Patent Publication Number: US-7588420-B2

Title: Customized fan blade and method of making same

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The present invention relates to fans. 
     More particularly, this invention relates to fans of the type commonly employed to circulate air. 
     In a further and more specific aspect, the instant invention concerns a fan blade which can be readily and easily customized to accommodate the aesthetic considerations of the user. 
     2. The Prior Art 
     Fans are commonly employed to circulate air within a residence, a restaurant, an office or other structure. Common place are fans that are mounted in a horizontal configuration and fans that are mounted in a vertical configuration. Horizontally mounted fans, commonly referred to as ceiling fans, are generally suspended from an overhead by a shaft or chain. Vertical fans, commonly referred to floor mounted fans, are generally carried upon a stanchion. 
     Regardless of the mounting configuration, fans, as will be readily recognized by those skilled in the art and by users, include a motor, a hub rotatably driven by the motor and a blade assembly carried by the hub. The typical blade assembly includes a blade iron secured to the hub and having a distal end which supports the proximal end of a fan blade. For this purpose the distal end of the blade iron includes a surface for receiving the proximal end of the fan blade there against. The distal end of the blade iron also includes an arrangement of threaded bores for receiving screws which extend through corresponding openings in the proximal end of the fan blade. 
     Fan blades are typically fabricated of rigid sheet material such as wood or metal. Such blades tend to be rather prosaic and without aesthetic value. More recently, the prior art has attempted to enhance fan blades. The enhanced fan blades frequently require an especially fabricated frame that is not within the normal scope of the art of fan blade fabrication. Other enhanced fan blades provided by the prior art require especially fabricated blade irons. In general, the enhanced blades touted by the prior art are complex and expensive to manufacture. 
     It would be highly advantageous, therefore, the remedy the foregoing and other deficiencies inherent in the prior art. 
     SUMMARY OF THE INVENTION 
     The above problems and others are at least partially solved and the above objects and others realized in a method of fabricating a fan blade which comprises first providing a platen including a first side having an outwardly directed surface, a second side having a surface outwardly directed in opposition to the surface of the first side and a peripheral edge conjoining the sides. The method continues with overlaying strands upon one of the first and second sides. 
     The fan blade described above is for use in combination with a conventional fan having a motor, a hub rotatably driven by the motor and a blade iron extending from the hub and having a distal end to which the fan blade can be secured. 
     In accordance with the principles of the instant invention, the method continues by profiling the peripheral edge of the platen to correspond with a predetermined contour. Next is configuring the proximal end of the platen for attachment to the distal end of the blade iron. This is followed by forming openings in the proximal end of the platen to align with attachment openings in the distal end of the blade iron. 
     A further, in accordance with the principles of this invention, is dividing the strands into warp strands and woof strands. This is followed by interlacing the woof strands with the warp strands in accordance with a predetermined pattern. Extending the warp strands longitudinal of the platen or, alternately, extending the warp strands lateral of the platen are within the purview of the invention. 
     Within the scope of the present invention is encircling the strands over the peripheral edge onto the surface of the other of the first and second sides of the platen. Applying a coating to the strands is accomplished after the strands are placed upon one or more surfaces of the platen as desired. Fabricating the strands of cordage or, alternately, of osier is also within the teachings of this invention. 
     The fan blade constructed in accordance with the foregoing method includes a platen having a first side, a second side, a peripheral edge conjoining the sides and a proximal end adapted for attachment to the distal end of a blade iron. A plurality of strands is carried by the platen in juxtaposition with at least one of the first and second sides. The strands include a plurality of warp strands overlying at least one of the first and second sides of the platen and a plurality of woof strands interlaced with the warp strands in accordance with a predetermined pattern. 
     In accordance with the principles of the present invention, the strands encircle the peripheral edge to be received in juxtaposition with the other of the first and second sides of the platen. The warp strands extend longitudinally of the platen. Alternately, the warp strands extend laterally of the platen. 
     Further, in accordance with the principles of the instant invention, the peripheral edge of the platen is profiled to a predetermined pattern. The strands are fabricated of osier or, alternately, of cordage. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The foregoing, and further and more specific objects and advantages of the instant invention, will become readily apparent to those skilled in the art from the following detailed description of preferred embodiments thereof, taken in conjunction with the drawings, in which: 
         FIG. 1  is a perspective view of a skein of strands useful in connection with the instant invention; 
         FIG. 2  is a perspective view of a platen used in connection with the present invention; 
         FIG. 3  is a perspective view of the platen and the strands as would appear during an initial stage of fabricating a fan blade in accordance with a method of the invention; 
         FIG. 4  is a plan view showing the fan blade of  FIG. 3  as it would appear during an intermediate step of fabrication in accordance with a method of the instant invention; 
         FIG. 5  is a plan view of the fan blade of  FIG. 4 , is it would appear during a subsequent intermediate stage of fabrication; 
         FIG. 6  is a perspective of the fan blade of  FIG. 5  as it would appear during a final stage of the method of fabrication of the present invention; 
         FIG. 7  is a perspective view of the reverse side of the fan blade seen in  FIG. 6 ; and 
         FIG. 8  is perspective view of a fan blade seen during an optional final step in the method of this invention. 
     
