Patent Publication Number: US-11649831-B2

Title: Ceiling fan with mounting assembly

Description:
CROSS-REFERENCE TO RELATED APPLICATION(S) 
     This application claims priority to and is a continuation of U.S. patent application Ser. No. 16/738,002, filed Jan. 9, 2020, currently allowed, the entirety of which is incorporated herein by reference. 
    
    
     BACKGROUND 
     Ceiling fans are machines typically suspended from a structure for moving a volume of air about an area. While the structure to which the ceiling fan is mounted is typically a ceiling or part of a ceiling, such as a joist or beam, the structure can be a wall or any other structure for that matter. 
     The ceiling fan includes a motor, with a rotor and stator, suspended from and electrically coupled to the structure. A set of blades mount to the rotor such that the blades are rotatably driven by the rotor and can be provided at an angled orientation to move a volume of air about the area. 
     A common ceiling mount is a ball-and-socket or ball mount has the advantage of permitting the ceiling fan to pivot relative to the ceiling in response to a reaction force from the rotating blades. A disadvantage of the ball mount is that if the ball is not rotationally constrained, the ceiling fan can precess about the rotational axis, which can interfere with wires and the like that extend through the ceiling and into the ceiling fan via the mount. Ball mounts are, thus, typically rotational constrained to prevent precession, which limits the ball amount to one degree of rotational freedom. 
     BRIEF DESCRIPTION 
     In one aspect, the disclosure relates to a ceiling fan mount assembly for suspending a ceiling fan from a surface, the ceiling fan mount assembly comprising: a downrod; a mounting bracket including a seat; and a dual axis gimble for connecting the downrod to the mounting bracket, wherein the dual axis gimble comprises: an outer hanger ball positioned within the seat of the mounting bracket; and an inner hanger ball positioned within and rotatably connected to the outer hanger ball, and with the inner hanger ball coupled to the downrod. 
     In another aspect, the disclosure relates to a mount kit for connecting a ceiling fan to a surface, the mount kit comprising: a downrod; a mounting bracket including a seat; and a dual axis gimble for connecting the downrod to the mounting bracket, wherein the dual axis gimble comprises: an outer hanger ball sized to position within the seat of the mounting bracket, and the outer hanger ball including an interior; and an inner hanger ball sized to position within the interior of the outer hanger ball, and with the inner hanger ball coupled to the downrod. 
     In another aspect, the disclosure relates to a mount kit for connecting a ceiling fan to a surface, the mount kit comprising: a downrod; a mounting bracket; and a dual axis gimble for connecting the downrod to the mounting bracket, wherein the dual axis gimble comprises: an outer hanger ball configured to couple to the mounting bracket; and an inner hanger ball sized to position within the outer hanger ball, and with the inner hanger ball including an opening sized to receive the downrod. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       In the drawings: 
         FIG.  1    is a schematic view of a structure with a ceiling fan assembly suspended from a structure and including a ceiling fan mount. 
         FIG.  2    is an exploded view of the ceiling fan mount of  FIG.  1    illustrating a dual axis gimble. 
         FIG.  3    is a partially exploded perspective view of the dual axis gimble and a downrod of  FIG.  2   . 
         FIG.  4    is an assembled perspective view of the dual axis gimble of  FIG.  3    and the downrod. 
         FIG.  5    is a perspective view of the assembled dual axis gimble of  FIG.  4    seated in a mounting bracket. 
     
    
    
     DETAILED DESCRIPTION 
     The disclosure is related to a ceiling fan and ceiling fan blade, which can be used, for example, in residential and commercial applications. Such applications can be indoors, outdoors, or both. While this description is primarily directed toward a residential ceiling fan, it is also applicable to any environment utilizing fans or for cooling areas utilizing air movement. 
     As used herein, the term “set” or a “set” of elements can be any number of elements, including only one. All directional references (e.g., radial, axial, proximal, distal, upper, lower, upward, downward, left, right, lateral, front, back, top, bottom, above, below, vertical, horizontal, clockwise, counterclockwise, upstream, downstream, forward, aft, etc.) are only used for identification purposes to aid the reader&#39;s understanding of the present disclosure, and do not create limitations, particularly as to the position, orientation, or use of aspects of the disclosure described herein. Connection references (e.g., attached, coupled, connected, and joined) are to be construed broadly and can include intermediate members between a collection of elements and relative movement between elements unless otherwise indicated. As such, connection references do not necessarily infer that two elements are directly connected and in fixed relation to one another. The exemplary drawings are for purposes of illustration only and the dimensions, positions, order and relative sizes reflected in the drawings attached hereto can vary. 
