrical boxes, the National Electrical Code (NEC) Organization has approved only certain fan and electrical box designs, and mandated that only the approved designs be used on new fan installations. Although this mandate is helpful, it does not entirely prevent the above noted problems. Therefore, there is a need for safety mechanisms that will prevent the fan from falling, and potentially causing personal or property damage. 
     Various designs in the prior art attempt to solve the above noted problems with ceiling fans, and thereby reduce the possibility that the fan will fall. Some designs require that the mounting bracket be attached to the ceiling support using additional bolts or screws. However, such designs do not allow for easy installation or removal, given additional fasteners must be secured to the ceiling support. Likewise, removal of the fan after it is initially secured is difficult, requiring the removal of the additional fasteners. 
     Other designs include a single safety cable, which is connected to the fan by one end and to the ceiling support by the opposing end. This design may prevent the fan from falling if the fan mounting should fail, but complicates installation. In order to properly secure a single safety cable to the ceiling support, the fan and mounting bracket must be out of the way. The single cable must first be attached to the fan, and then attached to the ceiling support before the mounting bracket has been secured to the ceiling support (if the mounting bracket is attached beforehand, the single cable may not be properly secured). In the alternative, the single cable could first be attached to the ceiling support. However, the same problems arise. Specifically, the fan would first need to be attached to the mounting bracket, and then the single cable attached to the fan. Thereafter, the fan and mounting bracket would be secured to the ceiling support. Installation of the single safety cable mechanism is therefore inconvenient and difficult. 
     In addition, many conventional fan designs require partial un-assembly when attaching such a single safety cable mechanism. Thus, installation is further complicated given such un-assembly and subsequent re-assembly would be required when hanging the fan, instead of when the fan is on the floor. Therefore, the single safety cable is not a practical solution. Subsequent removal of the fan, for cleaning, maintenance, replacement, etc., is also complicated when using a single safety cable for similar reasons. 
     As such, a safety cable mechanism is needed which prevents a ceiling fan from falling, while maintaining simple and efficient installation and subsequent removal procedures. The present invention provides for a two-piece safety mechanism for ceiling mounted fans, which is easy to install and prevents the fan from falling more than a few inches should its normal mounting apparatus fail. 
     SUMMARY OF THE INVENTION 
     A two-piece safety mechanism for ceiling-mounted fans comprises first and second cables. The first cable has a first fastener extending from a first end and a first connector extending from a second end. The first fastener is for operable association with a first fastening mechanism for securing the first cable to a fae. The second cable has a second fastener extending from a first end. The second fastener is for operable association with a second fastening mechanism for securing the second cable to a ceiling support. The second cable also has a second connector extending from a second end. The second connector is releaseably attachable to the first connector, so that the first and second cables may form a continuous cable. 
     The present invention also relates to a ceiling fan including a two-piece safety mechanism. The ceiling fan with a two-piece safety mechanism comprises a mounting bracket for securing to a ceiling support, a ceiling fan for securing to the mounting bracket, and the two-piece safety mechanism described above. The ceiling fan comprises a motor, a motor housing having a plurality of radially extending fan blades operably associated with the motor, a downrod having a hanger ball for hanging the ceiling fan from the mounting bracket, and electrical wires associated with the motor. The first fastener of the first cable is secured to the fan, and the second fastener from the second cable is secured to the ceiling support. The first and second connectors from the first and second cables may be releaseably attached to form a continuous cable. The continuous cable retains the fan in close proximity to the ceiling support if the mounting bracket fails. 
     A method of securing a ceiling fan to a ceiling support comprises the following steps: securing a first end of a first cable to a ceiling fan; securing a first end of a second cable to a ceiling support; securing a mounting bracket to the ceiling support; hanging the ceiling fan from the mounting bracket; and connecting a second end of the first cable to a second end of the second cable so that the first and second cables attach to form a continuous cable. 
     The claimed invention also provides for a mounted ceiling fan comprising a mounting bracket secured to a ceiling support, a downrod having a hanger ball secured to the mounting bracket, a fan secured to the downrod, a first cable secured to the downrod, and a second cable secured to the ceiling support. The first and second cables further include first and second connectors, respectively, which are releaseably attached forming a continuous cable for retaining the fan in close proximity to the ceiling support should the mounting bracket fail. 
     In a second embodiment of the present invention, a safety mechanism for ceiling-mounted fans is provided, comprising a cable having a fastener extending from a first end and a connector extending from a second end. The fastener is for operable association with a first fastening mechanism for securing the cable to a fan. A shaped body, preferably L-shaped, is also provided, having a first end and a second end. The first end has a first opening for operable association with a second fastening mechanism for securing the shaped body to a ceiling support. The second end of the shaped body has a second opening configured for receiving the connector for releasably securing the connector therein. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is an elevational view of a two-piece safety mechanism according to the present invention; 
     FIG. 2 is an elevational view of a continuous cable according to the present invention; 
     FIG. 3 is a fragmentary exploded assembly view of a second connector according to the present invention; 
     FIG. 4 is a fragmentary exploded prospective view of a first connector according to the present invention; 
     FIG. 5 is an assembly view of a ceiling fan with the two-piece safety mechanism and a second installation method for the present invention; 
     FIG. 6 is an exploded assembly view of a ceiling fan with the two-piece safety mechanism and a third installation method for the present invention; and 
     FIG. 7 is an exploded view of an L-shaped body according to a second embodiment of the present invention. 
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     As best shown in FIG. 1, a two-piece safety mechanism  2  for a ceiling mounted fan comprises a first cable C 1  and a second cable C 2 . First cable C 1  has a first fastener  4  extending from a first end  6 , and a first connector  8  extending from a second end  10 . Second cable C 2  has a second fastener  12  extending from a first end  14 , and a second connector  16  extending from a second end  18 . Second connector  16  is operably associated with first connector  8  for releaseably attaching first cable C 1  and second cable C 2  to form a continuous cable, as best shown in FIG.  2 . The continuous cable may be easily detached, reforming first cable C 1  and second cable C 2  by simply disconnecting first connector  8  from second connector  16 . 
     As best shown in FIG. 3, second connector  16  is an elongate body having an opening  20 , which is configured to receive first connector  8 . Second connector  16  has opposed first and second major surfaces  22  and  24 , respectively. Opening  20  extends through major surfaces  22  and  24 . A side  26  extends between major surface  22  and major surface  24 . First and second slots  28  and  30 , respectively, extend through side  26  and into opening  20 , and cooperate with cylindrical opening  20  for receiving first connector  8  and second end  10  of first cable C 1 . 
     Side  26  of second connector  16  has a first end  32  and a second end  34 , as best shown in FIG.  3 . Second cable C 2  extends from second connector  16  proximate first end  32 . Opening  20  is proximate opposing second end  34 . First slot  28  extends from first major surface  22  through side  26  to a point intermediate to second major surface  24 . This intermediate point preferably is equidistant from major surfaces  22  and  24 . Second slot  30  extends through side  26  to opening  20  intermediate major surfaces  22  and  24 , extending from the intermediate point of first slot  28  to second end  34  of side  26 . Second slot  30  preferably is perpendicular to first slot  28 . Second slot  30  preferably is parallel to major surfaces  22  and  24 . In addition, second slot  30  may have ridges  36  for securing first cable C 1  and first connector  8 . 
     As best shown in FIG. 4, first connector  8  preferably is cylindrical, with flat surfaces  38  and  40 . First connector  8  is sized to be received in opening  20  of second connector  16 . First connector  8  is received in opening  20  so that second end  10  of first cable C 1  may be aligned with first slot  28 , as best shown in FIG.  3 . First connector  8  is inserted into opening  20 . Second end  10  of first cable C 1  is aligned with, and inserted into, slot  28 . Flat surfaces  38  and  40  may be flush with major surfaces  22  and  24  after insertion of first connector  8  into opening  20 . First connector  8 , along with second end  10  of first cable C 1 , is moved into second slot  30  by swiveling first connector  8  within opening  20 . Second end  10  of first cable C 1  thereafter moves into second slot  30  and past ridges  36 , so that first cable C 1  extends from slot  30  proximate second end  34  of second connector  16 . First and second slots  28  and  30 , along with ridges  36  cooperate to releaseably attach first and second cables C 1  and C 2 , thereby forming a continuous cable. The first and second connectors may be made of zinc, or other suitable materials. 
     In a preferred embodiment of the present invention, two-piece safety mechanism  2  is operably associated with a ceiling fan. Mounting components for a ceiling fan with safety mechanism  2  are best shown in FIG.  5 . Generally, a ceiling fan includes a fan motor  50 , which is attached to a downrod  52 . Downrod  52  includes a hanger ball  54 , which is operably associated with a mounting bracket  56  for hanging the ceiling fan from ceiling support S. Hanger ball  54  fits into a corresponding portion B of mounting bracket  56 . Mounting bracket  56  is secured to ceiling support S with a plurality of mounting screws  58 . A canopy  60  may cover hanger ball  54  and mounting bracket  56  for aesthetic purposes, and is secured to mounting bracket  56  using canopy screws  62 . These components of the ceiling fan are well known in the art. 
     First cable C 1  may be secured to downrod  52  above hanger ball  54 , as shown in FIG.  5 . Downrod  52  includes a corresponding opening O in which first fastener  4  may be secured using first fastening mechanism  64 . First fastener  4  includes an opening  66  through which first fastening mechanism  64  passes, as best shown in FIG.  2 . First fastening mechanism  64  may then be secured in corresponding opening O of downrod  52 , thereby securing first cable C 1 , as shown in FIG.  5 . In the preferred embodiment, first fastening mechanism  64  is a pin. However, any known fastening mechanism may be used, such as a bolt or a screw. First cable C 1  is preferably secured to the ceiling fan before the fan is being secured to mounting bracket  56 . 
     As best shown in FIG. 2, second cable C 2  may be secured to the ceiling support S, before mounting bracket  56  is secured to the ceiling support S. Second fastener  12  is secured to ceiling support S using a second fastening mechanism  68 . Second fastening mechanism  68  may also include any known fastening mechanism, but is preferably a screw or bolt. Second fastener  12  also includes an opening  70 , operably associated with second fastening mechanism  68 . 
     It should be understood, however, that first cable C 1  may be also be secured to the ceiling support S. First fastener  4  may be secured to ceiling support S using second fastening mechanism  68 . Likewise, second fastener  12  of second cable C 2  may be secured in opening O of downrod  52  using first fastening mechanism  64 . In this way, first cable C 1  and second cable C 2  are interchangeable. 
     In a preferred installation of a ceiling fan having two-piece safety mechanism  2 , second fastener  12  is secured directly to ceiling support S using second fastening mechanism  68 , as best shown in FIG.  2 . Then, mounting bracket  56  may be secured to ceiling support S proximate secured second fastener  12  using mounting screws  58 . Having already secured first fastener  4  to the ceiling fan as explained above, the ceiling fan may then be secured to mounting bracket  56  with corresponding hanger ball  54  on downrod  52 . First connector  8  may then be releaseably secured to second connector  16 , as explained above, along with the associated electrical wiring for the ceiling fan. 
     First connector  8  and second connector  16  may be easily joined together to form a continuous cable. The continuous cable retains the fan in close proximity to ceiling support S if mounting bracket  56  should fail. First connector  8  and second connector  16  fit securely together, with ridges  36  securing first end  6  of first cable C 1  within second slot  30 , so that vibrations from operation of a fixture do not cause first and second connectors  8  and  16  to detach. 
     A second installation for the claimed invention is best shown in FIG. 5, which depicts various mounting components for a ceiling fan, described above. Hanger ball  54  is operably associated with mounting bracket  56 , so that hanger ball  54  fits in corresponding portion B of mounting bracket  56 . Mounting bracket  56  is first secured to ceiling support S using mounting screws  58 . One of the plurality of mounting screws  58  is used to secure second fastener  12 . As best shown in FIG. 5, one of the mounting screws  58  is passed through opening  70  of second fastener  12 , through the respective area in mounting bracket  56 , and into ceiling support S. Thus, one of the mounting screws  58  functions as second fastening mechanism  68 . First fastener  4  of cable C 1  is secured to the ceiling fan as explained above. 
     A third method of installation of the claimed invention is best shown in FIG.  6 . Again, first fastener  4  of cable C 1  is secured to the ceiling fan as explained above. However, second cable C 2  is secured to an electrical box E prior to securing mounting bracket  56  to ceiling support S, as shown in FIG.  6 . Generally, electrical box E is secured to ceiling support S by a plurality of electrical box fasteners  72 , such as screws or bolts. One of the electrical box fasteners  72  may be used as second fastening mechanism  68 , as shown in FIG. 6, wherein second fastener  12  is secured to electrical box E using one of electrical box fasteners  72 , which in turn is fastened into ceiling support S. This method of installation may be desirable when an NEC approved electrical box is mounted in ceiling support S. 
     The two-piece safety mechanism of the present invention makes installation on ceiling fans very simple. First cable C 1  is attached to the ceiling fan when it is being assembled on the floor. Second cable C 2  is attached to the ceiling support (or electrical box) before the fan is hung from mounting bracket  56 . After installing the fan, cables C 1  and C 2  may be easily joined together using the specially designed first and second connectors,  8  and  16 . In addition, if the fan ever requires servicing, cleaning, replacing fan parts, etc., cables C 1  and C 2  may be easily detached. The two cables are simply disconnected after other disconnections have been made. 
     A second embodiment of the invention is best shown in FIG. 7, wherein second cable C 2  has been modified, and the intermediate cable between second fastener  12  and second connector  16  has been eliminated. As shown in FIG. 7, second fastener  12   a  and second connector  16   a  are molded as a single shaped body C 3 , preferably L-shaped, though shaped body C 3  need not be at a right angle. Shaped body C 3  includes elements corresponding to second fastener  12  and second connector  16 , which have been explained above, and correspondingly numbered. Second fastener  12   a  includes an opening  70 , which is operably associated with second fastening mechanism  68 . Shaped body C 3  is secured to ceiling support S using second fastening mechanism  68 , as explained above. Second connector  16   a  is operably associated with first connector  8  as explained above, and includes all corresponding elements, as shown in FIG.  7 . Shaped body C 3  therefore has corresponding openings  70  and  20 , which are preferably perpendicular to each other. Slots  28  and  30  are operably associated with opening  20 , and slot  30  is preferably parallel with opening  20 , and contains ridges  36  as described above. However, it should be understood that shaped body C 3  may also be secured in opening O of downrod  52  using first fastening mechanism  64 . 
     It will be apparent to one of ordinary skill in the art that various modifications and variations can be made in construction or configuration of the present invention without departing from the scope or spirit of the invention. Thus, it is intended that the present invention cover the modifications and variations of the invention, provided they come within the scope of the following claims and their equivalents.