Patent Publication Number: US-2023160399-A1

Title: Ceiling fan with mounting plate

Description:
BACKGROUND OF THE INVENTION 
     Typical ceiling fans are electrically powered, being electrically coupled to a building electrical supply. The ceiling fans include an electric motor that is suspended beneath a ceiling by a hollow downrod through which electrical wires extend from the building electrical supply to the motor. An annular array of fan blades are coupled to the motor such that the blades can rotate about the motor, pushing a flow of air. 
     Ceiling fans can utilize a mounting plate to support various components located above the motor. The mounting plate can have an opening through which a motor shaft can extend and couple to the downrod. The mounting plate can have an opening, through which the motor shaft extends, with a slot extending radially from the motor shaft that allows the mounting plate to slide down the motor shaft without damaging the wires exiting the motor shaft. 
     A technical issue with this type of mounting plate is that after assembly of the ceiling fan, the slot creates a pathway for water to reach the motor and other electrical components. Further, the configuration of the mounting plate can inhibit later access to the motor and other electronic components located below the mounting plate in order to repair a ceiling fan not operating properly. 
     BRIEF DESCRIPTION OF THE INVENTION 
     In one aspect, the disclosure relates to a ceiling fan assembly comprising a motor having a rotor and a stator, at least one blade operably coupled to the stator, a motor shaft extending from the stator and having an internal wire passage and a wire opening in a side of the motor shaft, with the wire opening providing access to the internal wire passage, a control mounting plate having a motor shaft opening through which the motor shaft extends, with the motor shaft opening being sized to define gap between motor shaft and the control mounting plate, and the control mounting plate is located, relative to the motor shaft, between the wire opening and the rotor and stator, the control mounting plate having opposing first and second sides, with the first side oriented toward the wire opening and the second side oriented toward the rotor and stator, an electronic control unit carried by a first side of the control mount and electrically connected to the motor by wires passing through the wire opening and wire passage, and a multiple segment plug occluding the gap. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       In the drawings: 
         FIG.  1    illustrates a schematic side view of a ceiling fan mounted to a structure and including a mounting assembly according to an aspect of the disclosure. 
         FIG.  2    is a perspective view of a portion of the ceiling fan of  FIG.  1    illustrating the mounting assembly including a split adapter according to an aspect of the disclosure. 
         FIG.  3    is a perspective view of the portion of the ceiling fan of  FIG.  2    with a portion of the mounting assembly removed according to an aspect of the disclosure. 
         FIG.  4    is a bottom perspective view of the split adapter of  FIG.  2    according to an aspect of the disclosure. 
         FIG.  5    is an exploded view of the split adapter of  FIG.  2    according to an aspect of the disclosure. 
         FIG.  6    is a perspective view of a portion of the ceiling fan of  FIG.  1    including a mounting assembly in a partially assembled view according to another aspect of the disclosure. 
         FIG.  7    is a top perspective view of a portion of the mounting assembly of  FIG.  6    according to an aspect of the disclosure. 
         FIG.  8    is a bottom perspective view of the portion of the mounting assembly of  FIG.  7    according to an aspect of the disclosure. 
     
    
    
     DETAILED DESCRIPTION 
     The present disclosure is directed to a ceiling fan assembly having a multi-segmented mounting plate, which can be assembled in pieces around the motor shaft below the wires instead of sliding over the wiring, negating the need for a slot in the mounting plate for wires. The lack of the slot eliminates a water path to the electrical components. For purposes of illustration, the present disclosure will be described with respect to an exemplary ceiling fan motor housed in an exemplary ceiling fan housing. It will be understood, however, that the disclosure is not so limited and can have general applicability in all ceiling fan or mounting applications, such lighting or suspension for industrial, commercial, and residential applications, as well as a plurality of different ceiling fan designs. It can also have application to ceiling fans comprising multiple motors or angularly oriented motors. Furthermore, the split adapter as described herein will be compatible with all ceiling fan assemblies. 
     The disclosure is related to a ceiling fan assembly 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  10  is suspended from a structure  12 , such as a ceiling of a building. A structure mount  14  secures to the structure  12  and seats a ball mount assembly  16 . A canopy  18  encloses the structure mount  14 , providing an aesthetically pleasing junction between the ball mount assembly  16  and the structure  12 . A downrod  20  couples to the ball mount assembly  16  at a first end  22 . A motor adapter assembly  24  couples to the downrod  20  at a second end  26 , opposite of the ball mount assembly  16 . A motor housing  30  and a motor shaft  32  couple to the motor adapter assembly  24  opposite of the downrod  20 . The motor housing  30  can be separated into an upper housing  34  and a lower housing  36 , with the upper housing  34  coupling to the motor adapter assembly  24 . The motor housing  30  encases a motor  38  having a rotor  40  and a stator  42 , with the motor shaft  32  extending from the motor  38  to the motor adapter assembly  24 . 
     A set of blade irons  44  can couple a set of complementary blades  46  to the motor  38 . The motor  38  can be electrically powered to rotatably drive the blades  46  to push a volume of air. Optionally, a light kit  47  or switch housing can be provided on the motor housing  30 , and is shown positioned at the bottom of the lower housing  36 . 
     A controller  48  can be mounted above the motor  38 , and encased in the upper housing  34 . The controller  48  can be electrically coupled to an electrical supply  50  to control operation of the ceiling fan  10  and supply power to the motor  38 . Alternatively, the controller  48  can be wirelessly or communicatively coupled to the ceiling fan  10 , configured to control operation of the ceiling fan  10  remotely, without a dedicated connection. Non-limiting examples of controls for the ceiling fan  10  can include fan speed, fan direction, or light operation. Furthermore, a separate wireless controller  52 , alone or in addition to the wired controller  48 , can be communicatively coupled to a controller or a wireless receiver in the ceiling fan  10  to control operation of the ceiling fan  10 . It is further contemplated in one alternative example that the ceiling fan be operated by the wireless controller  52  alone, and is not operably coupled with the wired controller  48 . 
     In ceiling fans having components mounted directly above the motor  38 , a mounting assembly  53  can support such components. By way of non-limiting example, components can include controllers, plates for securing other parts of the ceiling fan  10 , portions of the upper housing  34 , and other decorative features of ceiling fan  10 . 
     Turning to  FIG.  2   , the mounting assembly  53  includes a control mounting plate  54  and a split adapter  60 . The control mounting plate  54  forms a platform to support the controller  48  above the motor  38 . The control mounting plate  54  includes an upper side  56 , a lower side  57  opposite the upper side  56  and facing the motor  38 , and a central opening  58  through which the motor shaft  32  extends. A split adapter  60  surrounds the motor shaft  32  and occludes the remainder of the central opening  58  in the control mounting plate  54 . 
     The motor shaft  32  includes an interior  62  through which electrical wiring can pass. An upper wiring hole  64  and a lower wiring hole  66  are formed in the motor shaft  32  allowing electrical wires to pass from the interior  62  of the motor shaft  32  to an exterior side  68  of the motor shaft  32  in order to electrically connect the motor  38 , the controller  48 , and the electrical supply  50 . 
     In  FIG.  3   , the control mounting plate  54  has been removed for clarity. A first segment  70  and a second segment  72  couple together to form the split adapter  60 . The split adapter  60  can include an annular base  82  having an upper surface  74 , a lower surface  76  opposite the upper surface  74  and facing the motor  38 , and a motor shaft opening  78  through which the motor shaft  32  extends. It is contemplated that any number of segments  70 ,  72  can be combined to form the split adapter  60 . The split adapter  60  can further include a centrally located collar  80  circumscribing the motor shaft  32 , defining at least a portion of the motor shaft opening  78 , and extending axially from the annular base  82 . 
     The collar  80  can have a cut-out  84  corresponding to a defining edge  86  of the lower wiring hole  66  such that the collar  80  does not block a lower wiring opening  88 . The collar  80  can further include one or more apertures  90  ( FIG.  5   ) configured to receive a fastener, such as a bolt  91 , to removably fasten the split adapter  60  to the motor shaft  32 . 
     The base  82  includes an indexing rib  92  forming a circular shape, radially spaced from the collar  80 , on the upper surface  74 . The central opening  58  can receive the indexing rib  92  of the split adapter  60 . It is contemplated that the indexing rib  92  can have a peripheral shape complementary to the central opening  58  and the remainder of the upper surface  74  of the split adapter  60  confronts the lower side  57  of the control mounting plate  54 . 
     The base  82  can further include one or more apertures  93  configured to receive a fastener to secure the split adapter  60  to the motor  38 , the control mounting plate  54 , or both, and one or more apertures  94  configured to receive a fastener to secure the first segment  70  to the second segment  72  to one another. By way of non-limiting example, fasteners can include bolts, screws, pins, or any other fastener capable of securing corresponding elements together. 
       FIG.  4    is a perspective bottom view of the split adapter  60 . The lower surface  76  of the base  82  can include a lower portion  95  of the collar  80  at least partially defining the motor shaft opening  78 . The lower surface  76  can further include one or more circumferential ribs  96 , radially spaced from the collar  80 . One or more radial ribs  97  extend radially from the collar  80  and can intersect the one or more circumferential ribs  96 . The circumferential ribs  96  and the radial ribs  97  together with the indexing rib  92  provide stability and rigidity to the split adapter  60 . Further, the circumferential ribs  96  can help prevent water from reaching the motor  38 . 
