Patent Publication Number: US-9897095-B2

Title: Ceiling fan kit and method of mounting

Description:
BACKGROUND 
     The conventional ceiling fan includes a mounting bracket or ceiling plate, which couples to an electric outlet box or the building structure. In a mounting system utilizing a ceiling fan-rated outlet box, machine screws couple the mounting bracket to the outlet box. Alternatively, in a standard electrical outlet box or building structure, wood screws couple the mounting bracket to a wood stud, supporting the ceiling fan. In either event, the screws are tightened until a structure mount is securely mounted to the building structure. 
     A typical ceiling fan assembly comprises, a motor, a motor housing, a plurality of fan blades, a canopy, and an optional light assembly, which secures to the ceiling plate or mounting bracket by a downrod or a hanger rod. The downrod passes through a central opening in the canopy. One end of the downrod couples to a downrod coupler for mounting to the mounting bracket while the opposite end of the downrod mounts to the ceiling fan assembly, utilizing a motor coupler. A ball attaches to the downrod coupler and is received in a seat formed in the mounting bracket, mounting the ceiling fan assembly to the mounting bracket, and thus the ceiling fan unit to the ceiling. 
     Traditionally, ceiling fans are sold with a single mounting style being either a low-profile mount, a traditional-profile mount, or a high or angled profile mount. A low-profile mount mounts the ceiling fan close to the ceiling, reducing the chance of collision with the fan blades during operation. When utilizing a low-profile mount, the canopy typically extends from the fan motor housing to the ceiling, completely covering the downrod. Conversely, in a traditional-profile or high profile mount, the downrod is visible, with a canopy that extends from the ceiling down to a portion of the downrod creating an aesthetic transition between the two. A traditional-profile mount or a high profile mount extend further from the ceiling, as compared to a low-profile mount, in order to optimize fan efficiency by increasing space above the fan promoting greater airflow. 
     Consumers purchase mounting styles based upon the consumer&#39;s ceiling in order to optimize fan efficiency, maintain safety, and promote aesthetic value. A consumer with a low height ceiling, generally less than 8 feet, will be limited to purchasing a low-profile mount ceiling fan to accommodate the low ceiling. A consumer with a normal height ceiling, generally 8 to 10 feet, will be limited to purchasing a traditional-profile ceiling fan to optimize fan efficiency. Finally, a consumer with a high, vaulted, or angled ceiling, extending higher than 10 feet, will purchase a ceiling fan specifically accommodating the specific ceiling style, such as a ceiling fan with high-profile mount utilizing an elongated downrod. 
     If a consumer wants to purchase a ceiling fan style specifically designed for a traditional-profile mount, but has a low-profile ceiling, the consumer will have to worry about the low hanging fan blades. Furthermore, if a consumer moves to another home with a different height ceiling or wants to move the ceiling fan to another room with a different height ceiling, the ceiling fan will have an incorrect mounting profile to accommodate new room. Transitioning ceiling fans between different heights or finding a ceiling fan style specific to a ceiling type often limits a consumer in purchasing and style options. 
     Additionally, installing the ceiling fan while making internal, electrical wiring connections is difficult. Holding the ceiling fan assembly while making connections is challenging. In a low-profile mount, the canopy extends from the fan assembly to the ceiling, creating a situation where the size of the canopy prevents an installer from making internal electrical connections. Installation requires an installer to hold the ceiling fan assembly while simultaneously making mounting or electrical connections, making the endeavor at least a two-person job and raising issues with safety. 
     BRIEF SUMMARY 
     A ceiling fan kit with a first downrod, a second downrod being longer than the first downrod, a structure mount configured to attach either downrod to a structure, an adjustable length canopy configured for use with the first downrod, and a non-adjustable length canopy configured for use with the second downrod. The adjustable length canopy is extendable and retractable and may provide a low-profile ceiling mount when used in conjunction with the first downrod. The non-adjustable canopy may provide a traditional-profile mount when used in conjunction with the second downrod. The extended length of the adjustable length canopy may be a greater length than the first downrod and the non-adjustable length canopy. The non-adjustable length canopy may be of a length less than the length of the second downrod. The structure mount may comprise a mounting bracket. 
     The kit may comprise additional elements such as fan motor assembly including at least one fan blade, and a downrod coupler for retaining either downrod. The downrod coupler may comprise a ball mount for coupling to either downrod, where the mounting bracket may retain the ball. 
     A method of installing a ceiling fan comprising the steps of: (A) selecting a downrod from at least a first downrod and a second downrod, where the second downrod is longer than the first downrod; (B) selecting a canopy from either an adjustable length or a non-adjustable length canopy based on the selected downrod; (C) mounting the selected downrod to a downrod coupler; (D) positioning the selected canopy about the selected downrod; (E) mounting the downrod to a fan assembly; and (F) mounting the downrod coupler to a structure mount. The method may further comprise securing the downrod coupler to the structure mount. 
     When the adjustable length canopy is selected, the method may further comprise extending the length of the adjustable length canopy after securing the downrod coupler to the structure mount and securing the adjustable length canopy to the structure mount after extending the length. Securing the downrod coupler to the structure mount may include placing a ball on the downrod coupler within a complementary seat on the structure mount. The adjustable length canopy may include telescoping segments. 
     When selecting the non-adjustable length canopy, the method may further comprise sliding the non-adjustable length canopy along the selected downrod until a portion of the non-adjustable length canopy is adjacent to the structure mount or securing the portion of the non-adjustable length canopy to the structure mount. 
     The method may further comprise selecting the adjustable length canopy when the selected downrod is the first downrod or selecting a non-adjustable length canopy when the selected downrod is the second downrod. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  depicts an exploded view of an embodiment of a ceiling fan kit. 
         FIG. 2  depicts a perspective view of an embodiment of an assembled ceiling fan with a non-adjustable length canopy. 
         FIG. 3  depicts a detailed view of the ceiling fan mounting components of  FIG. 2 . 
         FIG. 4  depicts a perspective view of an embodiment of an assembled ceiling fan with an adjustable length canopy. 
         FIG. 5  depicts a detailed view of the ceiling fan mounting components of  FIG. 4  with an extended adjustable length canopy. 
         FIG. 6  depicts a detailed view of the ceiling fan mounting components of  FIG. 4  with a retracted adjustable length canopy. 
         FIG. 7  depicts a flow chart of steps comprising a method of mounting the kit of  FIG. 1 . 
     
    
    
     DETAILED DESCRIPTION 
     Turning now to the drawings and to  FIG. 1  in particular, one combination of combinable ceiling fan parts comprising elements of a kit are shown.  FIG. 1  is non-limiting, showing one set of combinable elements, comprising a kit, which may contain more or less elements than what is illustrated and described. The kit comprises general modular fan assembly elements, many of which are exchangeable for other elements with different designs, quantities, qualities, or functionalities. 
     The ceiling fan kit  10  shown comprises a modular fan assembly  60 , wiring harness  50 , downrod set  40 , mounting assembly  30 , and canopy set  20 . The modular fan assembly  60  comprises a motor  70 , including motor wires  68 , blade mounting ring  66 , which mounts a plurality of fan blades  72 . The upper motor housing  62 , with a canopy rest  92  situated on an outer surface, and lower motor housing  74  enclose the motor  70  while leaving an annular opening through which the fan blades  72  extend. A motor coupler  64  mounts to an upper end of the motor  70 , and a motor coupler brace  76  mounts to a lower end of the motor  70 . A light globe or shade  78  mounts to the lower end of the lower motor housing  74 . 
     The downrod set  40  comprises a short downrod  42  and a long downrod  44 . The long downrod  44  can be a downrod of any length being greater than the length of the short downrod  42 . The short downrod  42  is suitable for a low profile mounting of the motor  70  to the ceiling, whereas the long downrod  44  may be suitable for a traditional-profile mounting, high-profile mounting, or mounting the motor  70  to an angled or vaulted ceiling. While two downrods are shown, more than two downrods having differing lengths may be included in the downrod set  40 . 
     The wiring harness  50  includes wiring  54 , which can terminate on one or more ends with a connector  52 . The connector  52  can be preassembled to the wiring  54  or can be ready for assembly by the installer. In either case, the connector  52  may be a push connector having multiple slots or openings in which the leads of the wiring  54  may be pushed in to establish an electrical connection between the wiring  54  and the connector  52 . Further, the ceiling fan kit  10  may comprise a set of harnesses, complementary to each downrod in the downrod set  40 . Harnesses may be pre-installed within each downrod or may require installation. Still further, the ceiling fan kit  10  may have no wiring harness  50  or may include a length of wire that can be stripped and cut to electrically couple the motor  70  to the structure power supply. 
     The mounting assembly  30  comprises a structure mount  34 , downrod coupler  36 , and a ball  32 . The structure mount  34  can be mounted to the ceiling or other structure to which the motor  70  is to be mounted. A portion of the structure mount  34  forms a seat adapted to receive the ball  32 . The ball  32  couples to the downrod coupler  36 , which couples to the selected downrod  42 ,  44 . The ball  32 , upon resting in the seat, can provide for pivoting movement of the downrod  42 ,  44  relative to the structure mount  34 . The ball  32  can have a tri-lobe configuration to improve the seating and pivoting movement relative to the structure mount  34 . 
     The canopy set  20  can comprise a non-adjustable length canopy  22 , best suited for a traditional mounting, and an adjustable length canopy  24 , best suited for a low profile mounting. While two canopies are shown in the canopy set  20 , more than two canopies may be included in the canopy set  20 . 
     The elements of the ceiling fan kit  10  are interconnectably combinable, as shown in  FIG. 1 , to form a ceiling fan structure, which is mountable to a building structure having electrical connectivity. As may be appreciated, different combinations of the downrods  42 ,  44  and the canopies  22 ,  24  may be selected such that either a low-profile mounting or a traditional-mounting of the motor  70  to the structure mount  34  can be accomplished without the need for abandoning the structure mount  34  in the low profile mounting or having a special structure mount  34  for each of the low-profile and traditional-profile mounting. More specifically, the short downrod  42  and the adjustable length canopy  24  may be combined to create a ceiling fan structure having a low-profile mount or the long downrod  44  and the non-adjustable length canopy  22  may be combined to create a ceiling fan structure having a traditional-profile mount. In further ceiling fan kits  10 , any number or variety of downrods may be included, being complementary to any number or variety of canopies, accommodating a variety of ceiling heights or building structures, including but not limited to, low heights ceilings, normal height ceilings, high ceilings, or vaulted or angled ceilings as well as building beams, rafters, or supports or any other building structure of which it may be desirable to mount a fan. 
     Turning now to  FIG. 2 , selected elements from the ceiling fan kit  10  are shown assembled into a traditional-profile assembly  80 . More specifically, the long downrod  44  and the non-adjustable length canopy  22  are selected by the installer and then combined with the other elements to form the traditional-profile assembly  80 . The modular fan assembly  60  has been combined and is mounted to the long downrod  44  at the motor coupler  64 . 
     The mounting assembly  30  has been combined. The downrod coupler  36  couples the end of the long downrod  44 , opposite of the modular fan assembly  60 , to the ball  32 . The ball  32  is seated in the structure mount  34 , mounting the modular fan assembly  60  to the ceiling. The non-adjustable length canopy  22  positions around and attaches to the structure mount  34 , resting flush against the ceiling. 
     The coupling of the long downrod  44  between the structure mount  34  and the modular fan assembly  60  is best shown with respect to  FIG. 3 , which is a section view of an upper portion of the traditional-profile assembly  80 . The modular fan assembly  60  couples to the long downrod  44  by the motor coupler  64  utilizing a screw  82 . The inner surface of the upper motor housing  62  rests on top of a portion of the motor coupler  64  situated inside of the upper motor housing  62 . 
     Opposite of the motor coupler  64 , the long downrod  44  mounts to the downrod coupler  36  with a pin  84 . The ball  32  is adapted to receive and support the downrod coupler  36  such that the downrod coupler  36  rests on a ledge extending into an internal recess within the ball  32 . The structure mount  34  has a seat  86  adapted to receive the ball  32 . Upon attaching the structure mount  34  to the ceiling and positioning the ball  32  within the seat  86 , the structure mount  34  couples the other combined elements comprising the ceiling fan kit  10  to the ceiling. 