    
    
     DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT 
     Turning now to the drawings in which like reference characters indicate corresponding element through out the several views, attention is first directed to  FIG. 1  is which is seen a skein  10  of strands  12 . Strands  12  may be of various materials. It is within the scope of the instant invention that strands  12  may be fabricated of osier, as exemplified by pliable twigs, willows, dogwood and bamboo. It is also within the teachings of this invention that strands  12  be fabricated of cordage. Exemplary is natural cordage, such as cotton and wool, and synthetic cordage, such as nylon and rayon. 
     Referring now to  FIG. 2 , there is seen a platen  13 . With momentary reference to  FIG. 6  and  FIG. 7 , it is seen that platen  13  includes first side surface  14  and second side surface  15 . The side surfaces  14  and  15  face outwardly in mutually opposing directions. Peripheral edge  17  extends about platen  13  and conjoins first side surface  14  and second side surface  15  and includes first longitudinal edge  18 , second longitudinal edge  19 , inner lateral edge  20  and outer lateral edge  22 . Platen  13  is further defined as having a proximal end  23  and a distal end  24 . Platen  13  may be fabricated of any rigid sheet material, such as wood, metal or composition. 
     An arrangement of openings  25  extend through platen  13  proximate proximal end  23 . As will be readily appreciated by those skilled in the art, a conventional fan includes a motor, a hub rotatably driven by the motor and several blade irons extending radially outward from the hub and terminating with a distal end. The distal end includes a receiving surface for receiving the proximal of a fan blade there against. The distal end of the blade iron also includes an arrangement of openings, such as threaded bores for receiving screws which secure the proximal end of the fan blade to the distal end of the blade iron. Openings  25  in platen  13  are sized and arranged to coincide with the attachment openings in the distal end of a conventional blade iron. 
     The contour of peripheral edge  17  of platen  13 , as seen in  FIG. 3 , was chosen herein for purposes of illustration. It is within the scope of the present invention that peripheral edge  17  can be profiled to a contour consistent with the aesthetic considerations of the user or owner. 
     Strands  12 , as viewed with reference to  FIG. 3 , are divided into warp strands  27  and woof strands  28 . Warp strands  27  are placed in juxtaposition with first side surface  14 , or alternately with second side surface  15 , of platen  13 . Woof strands  28  are then interlaced with warp strands  27 . The interlacing can be conventional weaving or in accordance with a predetermined pattern consistent with the desires of the owner or user. For purposes of illustration, warp strands  27  extend longitudinal of platen  13  and woof strands  28  extend lateral of platen  13 . Consistent with the teachings of the present invention, warp strands  27  may extend lateral of platen  13  and woof strands  28  extend longitudinal of platen  13 . It is also within the purview of this invention that warp strands  27  and woof strands  28  be placed diagonally of platen  13 . 
     The interlacing or weaving of woof strands  28  with warp strands  27  continues, as seen in  FIG. 4 , until the entire side surface  14  is covered to provide a customized fan blade  29  as viewed in  FIG. 5 . Consistent with the principles of the instant invention, the interlaced warp strands  27  and woof strands  28  may cover one surface of platen  13  or, alternately, encircle the peripheral edge  17  and continue to be interlaced over the other side surface of platen  13  to provide an alternate customized fan blade  30  as illustrated in  FIG. 6  and  FIG. 7 . If the interlaced warp strands  27  and woof strands  28  are confined to only one side of platen  13 , an adhesive is required to bond the strands to the respective side. 
     Attention is now directed to  FIG. 6 , in which it is seen that openings  25  are extended through the several strands  12 . Such extension may sever the strands. To prevent the severed strands from raveling, a ferrule or grommet  30  is inserted into each side of each opening  25  with the flange thereof captivating the loose ends of the severed strands. 
     If desired, as illustrated by spray gun  32  in  FIG. 8 , a finish may be applied to the customized fan blade  29 . The finish may be for preservation purposes, such as lacquer, or for color enhancing as by paint. 
     The present invention is described above with reference to a preferred embodiment. However, those skilled in the art will recognize that changes and modifications may be made in the described embodiment without departing from the nature and scope of the present invention. For example, while the preferred embodiment utilized a custom made platen, it is within the purview of the invention that the surface treatment and customizing features can be applied to a conventional, commercially available fan blade. Also, the woof strands can be interlaced with the warp strands in patterns other than those illustrated. 
     Various further changes and modifications to the embodiment herein chosen for purposes of illustration will readily occur to those skilled in the art. To the extent that such modifications and variations do not depart from the spirit of the invention, they are intended to be included within the scope thereof. 
     Having fully described the invention in such clear and concise terms as to enable those skilled in the art to understand and practice the same, the invention claimed is: