Patent Publication Number: US-7217098-B2

Title: Tower fan assembly

Description:
RELATED CASES 
   This is a continuation-in-part of Ser. No. 10/727,748, filed Dec. 3, 2003, now U.S. Pat. No. 6,953,322 entitled “Tower Fan Assembly”, whose entire disclosure is incorporated by this reference as though set forth fully herein. 

   BACKGROUND OF THE INVENTION 
   1. Field of the Invention 
   The present invention relates to a fan assembly, and in particular, to a tower fan assembly. 
   2. Description of the Related Art 
   Numerous conventional fan assemblies are readily available in the marketplace. Tower fan assemblies are particularly desirable because of their ability to quickly circulate a large amount of air in a small area. Most conventional tower fans have an outer housing that oscillates together with the blower. Unfortunately, an oscillating outer housing can pose safety concerns, especially to children and pets. 
   Another drawback that is frequently experienced by conventional tower fan assemblies is that the oscillating blower and outer housing wobbles because almost the entire fan assembly sits on a single shaft which functions to oscillate the blower and outer housing. A wobbling fan assembly is not stable. 
   Thus, there still remains a need for a tower fan assembly that overcomes the above drawbacks. 
   SUMMARY OF THE INVENTION 
   It is an objective of the present invention to provide a tower fan assembly where the outer housing is stationary. 
   It is another objective of the present invention to provide a tower fan assembly which provides improved stability during operation and use. 
   It is yet another objective of the present invention to provide a smooth glide mechanism for the blower in a tower fan assembly. 
   It is a further objective of the present invention to provide a tower fan assembly where the extent and degree of the oscillation of the fan can be adjusted. 
   It is yet a further objective of the present invention to provide a tower fan assembly which has an improved oscillation motor assembly for oscillating the fan. 
   The objectives of the present invention can be accomplished by providing a fan assembly that has a base portion that remains stationary during the operation of the fan assembly, the base portion having a stationary base support plate. The assembly also includes a blower portion that includes an oscillating top plate, a blower that is coupled to the top plate and which oscillates when the top plate oscillates, and a grill cover that is coupled to the base support plate so that the grill cover remains stationary even when the top plate and the blower oscillates. The assembly can optionally include a smooth glide mechanism positioned between the top plate and the base support plate for supporting the oscillation of the top plate about the base support plate. 
   In another embodiment of the present invention, a fan assembly has a base portion having a fixed base, a blower portion that includes an oscillating blower mount that is operably coupled to the fixed base, and a blower that is coupled to the blower mount and which oscillates when the blower mount oscillates. The assembly further includes a degree swing setting assembly that controls the degree of oscillation to be experienced by the blower mount. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIG. 1  is a cross-sectional perspective view of a tower fan assembly according to one embodiment of the present invention. 
       FIG. 2  is an exploded perspective view of the assembly of  FIG. 1 . 
       FIG. 3  is an enlarged, exploded top perspective view of certain components of the assembly of  FIG. 1 . 
       FIG. 4  is an enlarged, exploded bottom perspective view of the components in  FIG. 3 . 
       FIG. 5  is a cross-sectional view of the components in  FIG. 3 . 
       FIG. 6  is an exploded perspective view of a tower fan assembly according to another embodiment of the present invention. 
       FIG. 7  is an enlarged exploded top perspective view of some of the components of the assembly of  FIG. 6 . 
       FIG. 8  is an enlarged exploded bottom perspective view of some of the components of the assembly of  FIG. 6 . 
       FIGS. 9 and 10  are different side cross-sectional views of some of the components of the assembly of  FIG. 6 . 
       FIGS. 11 and 12  are different bottom perspective cross-sectional views of some of the components of the assembly of  FIG. 6 . 
       FIG. 13  is a bottom perspective cross-sectional view of the blower mount of  FIG. 6 . 
       FIG. 14  is an exploded top perspective view of the assembly of  FIG. 6 . 