       FIG.  5    illustrates the split adapter  60  separated into the first segment  70  and the second segment  72 . While the first segment  70  and the second segment  72  bisect the split adapter  60  generally in half, along a diameter  98 , it is contemplated that any number of segments  70 ,  72  can be combined to form the split adapter  60 . For the purposes of clarity, it is to be understood that the first segment  70  is complementary in shape to the second segment  72 . Therefore, only elements of the first segment  70  will be described herein with it being understood that elements of the first segment  70  also apply to the second segment  72  with corresponding numerals for the second segment  72  unless otherwise indicated. A collar member  110  of the first segment  70  and a collar member  112  of the second segment, form the collar  80  when assembled. It is contemplated that each collar member  110 ,  112  can form at least a portion of the cut-out  84 . Alternatively, the cut-out  84  can be formed by only the collar member  110  or the collar member  112 . Each collar member  110 ,  112  includes the aperture  90  to receive a fastener, however it is also contemplated that only collar member  110  or collar member  112  includes the aperture  90 . Each collar member  110 ,  112  further includes an upper end  120  and a lower end  122 . Each upper end  120  projects upward from the upper surface  74  of the split adapter  60  forming an upper portion  99  ( FIG.  3   ) of collar  80  when the first and second segments  70 ,  72  are coupled. Each lower end  122  projects downward from the lower surface  76  to form the lower portion  95  of collar  80  ( FIG.  4   ) when the first and second segments  70 ,  72  are coupled. 
     Further, the first and second segments  70 ,  72  each include an understep  124  and a complementarily shaped overstep  126 , opposite the understep  124 , configured to overlappingly couple the first and second segments  70 ,  72 . The understep  124  extends radially, from the collar  80 . The understep  124  includes a depending riser  128 , depending from the upper surface  74 , and a tread  130 , extending from the depending riser  128  at about a 90 degree angle. Alternatively, the tread  130  can extend from the depending riser  128  at any angle complementary to the overstep  126 . A tread portion  132  of the lower surface  76  of the base  82  and a radial riser rib  134  located on the lower surface  76  and complementary in height to the height of the depending riser  128 , form the overstep  126 . The radial riser rib  134  can optionally be formed by at least a portion of one of the radial ribs  97 . 
     To form the split adapter  60 , the first segment  70  couples to the second segment  72  in an overlapping relationship such that the overstep  126  of the first segment  70  overlies the understep  124  of the second segment  72 , the overstep  126  of the second segment  72  overlies the understep  124  of the first segment  70 , and the indexing rib  92  forms a circle on the upper surface  74  of the base  82 . Optionally, each of the understep  124  and the overstep  126  can include the apertures  94  on the overstep  126  and an aperture  136  on the understep  124  are configured to receive a fastener to fasten the first segment  70  to the second segment  72  during assembly of ceiling fan  10 . By way of non-limiting example, fasteners can include bolts, screws, pins, or any other fastener capable of securing corresponding elements together. 
     During assembly of the ceiling fan  10 , the split adapter  60  can be assembled around the motor shaft  32 , above the motor  38 , and below the lower wiring hole  66 . Fasteners can secure the split adapter  60  through the apertures  90  to the motor shaft  32  and through the apertures  93 ,  94  to the motor  38 , control mounting plate  54 , or both. By way of non-limiting example, can include bolts, screws, pins, or any other fastener capable of securing corresponding elements together. Because the split adapter  60  is assembled in segments  70 ,  72 , in case of a malfunction of the ceiling fan  10 , the split adapter  60  can be similarly disassembled post-installation. Disassembling the split adapter  60  creates a large enough central opening in the control mounting plate  54  to enable the control mounting plate  54  to be slid vertically with respect to the motor shaft  32  without damaging or contacting any wiring exiting the interior  62  through the upper and lower wiring holes  64 ,  66 . Removal of the split adapter  60  allows easier access to the motor  38  and wiring than when using a solid, single piece adapter or control mounting plate. The ability to access the motor and wiring allows a malfunctioning ceiling fan to be repaired rather than requiring replacement. 
     In another aspect of the present disclosure, the mounting assembly  53  can include a single split adapter mounting plate  200 .  FIG.  6    illustrates partially assembled view of the split adapter mounting plate  200  of a ceiling fan  10 . A first segment  212  and a second segment  214  couple together to form the circular-shaped split adapter mounting plate  200 . While illustrated as the first segment  212  and the second segment  214  bisect the split adapter mounting plate  200  generally in half, along a diameter  215  ( FIG.  7   ), it is contemplated that any number of segments  212 ,  214  can be combined to form the split adapter mounting plate  200 . By way of non-limiting example, the first segment  212  is a mirror image and complementarily shaped to the second segment  214 , therefore, only elements of the first segment  212  will be described herein with it being understood that elements of the first segment  212  also apply to the second segment  214  in mirror image. 
     Turning to  FIG.  7   , the first segment  212  can include a top surface  216 , a bottom surface  218  opposite the top surface  216  and confronting the motor  38 , and a center channel  220 . The center channel  220  can be located at or near the center of the diameter  215  and have a curved interior  222  configured to form a motor shaft opening  224  through which the motor shaft  32  can extend when the first segment  212  is coupled to the second segment  214 . The center channel  220  includes an upper edge  226  at the top surface  216  and a lower edge  228  depending from the bottom surface  218 . The lower edge  228  of each of the first and second segments  212 ,  214  can form a lower collar  230  of the motor shaft opening  224 . 
     A first flanged side  232  and a second flange side  234  each flank a portion of and at least partially define the center channel  220  on each of a pair of radial sides  236  of the curved interior  222 . A first aperture  238  is formed in the first flange side  232 , while a second aperture  240  is formed in the second flange side  234 . The first aperture  238  in the first segment  212  is configured to couple with the second aperture  240  in the second segment  214 . Likewise, the second aperture in the first segment  212  is configured to couple with the first aperture  238  in the second segment  214 . By way of non-limiting example, the first aperture  238  can be a pocket hole formed in the top surface  216  such that a fastener can be driven from the top surface  216 , through the first aperture  238  of the first segment  212  and into the second aperture  240  of the second segment  214  to secure the first and second segments  212 ,  214  to each other during assembly of the split adapter mounting plate  200  around the motor shaft  32 . Additionally, the first and second segments  212 ,  214  can include any number of additional apertures  242  configured to receive fasteners to fasten the split adapter mounting plate  200  to the motor  38 . 
     The first segment  212  further includes one or more tab openings  244  complementarily shaped in order to receive tabs  246  projecting outward from the diameter  215  of the split adapter mounting plate  200 . Each tab  246  includes a snap element  248  at a distal end configured to form cooperating snap-fit connections between each tab  246  and each tab opening  244 . 
       FIG.  8    illustrates a bottom perspective view of the first segment  212  of the split adapter mounting plate  200 . The bottom surface  218  includes one or more support structures for the split adapter mounting plate  200 . One or more circumferential ribs  250 , radially spaced from the center channel  220 . One or more radial ribs  252  extend from the center channel  220  and can intersect the one or more circumferential ribs  250 . The circumferential ribs  250  can be utilized to align the split adapter mounting plate  200  during installation. The circumferential ribs  250  and the radial ribs  252  provide stability and rigidity to the split adapter mounting plate  200 . Further, the circumferential ribs  250  can help prevent water from reaching the motor  38 . 
     During assembly of the ceiling fan  10 , the split adapter mounting plate  200  can be assembled around the motor shaft  32 , above the motor  38 , and below the lower wiring hole  66 . Fasteners can secure the first and second segments  212 ,  214  of the split adapter mounting plate  200  through the apertures  238 ,  240  together and to the motor  38  through apertures  242 . By way of non-limiting example, can include bolts, screws, pins, or any other fastener capable of securing corresponding elements together. Because the split adapter mounting plate  200  is assembled in segments  212 ,  214 , in case of a malfunction of the ceiling fan  10 , the split adapter mounting plate  200  can be similarly disassembled post-installation. Disassembling the split adapter mounting plate  200  enables access to the electrical elements of the ceiling fan  10  without damaging or contacting any wiring exiting the interior  62  through the upper and lower wiring holes  64 ,  66 . Removal of the split adapter mounting plate  200  allows easier access to the motor  38  and wiring than when using a solid, single piece adapter or mounting plate. The ability to access the motor and wiring allows a malfunctioning ceiling fan to be repaired rather than requiring replacement 
     To the extent not already described, the different features and structures of the various embodiments can be used in combination, or in substitution with each other as desired. That one feature is not illustrated in all of the embodiments is not meant to be construed that it cannot be so illustrated, but is done for brevity of description. Thus, the various features of the different embodiments can be mixed and matched as desired to form new embodiments, whether or not the new embodiments are expressly described. All combinations or permutations of features described herein are covered by this disclosure. 
     This written description uses examples to explain the disclosure, including the best mode, and to enable any person skilled in the art to practice the disclosure, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the disclosure is 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.