     Referring now to  FIG.  1   , a ceiling fan assembly  10  is suspended from a structure  12 . In non-limiting examples, the ceiling fan assembly  10  can include one or more ceiling fan components including a ceiling fan mount  14  with a downrod  18 , a canopy  16 , a motor adapter  20 , a motor housing  22  at least partially encasing a motor  24  having a rotor  26  and a stator  28 , a light kit  30 , a set of blade irons  32 , and a set of blades  42 . In additional non-limiting examples, the ceiling fan assembly  10  can include one or more of a controller, a wireless receiver, a light glass, a light cage, a spindle, a finial, a switch housing, blade forks, blade tips or blade caps, or other ceiling fan components. 
     The downrod  18  can have a first end  34  and second end  36 . The first end  34  of the downrod  18  can be coupled to the motor  24 . Alternatively, the first end  34  of the downrod  18  can be configured to couple to at least one component of a ceiling fan. The second end  36  of the downrod  18  can be coupled to at least a dual axis gimble. While the at least dual axis gimble illustrated as a dual axis gimble  38 , it is contemplated that the at least dual axis gimble can be a three axis gimble. The dual axis gimble  38  is a pivoted support that allows the rotation of an object about two axes, providing at least two degrees of rotational freedom. 
     At least one fan blade  42  can be carried by the rotor  26 . For example, the at least one fan blade  42  can extend radially from the ceiling fan assembly  10 , and can be rotatable to drive a volume of fluid such as air. That is, the at least one fan blade  42  can be operably coupled to the motor  24  at the rotor  26 , such as via the blade irons  32 . The at least one fan blade  42  can include a set of blades  42 , having any number of blades, including only one blade. 
     The structure  12  can be a ceiling, for example, from which the ceiling fan assembly  10  is suspended. It should be understood that the structure  12  is schematically shown and is by way of example only, and can include any suitable building, structure, home, business, or other environment wherein moving air with a ceiling fan is suitable or desirable. The structure  12  can also include an electrical supply  44  and can electrically couple to the ceiling fan assembly  10  to provide electrical power to the ceiling fan assembly  10  and the motor  24  therein. It is also contemplated that the electrical supply be sourced from somewhere other than the structure  12 , such as a battery or generator in non-limiting examples. 
     A controller  46  can be electrically coupled to the electrical supply  44  to control operation of the ceiling fan assembly  10  via the electrical supply  44 . Alternatively, the controller  46  can be wirelessly or communicatively coupled to the ceiling fan assembly  10 , configured to control operation of the ceiling fan assembly  10  remotely, without a dedicated connection. Non-limiting examples of controls for the ceiling fan assembly  10  can include fan speed, fan direction, or light operation. Furthermore, a separate wireless controller  48 , alone or in addition to the wired controller  46 , can be communicatively coupled to a controller or a wireless receiver in the ceiling fan assembly  10  to control operation of the ceiling fan assembly  10 . It is further contemplated in one alternative example that the ceiling fan be operated by the wireless controller  48  alone, and is not operably coupled with the wired controller  46 . 
     Referring to  FIG.  2   , the ceiling fan mount  14  and the canopy  16  are illustrated in an exploded view. The ceiling fan mount  14  can include the downrod  18 , the dual axis gimble  38 , and a mounting bracket  50 . The ceiling fan mount  14  can couple to or further include the canopy  16 . The canopy  16  can be a decorative cover to encase or hide at least a portion of the ceiling fan mount  14 . The canopy  16  can include a shell portion  54  that can secure to a first plate  56  or a second plate  58 . The second plate  58  can fasten to the mounting bracket  50 . By way of non-limiting example, casing fasteners  60  and casing fastener plates  62  can couple the second plate  58  to the mounting bracket  50 . The second plate  58  can couple to the first plate  56 , which can abut the structure  12 , therefore configuring the mounting bracket  50  to mount to the structure  12 . The shell portion  54  of the canopy  16  can slidably receive the downrod  18 . When positioned, the shell portion  54  can circumscribe the mounting bracket  50  and can fasten to at least the second plate  58 . 