   

   DESCRIPTION OF THE PREFERRED EMBODIMENTS 
   The following detailed description is of the best presently contemplated modes of carrying out the invention. This description is not to be taken in a limiting sense, but is made merely for the purpose of illustrating general principles of embodiments of the invention. The scope of the invention is best defined by the appended claims. 
     FIGS. 1–5  illustrate one embodiment of a tower fan assembly  10  according to the present invention. The tower fan assembly  10  has a base portion  12 , a blower portion  14  and a control portion  16 . 
   Referring to  FIGS. 2 and 5 , the base portion  12  is stationary, and has a base plate  20 , a base support that is made up of a left shell  22  and a right shell  24 , and a fixed and stationary base support plate  26 . The base support plate  26  has an annular wall  28  extending upwardly from a bottom wall  30  to define an accommodation space  32  that houses the components of the oscillation assembly for the blower (described below). A central mount  34  extends upwardly from the bottom wall  30  at the center of the accommodation space  32 . A bore extends through the mount  34 , and a mounting shaft  36  extends through the bore. An annular flange  38  extends from the annular wall  28 , with the flange  38  adapted to be seated on the shoulder  40  of the shells  22  and  24 . The flange  38  itself defines an annular shoulder  42 . 
   Referring to  FIGS. 2–5 , the blower portion  14  includes a blower  50 , a blower housing  52 , a grill cover that includes two separate grill shells  54  and  56 , and an oscillation assembly. The blower  50  has a plurality of blades  51 , and is driven by a blower motor  66 . The blower  50  is retained inside the blower housing  52 , which is in turn retained inside the grill shells  54  and  56 . A base ring  96  is provided at the bottom of the blower housing  52 . The bottom edges of the grill shells  54 ,  56  are adapted to be supported on the shoulder  42  of the base support plate  26 , as best shown in  FIG. 1 . For example, the bottom edges of the grill shells  54 ,  56  can be fixedly secured to the base support plate  26  by screws or other similar attachment mechanisms. 
   The oscillation assembly is also retained inside the grill shells  54  and  56 , and includes an oscillating top plate  58  on which the base ring  96  of the blower housing  52  is mounted, an oscillation motor  60  that is secured to the bottom wall  30  inside the accommodation space  32 , and an oscillating link arm  62  having one end  61  coupled to a crank  63  of the motor  60  and another end  65  coupled to a pivot pin  69  that extends from an arm  72  adjacent a support piece  70  (see  FIGS. 3–5 ). The oscillating top plate  58  has an annular wall  90  that defines an internal space  92 . A spacer grease bushing  68  can be positioned between the top of the mount  34  and a support piece  70  that is suspended from the top plate  58  by four arms  72 . The support piece  70  and its four arms  72  are retained inside the internal space  92 . The support piece  70  has a bore through which the mounting shaft  36  extends, and has a depression  74  at its top surface for receiving the enlarged top end  76  of the mounting shaft  36 . The spacer grease bushing  68  also has an opening through which the mounting shaft  36  extends. Thus, the mounting shaft  36  is retained by the support piece  70  and extends through the spacer grease bushing  68  and the mount  34  of the base support plate  26  to function as a oscillation axis for the oscillating top plate  58  to oscillate about the fixed base support plate  26 . In addition, the blower motor  66  can be secured (e.g., by screws) to the top plate  58 . 
   The oscillation assembly can optionally include a smooth glide mechanism  64  which facilitates smoother oscillation of the oscillating top plate  58  with respect to the fixed base support plate  26 . The smooth glide mechanism  64  can be embodied in the form of a retainer ring  78  that retains a plurality of spaced apart ball bearings  80 . An annular ball bearing track  82  is provided along the top edge of the annular wall  28  of the fixed base support plate  26 , and a corresponding annular ball bearing track  84  is provided along the bottom edge of the annular wall  90  of the oscillating top plate  58 , with the bearings  80  seated between the tracks  82  and  84 . Thus, the bearings  80  help to improve the sliding oscillation movement of the annular wall  90  of the oscillating top plate  58  as it oscillates with respect to the fixed annular wall  28  of the base support plate  26 . 
   The control portion  16  includes a control panel  86  secured to a control panel base plate  88 . The control panel  86  includes the switches and other control buttons for operating the tower fan assembly  10 . The control panel base plate  88  is mounted on the top of the shells  54  and  56  by screws or similar attachment mechanisms. A hollowed handle  98  can be formed on the control panel base plate  88  to allow a user to insert his or her fingers inside the hollowed space for gripping the assembly  10 . 
   In operation, the user turns on the motor  60 , which will cause the crank  63  to rotate. Since the crank  63  is coupled to the link arm  62 , rotation of the crank  63  will cause the link arm  62  to oscillate in a reciprocating back and forth motion. Since the link arm  62  is also coupled to the top plate  58  (via the pin  69  and an arm  72 ), oscillation of the link arm  62  will cause the top plate  58  to oscillate about the axis defined by the mounting shaft  36 . Since the blower  50  is coupled (via the blower housing  52 ) to the top plate  58 , the oscillation of the top plate  58  will likewise cause the blower  50  to oscillate as it blows out air. However, since the grill shells  54  and  56  are fixedly connected to the fixed base support plate  26  (via the shoulder  42 ), the grill shells  54  and  56  do not oscillate and remain stationary at all times. 
   Thus, the tower fan assembly  10  of the present invention provides a grill cover (i.e., shells  54 ,  56 ) that acts as an outer housing that remains stationary at all times even while the blower  50  housed therein is being oscillated. In addition, the smooth glide mechanism  64  allows the top plate  58  to be oscillated about the fixed base support plate  26  in a smooth manner which reduces friction, and wear and tear, thereby increasing the life and effectiveness of the oscillating blower  50 . Also, the smooth glide mechanism  64  improves the balance and stability of the oscillating top plate  58  and the blower  50  because the oscillating top plate  58  and blower  50  are now supported (via the smooth glide mechanism  64 ) on the stationary base support plate  26 , instead of being supported on a single shaft. 
     FIGS. 6–14  illustrate another embodiment of a tower fan assembly  110  according to the present invention. The tower fan assembly  110  has a base portion (not shown), a blower portion  114  and a control portion  116  that can be the same as the control portion  16  described above. 
   Referring to  FIGS. 9–11 , the base portion is similar to the base portion  12  described above, except that it has a fixed base  126  instead of the base support plate  26  in  FIGS. 1–5 . The fixed base  126  has an annular wall  128  extending upwardly from a bottom wall  130  to define an accommodation space  132  that houses the components of the oscillation assembly for the blower and a blower motor  166  (described below). An annular flange  138  extends from the annular wall  128  and defines an annular shoulder  142 . 
   Referring to  FIGS. 6–13 , the blower portion  114  includes a blower  150 , a blower housing  152 , an oscillation assembly, and a grill cover that includes two separate grill shells  154 . Only one grill shell  154  is shown in  FIG. 6 , but the other grill shell can be the same as grill shell  56  or  154 . The blower  150  has a plurality of blades  151 , and is driven by a blower motor  166  via a shaft  136  that extends from the top of the blower motor  166 . The blower  150  is retained inside the blower housing  152 , which is in turn retained inside the grill shells  154 . A base ring  196  is provided at the bottom of the blower housing  152 . 
   The oscillation assembly is also retained inside the grill shells  154 , and includes an oscillating blower mount  158  on which the base ring  196  of the blower housing  152  is mounted, and a forward/reverse oscillation motor  160  that is retained inside the accommodation space  132 . The oscillation motor  160  is retained in a fixed location inside the accomodation space  132  by guide walls  133  that are secured to the bottom wall  130 . The oscillating blower mount  158  has an annular wall  190  that defines an internal space  192 . The blower motor  166  is secured to the bottom wall  130 , and can also be secured (e.g., by screws) to the top plate  168  of the blower mount  158 . Air intake vents  169  can be provided on the top plate  168  to vent hot air from inside the accomodation spaces  132  and  192 , which together form a singular accomodation space. 
   An annular flange  172  extends from the annular wall  190  of the blower mount  158 , with the flange  172  adapted to be seated on the shoulder  142  of the fixed base  126 . The flange  172  itself defines an annular shoulder  174 . The bottom edges of the grill shells  154  can be fixedly secured to either the shoulder  174  or the flange  138 , depending on whether the manufacturer wishes the grill shells  154  to oscillate together with the oscillating blower  150 . For example, the grill shells  154  will oscillate together with the blower  150  if the bottom edges of the grill shells  54  are fixedly secured to the shoulder  174 , the flange  172 , or the annular wall  190  of the oscillating blower mount  158 . On the other hand, the grill shells  154  will not oscillate with the blower  150  if the bottom edges of the grill shells  54  are fixedly secured to the flange  138  of the fixed base  126 . 
   A blower mount bearing  161  is seated in a recess  163  provided in the top plate  168 . A collar lock  165  is positioned above the blower mount bearing  161 . The shaft  136  of the blower motor  166  extends through the recess  163 , the blower mount bearing  161 , and the collar lock  165 . The collar lock  165  functions to retain the shaft  136  and the blower mount bearing  161  in the recess  163 . 
   A blower mount gear  170  is retained inside the internal space  192  and secured (e.g., by molding) to the bottom of the top plate  168  of the blower mount  158 . An oscillation motor gear  162  is mounted on the top of the oscillation motor  160 , and is engagably coupled to the blower mount gear  170  so that oscillation or turning of the oscillation motor gear  162  will cause the blower mount gear  170  to oscillate or turn as well. Thus, when the oscillation motor  160  is turned on, the oscillation motor gear  162  will oscillate in its rotation, causing the blower mount gear  170  that engages it to oscillate about the oscillation motor gear  162 . As the blower mount gear  170  oscillates, the blower mount  158  that is secured thereto will oscillate as well, resulting in the oscillation of the blower  150  and the blower housing  152 . 
   The present invention provides a degree swing setting assembly that allows for the degree of oscillation of the blower mount  158  to be selected and controlled by a user. The swing setting assembly includes a plurality of sets of degree swing sensors  202 , a plurality of spring-loaded power sensors  204 , a plurality of power supply contact rings  206 , and a plurality of spring-loaded power supply contact switches  208 . 
   Specifically, referring to  FIGS. 7–14 , a plurality of sets of degree swing sensors  202  are provided in spaced-apart manner along the annular wall  190  to sense the degree of rotation of the blower  150 . These degree swing sensors  203  are carried by the oscillating blower mount  158 , and therefore oscillate together with the blower mount  158 . Each set of sensors  202  has two sensors  202  that define the left and right limits of the desired degree swing. Any number of sets of degree swing sensors  202  can be provided. For example, if six degree sensors  202  are provided, the user will be able to select three different degree swing settings. The user can select the desired limits of oscillation of the blower  150  by pressing the appropriate button  125  on the top of the control panel  116  (see  FIG. 14 ). A plurality of buttons  125  are provided on the control panel  116 , each allowing the user to select a different degree swing. Any number of degree swings can be provided, including 45 degrees, 90 degrees, 135 degrees, 180 degrees, etc. Therefore, the two sensors for the  45  degree swing will be spaced apart along the internal surface of the annular wall  190  by about 45 degrees, the two sensors for the 90 degree swing will be spaced apart along the internal surface of the annular wall  190  by about 90 degrees (and further apart from each other than the sensors for the 45 degree swing), and so on. 