     Turning now to  FIG. 4 , selected elements from the ceiling fan kit  10  are shown assembled into a low-profile assembly  90 . Specifically, the short downrod  42  and the adjustable length canopy  24  are selected by the installer and then combined with the other elements to form the low-profile assembly  90 . The modular fan assembly  60  is combined in the same manner for mounting to the ceiling as in  FIG. 2 , regarding the installation of a traditional-profile assembly  80 . 
     The adjustable length canopy  24  extends between the upper motor housing  62  and the structure mount  34 , while enveloping the structure mount  34  and short downrod  42 , to effectively fill in any gap between the upper motor housing  62  and the structure to which the upper motor housing  62  is mounted. In this manner, the adjustable length canopy  24  provides a cover for the short downrod  42 , unlike the non-adjustable length canopy  22  in the traditional-profile mounting. 
     The adjustable length canopy  24  is comprised of two separate elements including an upper member  24   a  and a lower member  24   b , which may be moved relative to each other between an extended position ( FIG. 5 ) and a retracted position ( FIG. 6 ), which aids in the mounting of the upper motor housing  62  to the structure during installation. While the adjustable length canopy shown in  FIGS. 5 and 6  is comprised of two separate elements, the adjustable length canopy may consist of more than two elements configured in a similar telescoping arrangement. 
     The structure of the adjustable length canopy  24  is best seen with reference to  FIG. 5 . The upper member  24   a  has a stepped portion  26  having a series of reduced diameter portions, providing a step-like appearance, which transition to a smallest reduced diameter portion being identified as reduced portion  28 . The lower member  24   b  terminates in an opening  100  in which is received by an annular spacer  98 , which can be an absorption member to attenuate vibrations. The reduced portion  28  passes through the opening  100  to telescopically connect the upper member  24   a  and lower member  24   b . In the retracted position ( FIG. 6 ), the stepped portion  26  will abut the lower member  24   b  and function as a stop to limit the telescopic movement in the retracted position. As illustrated, the reduced portion  28  does not have a structure that would prevent removal of the reduced portion  28  from the opening  100 ; however, such a structure, like an angular flange, could be provided. 
     Still referring to  FIG. 5 , the mounting of the modular fan assembly  60  to the structure mount  34  using the short downrod  42  is similar to that described and shown in  FIG. 3  for the long downrod  44 . In the low-profile assembly  90 , using the short downrod  42 , the motor coupler  64  couples the modular fan assembly  60  to the short downrod  42  utilizing the upper motor housing  62  in the same manner as the modular fan assembly  60  may be coupled to the long downrod  44  as in  FIG. 3 . Furthermore, the short downrod  42  couples to the mounting assembly  30  in same manner as the long downrod  44  couples to the mounting assembly  30  as detailed in the discussion of  FIG. 3  as well. 
     Unlike the traditional-profile assembly  80 , in the low-profile assembly  90 , the lower member  24   b  of the adjustable length canopy  24  rests on the canopy rest  92 . The canopy rest  92  has a groove  96  with pad  94  situated in the bottom of the groove  96 . The groove  96  runs circumferentially around canopy rest  92  having a diameter adapted to receive the bottom edge of the lower member  24   b . The pad  94  can be an absorption member used to attenuate the transfer of vibrational forces between the modular fan assembly  60  and the adjustable length canopy  24 . 
     When in the extended position, the upper member  24   a  of the adjustable length canopy  24  can be coupled to the structure mount  34  by screws  82 . In the extended position, the adjustable length canopy  24  surrounds the structure mount  34 , the ball  32 , the downrod coupler  36 , and a portion of the short downrod  42 . In the extended position, the bottom edge of the reduced portion  28  of the upper member  24   a  is situated within the internal recess of the lower member  24   b.    
     Turning now to  FIG. 6 , in the retracted position, the upper member  24   a  is no longer attached to the structure mount  34 , making it possible for the reduced portion  28  to slide into the lower member  24   b . The stepped portion  26  rests on the spacer  98 , atop the upper rim of the lower member  24   b , to limit the amount the reduced portion  28  may be slid into the lower member  24   b . In the retracted position, external access to the internal recess of the structure mount  34  and the ball  32  is available for ease of installation. 
     The method of mounting the ceiling fan kit  10  of  FIG. 1  to the ceiling comprises selecting one downrod  42 ,  44  from the downrod set  40  and selecting one canopy  22 ,  24  from the canopy set  20  based upon the selected downrod  42 ,  44 . The structure mount  34  is attached to the ceiling. The wiring harness  50  is inserted within the selected downrod  42 ,  44 , which mounts to the downrod coupler  36 . The ball  32  slides up the selected downrod  42 ,  44  until it abuts the downrod coupler  36 . 
     The modular fan assembly  60  is combined such that the motor wires  68  extend out of the motor coupler  64 . Opposite of the downrod coupler  36 , one connector  52  of the wiring harness  50 , extending from inside the selected downrod  42 ,  44 , couples to the motor wires  68  and the selected downrod  42 ,  44  couples to the motor coupler  64 . The other connector  52  of the wiring harness  50  extends through and out of the ball  32 . 
     The selected canopy  22 ,  24  is positioned about the selected downrod  42 ,  44 . If the selected canopy  22 ,  24  is the non-adjustable length canopy  22 , it may be slid down the selected downrod  42 ,  44  until abutting the modular fan assembly  60 . If the selected canopy is the adjustable length canopy  24 , the lower member  24   b  rests on the canopy rest  92  within the groove  96 , while the reduced portion  28  of the upper member  24   a  is telescopically slid within the lower member  24   b . In either case, after positioning the selected canopy  22 ,  24 , the ball  32  is positioned within the seat  86  of the structure mount  34 , mounting the downrod coupler  36  to the structure mount  34 . The connector  52  extending through the ball  32  couples the wiring  54  to an electrical supply, providing electrical connectivity to the motor  70 . 
     If the selected canopy  22 ,  24  is the non-adjustable length canopy  22 , it is slid up the selected downrod  42 ,  44  and coupled to the structure mount  34 , covering the structure mount  34  and resting flush against the ceiling. If the selected canopy  22 ,  24  is the adjustable length canopy  24 , most of the upper member  24   a  is telescopically slid out of the lower member  24   b , while remaining only partially within the lower member  24   b , and couples to the structure mount  34 , covering the structured mount  34  and resting flush against the ceiling. 
     Turning now to  FIG. 7 , a flowchart depicting the steps comprising a method  108  of mounting the ceiling fan kit is shown. At  110 , an installer selects a downrod from a set of downrods including at least a first downrod and a second downrod where the second downrod is longer than the first. At  112 , the installer selects a canopy based on the selected downrod from  110 . The selected canopy of  112  is selected from a set of canopies including at least one adjustable length canopy and on non-adjustable length canopy. 
     At  114 , the installer mounts the selected downrod to a downrod coupler, and, at  116 , the installer positions the selected canopy about the selected downrod. At  118 , the installer mounts the selected downrod to a fan assembly and at  120 , the installer mounts the downrod coupler to a structure mount. In additional methods for mounting the ceiling fan kit,  116  and  118  may be completed in any order as a particular fan assembly may require. The fan assembly of  118  can be the combined modular fan assembly  60  of  FIG. 1 . The structure mount of  120  can be already attached to the ceiling, where mounting the downrod coupler to the structure mount, mounts the fan assembly to the ceiling. 
     The method  108  of mounting the kit, may comprise selecting the first downrod at  110  and selecting the adjustable length canopy at  112 , wherein mounting the first downrod and adjustable length canopy in  114  through  120  comprises a low-profile mount. The method  108  may also comprise selecting the second downrod at  110  and selecting the non-adjustable length canopy at  112 , wherein mounting the second downrod and the non-adjustable length canopy in  114  through  120  comprises a traditional-profile mount. 
     In the aforementioned, ceiling fan elements or combinations thereof are accommodating of either downrod  42 ,  44 , and either canopy  22 ,  24  in any combination utilizing at least one downrod  42 ,  44  and at least one canopy  22 ,  24 . The elements of the downrod set  40  and the canopy set  20  are modularly interchangeable with other elements of the ceiling fan kit  10 . 
     The ceiling fan kit as previously described may come in different configurations. For example, one configuration that is suitable when the fan assembly is not needed, may have a first downrod and second downrod longer than the first, adjustable and non-adjustable length canopies, and a structure mount. In another configuration, the ceiling fan kit can include just an adjustable length canopy, which is extendable between a retracted and an extended length, and the shorter downrod, which kit would be suitable for a low-profile mount. In such a configuration, the adjustable length canopy may comprise telescoping segments. The adjustable length canopy may have an extended length that is greater than the length of the shorter downrod. 
     Any of the kit configurations may further include a downrod coupler to retain a first end of either downrod to the structure mount. The downrod coupler may comprise a ball, mounting a first end of either downrod. The structure mount may be configured to mount to a structure and further comprise a mounting bracket to retain the ball. 
     Any of the kit configurations may further comprise a fan motor assembly to securely mount to a second end of the either downrod, opposite of the first end. The fan motor assembly may comprise at least one fan blade configured to mount to the fan motor. 
     The method of mounting the ceiling fan kit, consists of steps comprising selecting a downrod from at least a first downrod and a second downrod being longer than the first, selecting either an adjustable length canopy or nonadjustable length canopy based upon selection of the downrod, mounting the selected downrod to a downrod coupler, positioning the selected canopy about the selected downrod, and mounting the downrod to a fan assembly. The aforementioned method is but one method for mounting the ceiling fan kit, and has natural variations comprising steps in varying orders or combinations, or including additional steps. 
     In one variation, the method may comprise selecting the adjustable length canopy when the selected downrod is the first downrod. In another, the method may comprise selecting the non-adjustable length canopy when the selected downrod is the second downrod. 
     In a further variation, the method may comprise securing the downrod coupler to a structure mount. Securing the downrod to a structure mount may comprise placing a ball on the downrod coupler and within a complementary seat in the structure mount. The method may further comprise securing the selected canopy to the structure mount. 
     In another variation where the selected canopy is the adjustable length canopy, the method may further comprise extending the length of the canopy after securing the downrod coupler to the structure mount. Extending the length of the canopy may comprise extending telescoping segments of the adjustable length canopy. The adjustable length canopy can be secured to the structure mount after extending the length. 
     In yet another separate variation, where the non-adjustable length canopy is selected, the non-adjustable length canopy can be slid along the selected downrod until a portion of the non-adjustable length canopy is adjacent to the structure mount. Further, the non-adjustable length canopy can be secured to the structure mount. 
     As may be appreciated, this ceiling fan kit and method of mounting thereof solves problems associated with installing a ceiling fan designed for a specific ceiling height on another ceiling height. Additionally, an installer wishing to move a ceiling fan from one ceiling to another will be able to do so quickly and efficiently, regardless of differences among ceiling heights or designs. Having multiple selectable downrods as well as complementary canopies gives the installer options for different ceiling types rather than a single ceiling type. 
     Additionally, problems associated with using a non-adjustable canopy in a low profile environment are solved utilizing an adjustable length canopy, enabling easy internal electrical or mechanical connections to be made without interference from the canopy. The adjustable length canopy enables an installer to extend or retract the canopy for installation purposes, such as mechanical or electrical connections, while maintaining an aesthetically pleasing cover over the structure mount, ceiling hole, and electrical box after installation. 
     It should be understood that as used herein the term “ceiling” of a structure is intended to include not only the conventional ceiling of a building or house, but also any other structure, which can support a ceiling fan such as an exposed beam, post, or the like. 
     While the invention has been described in connection with certain specific embodiments thereof, it is to be understood that this is by way of illustration and not of limitation. Reasonable variation and modification are possible within the scope of the forgoing disclosure and drawings without departing from the spirit of the invention, which is defined in the appended claims.