     The dual axis gimble  38  is illustrated, by way of example, as having a ball-in-a-ball structure, however, all dual axis gimble structures are contemplated. The dual axis gimble  38  can include an outer hanger ball or first hanger ball  70  and an inner hanger ball or second hanger ball  72 . A second shaft  74  can pivotally couple the second hanger ball  72  to the second end  36  of the downrod  18 . 
     The mounting bracket  50  can include a seat  76  supported by a collar  78 . The collar  78  can receive the dual axis gimble  38  via a side opening  80 . A first shaft  82  can pivotally couple the first hanger ball  70  of the dual axis gimble  38  to the mounting bracket  50 . 
     Optionally, a fixing bar  84  can be secured to the mounting bracket  50  once the dual axis gimble  38  is seated in the seat  76  of the mounting bracket  50 . The fixing bar  84  can be secured with fasteners  86 . 
       FIG.  3    further illustrates the downrod  18  coupled to the second hanger ball  72  of the dual axis gimble  38 . A downrod passage  88  formed in the second hanger ball  72  receives the second end  36  of the downrod  18  into an interior portion  90  of the second hanger ball  72 . The downrod  18  extends into the interior portion  90  until the second shaft  74  can pass through the second end  36  of the downrod  18  and the second hanger ball  72 . That is, the second shaft  74  passes through the second end  36  of the downrod  18  to operably connect the downrod  18  to the dual axis gimble  38 . Opposing ends  92  of the second shaft  74  can extend beyond an exterior portion  94  of the second hanger ball  72 . That is, the opposing ends  92  extend externally from the second hanger ball  72 . 
     An interior wall  96  of the first hanger ball  70  can include at least one recess, illustrated, by way of non-limiting example, as grooves  98 . At least a portion of the grooves  98  can include corresponding supports  100  for the opposing ends  92  of the second shaft  74 . That is, the second shaft  74  rotatably connects the second hanger ball  72  to the first hanger ball  70  when the opposing ends  92  of the second shaft  74  are located in the corresponding supports  100  in the grooves  98  of the first hanger ball  70 , further illustrated in  FIG.  4   . 
     It is a matter of convenience that the opposing ends  92  of the second shaft  74  are used to mount the downrod  18  to the second hanger ball  72  while simultaneously providing nubs forming the opposing ends  92  to be received within the grooves  98  of the first hanger ball  70 . It is contemplated that the second end  36  of the downrod  18  can fasten or otherwise couple to the first hanger ball  70  in a variety of ways. By way of non-limiting example, pins, nubs, or protrusions from the first or second hanger ball,  70 ,  72  could extend into the downrod  18 . The pins, nubs, or protrusions need not be aligned with, formed by, or coupled to the second shaft  74 . 
     While the coupling of the first and second hanger balls  70 ,  72  is disclosed as the seating of opposing ends  92  in the corresponding supports  100 , it is contemplated that the first and second hanger balls  70 ,  72  can be coupled using any known technique. By way of non-limiting example, pins, nubs, or protrusions from the first hanger ball  70  can extend into a recess or receiving portion of the second hanger ball  72 . 
     Referring to  FIG.  4   , when the second hanger ball  72  is rotatably connected to the first hanger ball  70 , the second hanger ball  72  is located with an interior  102  of the first hanger ball  70  defined by the interior wall  96 . That is, the first hanger ball  70  circumscribes the second hanger ball  72  when the dual axis gimble  38  is assembled. 
     An inner rotational axis  104  is defined by the rotatable connection of the first and second hanger balls  70 ,  72 . That is, the inner rotational axis  104 , as illustrated by way of example, can be formed by the second shaft  74 . 
     As illustrated, by way of non-limiting example, opposing ends of the first shaft  82  of the first hanger ball  70  can include two pins  106  that extend from an exterior  108  of the first hanger ball  70 . The two pins  106  can extend from diametrically opposite portions of the first hanger ball  70 . 
       FIG.  5    further illustrates the dual axis gimble  38  located in the seat  76  of the mounting bracket  50 . A first shaft  82  rotatably connects the dual axis gimble  38  to the mounting bracket  50 . 
     Supports  110  in the mounting bracket  50  can receive the two pins  106  of the first shaft  82 . The first hanger ball  70  of the dual axis gimble  38  is located in the seat  76  of the mounting bracket  50  when the two pins  106  are located in the supports  110 . Therefore, the first hanger ball  70  is rotationally mounted to the mounting bracket  50  via the first shaft  82 . 
     An external rotational axis  112  is defined by the rotatable connection of the first hanger ball  70  and the mounting bracket  50 . That is, the external rotational axis  112 , as illustrated by way of example, can be formed by the two pins  106 . 
     The external rotational axis  112  and the inner rotational axis  104  provide a first and second rotational axes for the dual axis gimble  38 . As illustrated, by way of non-limiting example, the external rotational axis  112  and the inner rotational axis  104  can be in a same plane  116 . That is, the plane  116  can be defined by the external rotational axis  112  and the inner rotational axis  104 . 
     Further illustrated, by way of non-limiting example, the external rotational axis  112  and the inner rotational axis  104  cross or intersect at a point  114 . The point  114  can be located at the geometric center or the center of mass of the second shaft  74  in the plane  116 . An angle  118  measured between the external rotational axis  112  and the inner rotational axis  104  can be 90 degrees, however other angles are contemplated. 
     A non-limiting example of assembly of the ceiling fan mount  14  and canopy  16  can begin with the second plate  58  coupled to the mounting bracket  50  via the casing fasteners  60  and the casing fastener plates  62 . The first plate  56  can then be coupled to the second plate  58 . 
     The second end  36  of the downrod  18  slides through the downrod passage  88  in the second hanger ball  72 . The second end  36  of the downrod  18  protrudes into the interior portion  90  of the second hanger ball  72  until the second shaft  74  can extend or pass through the second hanger ball  72  and the second end  36  of the downrod  18 . The second shaft  74  has opposing ends  92  that protrude from the exterior portion  94  of the second hanger ball  72 . The opposing ends  92  of the second shaft  74  can enter the grooves  98  of the first hanger ball  70 . Once the opposing ends  92  of the second shaft  74  are located in the corresponding supports  100 , the first and second hanger balls  70 ,  72  are rotatably connected by the second shaft  74 . The second shaft  74  forms the inner rotational axis  104  of the dual axis gimble  38 . 
     The dual axis gimble  38  enters the mounting bracket  50  through the side opening  80  of the collar  78 . The dual axis gimble  38 , once inside the mounting bracket  50  is properly positioned or seated by the reception of the two pins  106  extending from the first hanger ball  70  by the supports  110  of the mounting bracket  50 . That is, when the first hanger ball  70  is located in the seat  76 , the first hanger ball  70  is rotatably connected to the mounting bracket  50  via the first shaft  82 . The seating of the dual axis gimble  38  in the seat  76  provides a connection between the second end  36  of the downrod  18  and the mounting bracket  50 . The first shaft  82  can define the external rotational axis  112  of the dual axis gimble  38 . 
     Optionally, the fixing bar  84  can be coupled to the mounting bracket  50  once the dual axis gimble  38  is seated. The fasteners  86  can be used to fasten the fixing bar  84  to the mounting bracket  50 . The fixing bar  84  can encourage the dual axis gimble  38  to remain properly positioned in the seat  76 . 
     The shell portion  54  can then be placed on the first end  34  of the downrod  18  so that the shell portion  54  circumscribes the downrod  18 . The shell portion  54  can then slide on the downrod  18  towards the first or second plates  56 ,  58 . Once fastened, the shell portion  54  will encase the mounting bracket  50 . 
     In operation, the assembled ceiling fan mount  14  with the canopy  16  can be coupled to the structure  12 . The dual axis gimble  38  can rotate on the first and second shafts  74 ,  82  that define the inner rotational axis  104  and the external rotational axis  112 . Rotation about the inner and external rotational axes  104 ,  112  can adjust the downrod  18  so that the ceiling fan assembly  10  remains level regardless of the structure  12  to which it is mounted. The inner and external rotational axis  104 ,  112  provide two degrees of rotational freedom. This gives increases the flexibility in mounting the ceiling fan assembly  10 , while preventing precession of the ceiling fan assembly  10 . 
     Benefits of aspects of the present disclosure include a providing at least two rotational axes about which the ceiling fan assembly can pivot when coupled to the surface. 
     Further, the at least dual axis gimble, when positioned in the seat, can help limit the movement of the downrod and motor housing, especially during operation. This is beneficial as, when in operation, inertia of the rotating blades can otherwise cause an unbalance or unwanted movement of the ceiling fan if too much rotation is allowing the ceiling fan mount. 
     Another benefit of the disclosure includes a reduction or elimination of reactionary forces when the inner and external rotational axes are located in the same plane with the point of intersection at the center of the second shaft. Reactionary forces are generated when a fan is running and supported by a mount that allows two-dimensional rotation where the axes of the two-dimensional rotation are not in the same plane. Reactionary forces can cause the fan to tilt when running. 
     To the extent not already described, the different features and structures of the various features can be used in combination as desired. That one feature is not illustrated in all of the aspects of the disclosure is not meant to be construed that it cannot be, but is done for brevity of description. Thus, the various features of the different aspects described herein can be mixed and matched as desired to form new features or aspects thereof, whether or not the new aspects or features are expressly described. All combinations or permutations of features described herein are covered by this disclosure. 
     This written description uses examples to detail the aspects described herein, including the best mode, and to enable any person skilled in the art to practice the aspects described herein, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the aspects described herein are defined by the claims, and can include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal languages of the claims. 
     Further aspects of the invention are provided by the subject matter of the following clauses: 
     A ceiling fan assembly that include a motor having a rotor and a stator, at least one fan blade operably coupled to the rotor, a downrod having first and second ends, with the first end coupled to the motor, a mounting bracket, and at least a dual axis gimble connecting the second end of the downrod to the mounting bracket. 
     The ceiling fan assembly of clause 1 where the mounting bracket comprises a seat and the dual axis gimble is located in the seat. 
     The ceiling fan assembly of any preceding clause wherein the dual axis gimble comprises a first hanger ball located in the seat. 
     The ceiling fan assembly of any preceding clause wherein the first hanger ball includes a first shaft rotationally connecting the first hanger ball to the mounting bracket to define a first rotational axis for the dual axis gimble. 
     The ceiling fan assembly of any preceding clause wherein the first shaft comprises two pins extending from diametrically opposite portions of the first hanger ball. 
     The ceiling fan assembly of any preceding clause wherein the dual axis gimble further comprises a second hanger ball located with an interior of the first hanger ball. 
     The ceiling fan assembly of any preceding clause wherein the second hanger ball is rotationally coupled to the first hanger ball to define a second rotational axis for the dual axis gimble. 
     The ceiling fan assembly of any preceding clause wherein the second hanger ball comprises a second shaft rotationally connecting the second hanger ball to the first hanger ball, with the second shaft forming the second rotational axis. 
     The ceiling fan assembly of any preceding clause wherein the second shaft passes through the second end of the downrod to operably connect the downrod to the dual axis gimble. 
     The ceiling fan assembly of any preceding clause wherein the second shaft passes through the second hanger ball. 
     The ceiling fan assembly of any preceding clause wherein the second shaft has opposing ends extending externally of the second hanger ball, and the opposing ends are rotationally supported by corresponding supports in the first hanger ball. 
     The ceiling fan assembly of any preceding clause wherein the second hanger ball comprises a downrod passage in which the second end of the downrod is received. 
     The ceiling fan assembly of any preceding clause wherein the mounting bracket comprises a collar supporting the seat and the collar has a side opening through which the first hanger ball is received. 
     The ceiling fan assembly of any preceding clause wherein the mounting bracket includes supports in which opposing ends of the first shaft are rotationally supported. 
     A ceiling fan mount for connecting a ceiling fan to a surface that includes a downrod having first and second ends, with the first end configured to couple to the ceiling fan, a mounting bracket configured to mount to the surface, and at least a dual axis gimble connecting the second end of the downrod to the mounting bracket. 
     The ceiling fan mount of any preceding clause wherein the mounting bracket comprises a seat and the dual axis gimble is received in the seat. 
     The ceiling fan mount of any preceding clause wherein the dual axis gimble comprises an inner hanger ball rotatably mounted to an outer hanger ball, which is rotatably mounted to the mounting bracket. 
     The ceiling fan mount of any preceding clause wherein the second end of the downrod is mounted to the inner hanger ball. 
     The ceiling fan mount of any preceding clause further comprising a first shaft rotationally mounting the outer hanger ball to the mounting bracket. 
     The ceiling fan mount of any preceding clause further comprising a second shaft mounting the second end of the downrod to the inner hanger ball and rotationally mounting the inner hanger ball to the outer hanger ball.