   A plurality of spring-loaded power sensors  204  is positioned inside the accomodation spaces  132  and  192 , and is secured to the bottom wall  130  via a sensor mount  210  that is fixedly secured (e.g., by screws) to the bottom wall  130 . Thus, the power sensors  204  do not oscillate. One of a plurality of wires (not shown) electrically couples each button  125  to a corresponding power sensor  204 . When a particular button  125  is activated, the corresponding power sensor  204  is turned on, with the other power sensors  204  remaining in a dormant or “off” mode. 
   A plurality of flat power supply contact rings  206  are snapped in place in tracks (not shown) provided in spaced-apart manner on the bottom of the annular shoulder  174  of the blower mount  158 . Thus, the contact rings  206  oscillate with the blower mount  158 . Each contact ring  206  has a contact  216  extending vertically therefrom. The contact rings  206  vary in diameter so that they are nested one within the other, so that the contacts  216  are arranged side-by-side, as best shown in  FIGS. 8 ,  11  and  13 . 
   A plurality of power supply contact switches  208  are secured to the shoulder  142  and are part of the fixed base  126 . Thus, the contact switches  208  do not oscillate. Each contact switch  208  is continuously aligned with, and electrically coupled to, a corresponding contact ring  206 . One of a plurality of wires (not shown) electrically couples each contact  216  to a corresponding set of sensors  202 . 
   When the oscillation motor  160  is turned on, the blower mount  158  will oscillate in the manner described above, but the limit of oscillation for the blower mount  158  will be defined by the set of degree swing sensors  202  selected by the user. For example, if the user selected a 90 degree swing, the motors  160  and  166  will cause the blower mount  158  (and the degree swing sensors  202  carried thereon) to turn in a forward direction until the activated power sensor  204  (i.e., the 90 degree power sensor  204 ) contacts a first of the two 90-degree sensors  202 . When the activated sensor  204  contacts the first 90-degree sensor  202 , the circuit formed by the corresponding degree swing sensor  202 , power sensor  204 , power supply contact ring  206 , and power supply contact switch  208  will be closed. This will cause the motor  160  will reverse directions to cause the blower mount  158  to oscillate in the reverse direction until the activated sensor  204  contacts the second 90-degree sensor  202 , at which time the motor  160  will again reverse the direction of the blower mount  158 . The same process repeats itself until the user turns off the motor  160 . As the blower mount  158  travels past other sensors  202  (e.g., the 45-degree sensors  202 ), the motor  160  will not change direction because the 45-degree power sensor  204  is not activated. 
   Referring to  FIGS. 7 ,  8  and  11 , the oscillation assembly can optionally include a smooth glide mechanism  164  which facilitates smoother oscillation of the oscillating blower mount  158  with respect to the fixed base  126 . The smooth glide mechanism  164  can be the same as the smooth glide mechanism  64  described above, and include a retainer ring that retains a plurality of spaced apart ball bearings  180 . Annular ball bearing tracks are provided along the top edge of the annular wall  128  of the fixed base  126  and along the bottom edge of the annular wall  190  of the oscillating blower mount  158 , with the bearings  180  seated between the tracks. 
   In operation, the user pre-selects the desired degree swing settings by pressing the appropriate button  125 , which also turns on the oscillation motor  160 , which will cause the oscillation gear  162  to oscillate the blower mount gear  170 . Since the blower mount gear  170  is fixedly secured to the blower mount  158 , oscillation of the blower mount gear  170  will cause the blower mount  158  to oscillate to the left and to the right about the axis defined by the shaft  136 . The left and right oscillation will be limited by the selected degree sensors  202  in the manner described above. If the user desires to set a different degree swing setting, the user merely presses a different button  125 , and oscillation of the blower mount  158  can be continued. When the user turns off the oscillation motor  160  (e.g., by activating an OFF button on the control panel  116 ), the oscillation motor  160  will reset to a start position (e.g., facing the center of the fan assembly  1   10 ) with respect to the blower mount gear  170 . 
   While the description above refers to particular embodiments of the present invention, it will be understood that many modifications may be made without departing from the spirit thereof. For example, the principles of the present invention can be equally applied to a heater or heating unit, or virtually any appliance that requires oscillation.