Patent Publication Number: US-2023160391-A1

Title: Ceiling fan and method for manufacturing ceiling fan blade

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This is a U.S. patent application which claims the priority and benefit of Chinese Patent Application Number 202111390402.3, filed on Nov. 23, 2021, the disclosure of which is incorporated herein by reference in its entirety. 
     TECHNICAL FIELD 
     The present disclosure relates to a ceiling fan and a method for manufacturing a ceiling fan blade. 
     BACKGROUND 
     Most of the fan blades of the existing ceiling fans are made of composite plates. This kind of composite plate fan blades has heavy weight and uses many materials, which will cause waste during processing. Moreover, this kind of composite plate fan blades cannot be recycled and reused after being damaged, which is not environmentally friendly. 
     The present disclosure just occurs based on the above shortcomings. 
     SUMMARY 
     The present disclosure aims to overcome the shortcomings of the prior art, and to provide a ceiling fan with simple structure and environment friendliness. 
     The present disclosure further provides a method for manufacturing a ceiling fan blade. 
     The present disclosure is implemented through the following technical scheme. 
     A ceiling fan includes a shell  1 , wherein an electric machine  2  is installed in the shell  1 , the electric machine  2  is connected with at least three connecting pieces  3 , and each of the connecting pieces  3  is detachably connected with a ceiling fan blade  4 , the ceiling fan blade  4  includes an inner core layer  41  made of a carbon-fiber material, an outside of the inner core layer  41  is connected with a blade main body layer  42  made of a molding pulp material, both upper and lower ends of the blade main body layer  42  are provided with a dampproof covering layer  43 , and an antistatic covering layer  44  is further arranged on an upper side of the blade main body layer  42 , the blade main body layer  42  is an aerofoil type blade, and the blade main body layer  42  includes an upper shell  421  and a lower shell  422  in clamping connection with the upper shell  421 , the upper shell  421  and the lower shell  422  are both hollow structures and a honeycomb structure  401  is arranged on the hollow portion of both the upper shell  421  and the lower shell  422 , a gap is formed between connecting surfaces of the upper shell  421  and the lower shell  422 , a sealing coating  423  is arranged in the gap, and a connecting spray coating  45  is sprayed on peripheral edges of the upper shell  421  and the lower shell  422 . 
     The lower shell  422  includes a lower connection plate  4221 , the lower connection plate  4221  is provided with a connecting protrusion  4222  and the lower connection plate  4221  is further provided with a plurality of protruded ribs  4223 , the upper shell  421  includes an upper connection plate  4211 , the upper connection plate  4211  is provided with a protrusion part  4212  and the protrusion part  4212  defines a fixing clamping groove  4213  capable of being fixed onto the rib  4223  in a clamping manner, the connecting protrusion  4222  and the protrusion part  4212  form the gap when the lower shell  422  and the upper connection plate  4211  are in clamping connection. 
     The upper shell  421  and the lower shell  422  both include a tabulate fixing part  51 , a tail edge of the fixing part  51  is connected with a blade part  52 , and between the fixing part  51  and the blade part  52  is arranged a transition part  53  allowing an oblique arrangement of the blade part  52  relative to the horizontal plane. 
     The transition part  53  is twisted from head to tail, such that one side of the blade part  52  is protruded upwards and the other side is protruded downwards, which makes the blade part  52  inclined towards a rotating direction. 
     The transition part  53  causes an inclined angle α in a range of 15-30 degrees between the blade part  52  and the horizontal plane. 
     An upper surface of the upper shell  421  near a tail part is provided with a protrusion  4214 , one side of the protrusion  4214  presents a cambered surface, and one side of the protrusion  4214  presents a vertical surface. 
     The connecting piece  3  is a connecting sheet, one end of the connecting sheet is fixed to the electric machine  2 , and between the other end of the connecting sheet and the ceiling fan blade  4  is arranged a quick installation structure  6  capable of connecting them. 
     The connecting piece  3  defines a plurality of connecting holes  31 , the ceiling fan blade  4  defines mounting holes  402  corresponding to the positions of the plurality of connecting holes  31 , the quick installation structure  6  includes a connecting pin  61  which can penetrate through the connecting piece  3  and the ceiling fan blade  4  at the same time, and the connecting pin  61  is connected with a clamping lock element  62  which, when clamped on the connecting pin  61 , can press against the connecting pin  61  and the surface of the ceiling fan blade  4  at the same time so as to fasten the ceiling fan blade  4  and the connecting piece  3 . 
     A rubber ring  403  is installed inside the mounting hole  402 , the rubber ring  403  defines in the middle a channel  4031  allowing the connecting pin  61  to pass through, both ends of the rubber ring  403  are provided with a protruded ring  4032 , between the two protruded rings  4032  is defined a meshing clamping groove  4033  which can fit the upper and lower surfaces of the ceiling fan blade  4  and can be meshed with the ceiling fan blade  4 , the clamping lock element  62  is a circular clamping lock sheet, the clamping lock sheet defines an opening clamping groove  621  allowing the connecting pin  61  to be clamped in, the clamping lock sheet at two ends of the opening clamping groove  621  is provided with an extension part  622  extending outwards, the extension part  622  defines a through hole  6221  allowing a quick installation tool to be inserted into, the opening of the opening clamping groove  621  can be expanded for the connecting pin  61  to be clamped in when a quick installation tool is inserted into the through hole  6221  and a force is applied, a head part of the connecting pin  61  presents an umbrella shape, the connecting pin  61  further defines a clamping lock groove  611  allowing the clamping lock element  62  to be clamped in, a diameter of the connecting pin  61  at the clamping lock groove  611  is less than other portions, and when the clamping lock sheet is clamped in the clamping lock groove  611 , upper and lower ends of the clamping lock sheet press against the rubber ring  403  and the inner wall of the connecting pin  61  respectively to as to fasten the connecting piece  3  and the ceiling fan blade  4 . 
     A method for manufacturing a ceiling fan blade includes the following steps of: 
     a. cutting a carbon fiber sheet along an outline of the ceiling fan blade to obtain an inner core layer  41 ; 
     b. importing a molding pulp into molds corresponding to an upper shell  421  and a lower shell  422  respectively to prepare an upper shell  421  and a lower shell  422 ; 
     c. hole-processing and groove-processing the inner core layer  41  and then brushing a glue over it and finally mounting it to the lower shell  422 ; 
     d. brushing a glue over corresponding fitting surfaces of the lower shell  422  and the upper shell  421  and then putting the upper shell  421  onto the lower shell  422 ; 
     e. sticking a dampproof covering layer  43  on outer surfaces of the upper shell  421  and the lower shell  422 ; 
     f. sticking an antistatic covering layer  44  on the outer surface of the upper shell  421 ; 
     g. spraying a connecting spray coating  45  along lateral surfaces of the upper shell  421  and the lower shell  422 . 
     Compared with the prior art, the present disclosure has the following advantages. The ceiling fan blade of the ceiling fan provided in the present disclosure is provided with the inner core layer. Since the inner core layer is a sheet made of a carbon-fiber material, two sides of the inner core layer are provided with the upper shell and the lower shell made of a molding pulp material, both the upper shell and the lower shell are hollow structures, and a honeycomb structure is arranged on the hollow portion, the weight of the whole ceiling fan blade can be reduced. In addition, the honeycomb structure is evenly distributed; therefore, the ceiling fan blade will have a more balanced rotation, without the occurrence of up-down offset and jitter. The inner core layer is connected to the upper shell and the lower shell using a strong glue, and the upper shell is connected to the lower shell using a strong glue too, which achieves secure fixing. The dampproof covering layer is stuck on surfaces of both the upper shell and the lower shell, to resist water and moisture. In addition, the antistatic covering layer is stuck on the surface of the upper shell, which can prevent the ceiling fan blade being stained with dust; meanwhile, the connecting spray coating also employs a glue to fasten the upper shell and the lower shell. If the ceiling fan blade is damaged, since the inner core layer is made of a carbon-fiber material and has a high compression resistance, the inner core layer can still be recycled and reused; furthermore, since the blade main body layer is made of a molding pulp material, it can still be recycled and reused even if damaged, which is more environmentally friendly. The whole ceiling fan to which the ceiling fan blade is connected has a lighter weight. It is convenient for a user to hang the ceiling fan. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG.  1    is a stereogram of a ceiling fan according to the present disclosure. 
         FIG.  2    is a sectional view of a ceiling fan blade of a ceiling fan according to the present disclosure. 
         FIG.  3    is a diagram of a lower shell of a ceiling fan according to the present disclosure. 
         FIG.  4    is a diagram of an upper shell of a ceiling fan according to the present disclosure. 
         FIG.  5    is a stereogram of a ceiling fan blade of a ceiling fan according to the present disclosure. 
         FIG.  6    is a plan view of a ceiling fan blade of a ceiling fan according to the present disclosure. 
         FIG.  7    is a stereogram of a ceiling fan blade and a connecting piece of a ceiling fan according to the present disclosure that are connected. 
         FIG.  8    is an exploded view of a ceiling fan blade and a connecting piece of a ceiling fan according to the present disclosure. 
         FIG.  9    is an enlarged view of part A shown in  FIG.  7   . 
         FIG.  10    is an explode view of a quick installation structure  6  according to the present disclosure. 
     
    
    
     DETAILED DESCRIPTION 
     The present disclosure is described below in further detail in combination with accompanying drawings. 
     As shown in  FIG.  1    to  FIG.  10   , the present disclosure provides a ceiling fan, including a shell  1 , wherein an electric machine  2  is installed in the shell  1 , the electric machine  2  is connected with at least three connecting pieces  3 , and each of the connecting pieces  3  is detachably connected with a ceiling fan blade  4 , the ceiling fan blade  4  includes an inner core layer  41  made of a carbon-fiber material, an outside of the inner core layer  41  is connected with a blade main body layer  42  made of a molding pulp material, both upper and lower ends of the blade main body layer  42  are provided with a dampproof covering layer  43 , and an antistatic covering layer  44  is further arranged on an upper side of the blade main body layer  42 , the blade main body layer  42  is an aerofoil type blade, and the blade main body layer  42  includes an upper shell  421  and a lower shell  422  in clamping connection with the upper shell  421 , the upper shell  421  and the lower shell  422  are both hollow structures and a honeycomb structure  401  is arranged on the hollow portion of both the upper shell  421  and the lower shell  422 , a gap is formed between connecting surfaces of the upper shell  421  and the lower shell  422 , a sealing coating  423  is arranged in the gap, and a connecting spray coating  45  is sprayed on peripheral edges of the upper shell  421  and the lower shell  422 . 
     The ceiling fan blade  4  of the ceiling fan provided in the present disclosure is provided with the inner core layer  41 . Since the inner core layer  41  is a sheet made of a carbon-fiber material, two sides of the inner core layer  41  are provided with the upper shell  421  and the lower shell  422  made of a molding pulp material, both the upper shell  421  and the lower shell  422  are hollow structures, and a honeycomb structure  401  is arranged on the hollow portion, the weight of the whole ceiling fan blade  4  can be reduced. In addition, the honeycomb structure  401  is evenly distributed; therefore, the ceiling fan blade will have a more balanced rotation, without the occurrence of up-down offset and jitter. The inner core layer  41  is connected to the upper shell  421  and the lower shell  422  using a strong glue, and the upper shell  421  is connected to the lower shell  422  using a strong glue too, which achieves secure fixing. The dampproof covering layer  43  is stuck on surfaces of both the upper shell  421  and the lower shell  422 , to resist water and moisture. In addition, the antistatic covering layer  44  is stuck on the surface of the upper shell  421 , which can prevent the ceiling fan blade  4  being stained with dust; meanwhile, the connecting spray coating  45  also employs a glue to fasten the upper shell  421  and the lower shell  422 . If the ceiling fan blade  4  is damaged, since the inner core layer  41  is made of a carbon-fiber material and has a high compression resistance, the inner core layer  41  can still be recycled and reused; furthermore, since the blade main body layer  42  is made of a molding pulp material, it can still be recycled and reused even if damaged, which is more environmentally friendly. The whole ceiling fan to which the ceiling fan blade  4  is connected has a lighter weight. It is convenient for a user to hang the ceiling fan. The antistatic covering layer is a paster coated with at least one of antistatic agent TM, octadecyl diethanolamine, PEG, methyl acrylate, polyethylene oxide and polyether ester amide. The dampproof covering layer  43  is one of a triamine polyester surface layer, a PVC wood grain veneer layer and a water transfer printing surface layer. The glue is PUR hot melt adhesive. The connecting spray coating  45  is RTV paint with waterproof and dampproof natures. The molding pulp is a pulp used for manufacturing pulp molded products, for example, the pulp with several additives mentioned in the paper “Research on strength properties of pulp molded products based on pulp additives” with the issue number of CNKI: SUN: SYHH.0.2020-01-033. 
     As shown in  FIG.  3    to  FIG.  4   , the lower shell  422  includes a lower connection plate  4221 , the lower connection plate  4221  is provided with a connecting protrusion  4222  and the lower connection plate  4221  is further provided with a plurality of protruded ribs  4223 , the upper shell  421  includes an upper connection plate  4211 , the upper connection plate  4211  is provided with a protrusion part  4212  and the protrusion part  4212  defines a fixing clamping groove  4213  capable of being fixed onto the rib  4223  in a clamping manner, the connecting protrusion  4222  and the protrusion part  4212  form the gap when the lower shell  422  and the upper connection plate  4211  are in clamping connection. The rib  4223  and the fixing clamping groove  4213  not only are used for distinguishing the lower shell  422  from the upper shell  421 , but also are matched and fixed to each other to enhance the overall support strength and stress strength of the blade main body layer  42 . 
     As shown in  FIG.  5    to  FIG.  6   , the upper shell  421  and the lower shell  422  both include a tabulate fixing part  51 , a tail edge of the fixing part  51  is connected with a blade part  52 , and between the fixing part  51  and the blade part  52  is arranged a transition part  53  allowing an oblique arrangement of the blade part  52  relative to the horizontal plane. The wind blown by the blade part  52  towards the underneath of the ceiling fan is in some angle, thus simulating the natural wind. Thus, the wind blown by the ceiling fan is softer and of wider range. 
     As shown in  FIG.  5    to  FIG.  6   , the transition part  53  is twisted from head to tail, such that one side of the blade part  52  is protruded upwards and the other side is protruded downwards, which makes the blade part  52  inclined towards a rotating direction. The transition part  53  causes an inclined angle α in a range of 15-30 degrees between the blade part  52  and the horizontal plane. The blade main body layer  42  is a large-area aerofoil type blade, and when the inclined angle α between the blade part  52  and the horizontal plane is set to be between 15 and 30 degrees, the air flow can be cut to be more delicate and soft and can be cut evenly and intensively, which better restores the softness and tenderness of the natural wind, and better suits the comfortable wind receiving point of the human body. Moreover, the ultra-far air supply distance of the blade main body layer  42  makes the cooling air from an air conditioner uniformly distributed in a room. 
     As shown in  FIG.  5   , an upper surface of the upper shell  421  near a tail part is provided with a protrusion  4214 , one side of the protrusion  4214  presents a cambered surface, and one side of the protrusion  4214  presents a vertical surface. The protrusion  4214  has the cambered surface protruded upwards, which cuts the air flow more smoothly, and then reduces the hindrance suffered by the tail part and reduces the noise the ceiling fan blade  4  causes when cutting the air flow. 
     As shown in  FIG.  7   , the connecting piece  3  is a connecting sheet, one end of the connecting sheet is fixed to the electric machine  2 , and between the other end of the connecting sheet and the ceiling fan blade  4  is arranged a quick installation structure  6  capable of connecting them. The quick installation structure  6  is provided for a user to perform quick installation. 
     As shown in  FIG.  8    and  FIG.  9   , the connecting piece  3  defines a plurality of connecting holes  31 , the ceiling fan blade  4  defines mounting holes  402  corresponding to the positions of the plurality of connecting holes  31 , the quick installation structure  6  includes a connecting pin  61  which can penetrate through the connecting piece  3  and the ceiling fan blade  4  at the same time, and the connecting pin  61  is connected with a clamping lock element  62  which, when clamped on the connecting pin  61 , can press against the connecting pin  61  and the surface of the ceiling fan blade  4  at the same time so as to fasten the ceiling fan blade  4  and the connecting piece  3 . 
     As shown in  FIG.  8    to  FIG.  10   , a rubber ring  403  is installed inside the mounting hole  402 , the rubber ring  403  defines in the middle a channel  4031  allowing the connecting pin  61  to pass through, both ends of the rubber ring  403  are provided with a protruded ring  4032 , between the two protruded rings  4032  is defined a meshing clamping groove  4033  which can fit the upper and lower surfaces of the ceiling fan blade  4  and can be meshed with the ceiling fan blade  4 , the clamping lock element  62  is a circular clamping lock sheet, the clamping lock sheet defines an opening clamping groove  621  allowing the connecting pin  61  to be clamped in, the clamping lock sheet at two ends of the opening clamping groove  621  is provided with an extension part  622  extending outwards, the extension part  622  defines a through hole  6221  allowing a quick installation tool to be inserted into, the opening of the opening clamping groove  621  can be expanded for the connecting pin  61  to be clamped in when a quick installation tool is inserted into the through hole  6221  and a force is applied, a head part of the connecting pin  61  presents an umbrella shape, the connecting pin  61  further defines a clamping lock groove  611  allowing the clamping lock element  62  to be clamped in, a diameter of the connecting pin  61  at the clamping lock groove  611  is less than other portions, and when the clamping lock sheet is clamped in the clamping lock groove  611 , upper and lower ends of the clamping lock sheet press against the rubber ring  403  and the inner wall of the connecting pin  61  respectively to as to fasten the connecting piece  3  and the ceiling fan blade  4 . The connecting piece  3  is a fan blade pin. When connect the fan blade pin to the ceiling fan blade  4 , first install the rubber ring  403  in the mounting hole  402  of the ceiling fan blade  4 , such that the rubber ring  403  can be meshed with the side wall of the mounting hole  402 , then align the ceiling fan blade  4  to the connecting hole  31  on the connecting piece  3 , now the channel  4031  on the rubber ring  403  is aligned to the connecting hole  31 , next make the connecting pin  61  pass through the connecting hole  31  and the channel  4031  in turn and make the clamping lock groove  611  exposed to one side of the ceiling fan blade  4 , and insert a circlip plier into the through hole  6221  on the extension part  622  and press the circlip plier, now the circlip plier expands the groove opening of the opening clamping groove  621  of the clamping lock element  62 , then clamp the clamping lock element  62  in the clamping lock groove  611  of the connecting pin  61  and finally loosen the hand. Since the clamping lock element  62  has a deformation capability, the clamping lock element  62  can be meshed on the connecting pin  61  through the circumferential surface of the opening clamping groove  621  when reset, now the upper and lower ends of the clamping lock element  62  press against the rubber ring  403  and the inner wall of the connecting pin  61  respectively to as to fasten the connecting piece  3  and the ceiling fan blade  4 . 
     In another aspect, the present disclosure further provides a method for manufacturing a ceiling fan blade, including the following steps of: 
     a. cutting a carbon fiber sheet along an outline of the ceiling fan blade to obtain an inner core layer  41 ; 
     b. importing a molding pulp into molds corresponding to an upper shell  421  and a lower shell  422  respectively to prepare an upper shell  421  and a lower shell  422 ; 
     c. hole-processing and groove-processing the inner core layer  41  and then brushing a glue over it and finally mounting it to the lower shell  422 ; 
     d. brushing a glue over corresponding fitting surfaces of the lower shell  422  and the upper shell  421  and then putting the upper shell  421  onto the lower shell  422 ; 
     e. sticking a dampproof covering layer  43  on outer surfaces of the upper shell  421  and the lower shell  422 ; 
     f. sticking an antistatic covering layer  44  on the outer surface of the upper shell  421 ; 
     g. spraying a connecting spray coating  45  along lateral surfaces of the upper shell  421  and the lower shell  422 .