Patent Abstract:
A ceiling fan including a motor having a rotating flange; a single integrally formed fan blade, wherein the fan blade includes two substantially equally weighted wing portions disposed opposite each other; and a center portion disposed between and integrally formed with the two wing portions and having a passageway therethrough, wherein the passageway is sized such that the fan motor fits at least partially within the passageway; and means for attaching the center portion of the fan blade to the rotating flange of the motor is provided.

Full Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application is a continuation of U.S. application Ser. No. 12/986,908, filed Jan. 7, 2011. The contents of said application are hereby incorporated in their entirety by reference. 
     
    
     FIELD OF THE INVENTION 
       [0002]    This invention relates to a ceiling fan having a single fan blade having an integral central portion which functions as a motor housing. 
       BACKGROUND OF THE INVENTION 
       [0003]    Ceiling fans typically include a motor having a rotating flange which rotates about an axis that is collinear with a downrod by which the fan is attached to the ceiling. The fan motor is typically encased in a motor housing which wraps about the motor while leaving partial access to the rotating flange. Such partial access to the rotating flange is required so that the fan blades may be attached to the rotating flange. The requirement of a partial access often leads to an increase in the heat, vibration and noise into the surrounding environment. Furthermore, a partial access may subject the internal components to premature failure in environments that are high in salinity, humidity, or dust (e.g., due to rusting, corrosion, or seizing). Commercially available ceiling fans include numerous examples in which the fan blades are attached to the rotating flange by use of blade irons. Other known ceiling fans use means for attaching the fan blades directly to the rotating flange without the use of blade irons. 
         [0004]    In both types of known ceiling fans, the motor, including the motor housing, is first suspended from the ceiling. The ceiling fan installer may then attach the blade irons, either separately or in a blade iron and blade combination. Alternatively, the ceiling fan installer may attach the fan blades directly to the rotating flange. In any event, the ceiling fan installer must work in an uncomfortable position, generally screwing fasteners into the rotating flange from underneath the ceiling fan motor to install multiple numbers of ceiling fan blade irons and/or blade combinations. 
         [0005]    Further, both types of known ceiling fans require multiples of fan blade irons and blade combinations. This often leads to fasteners such as screws wearing out or corroding over time, thus potentially causing a safety hazard as a fan blade can become detached from the rest of the ceiling fan during use. This is also true for other mechanisms or devices other than screws used to secure fan blades to the ceiling fan. For example, U.S. Pat. No. 6,149,388 discloses the use of a collar having recessed sectors and protrusions to prevent disengagement from the ceiling fan Like other fan blade irons, the collar system is also subject to wearing out and corrosion over time. 
         [0006]    The requirement for multiples of fan blade irons and blade combinations also leads to an imbalance of the entire ceiling fan during operation, and the ceiling fan must often be adjusted by the use of fan blade weights of various measures. This can be a time-consuming process for the ceiling fan installer to properly correct the imbalance. U.S. Pat. No. 6,364,612 discloses the use of springs fitted onto the vanes (e.g., fan blade irons) to absorb the swinging force of the ceiling fan to correct the imbalance. However, use over a period of time will eventually cause such springs to wear out and result in the ceiling fan operating in an imbalanced state. 
         [0007]    In addition, the use of motor housings to conceal the fan motor results in a need to mold or otherwise manufacture an additional item(s) and in additional assembly time for the manufacturer and/or ceiling fan installer. Use of additional items can increase materials having differing weights and densities. These differences can result in an unbalanced or imbalanced ceiling fan during operation as described above, thus necessitating the use of fan blade weights. These needs may result in additional expenditure of resources such as time, materials, and cost. 
       SUMMARY OF THE INVENTION 
       [0008]    A first aspect of the invention provides a ceiling fan comprising a motor having a rotating flange; a single integrally formed fan blade comprising two substantially equally weighted wing portions disposed opposite each other and a center portion disposed between and integrally formed with the two wing portions and having passageway therethrough, wherein the passageway is sized such that the fan motor fits at least partially within the passageway; and means for attaching the center portion of the fan blade to the rotating flange of the motor. In some embodiments, the wing portions present substantially equal air movement and balanced rotation. 
         [0009]    In one specific embodiment, the ceiling fan further comprises a light kit disposed below the passageway. In some embodiments, the ceiling fan further includes a cap disposed above the passageway. 
         [0010]    In certain embodiments, the wing portions of the fan blade each exhibit a twist. 
         [0011]    In some embodiments of the invention, the means for attaching the center portion of the fan blade to the rotating flange of the motor comprises a plurality of fastener openings and a plurality of alignment indentations on the rotating flange; a ring comprising a plurality of fastener openings and a plurality of alignment posts, wherein the fastener openings of the ring align with the fastener openings of the rotating flange and the alignment posts of the ring mate with the alignment indentations of the rotating flange wherein the ring further comprises means to attach the center portion of the fan blade with the ring. 
         [0012]    In some embodiments of the invention, the center portion of the fan blade further comprises a plurality of extensions extending radially inwardly wherein each extension includes a fastener opening. 
         [0013]    Yet another aspect of the invention provides a ceiling fan comprising a motor having a rotating flange; a single integrally formed fan blade comprising two substantially equally weighted wing portions disposed opposite each other and a center portion disposed between and integrally formed with the two wing portions and having a passageway therethrough, wherein the passageway is sized such that the fan motor fits at least partially within the passageway; and means for attaching the center portion of the fan blade to the rotating flange of the motor. 
         [0014]    Yet another aspect of the invention provides a ceiling fan comprising a motor having a rotating flange; a single integrally formed fan blade comprising two substantially equally weighted wing portions disposed opposite each other and a center portion disposed between and integrally formed with the two wing portions and having a passageway therethrough, wherein the passageway is sized such that the fan motor fits at least partially within the passageway; means for attaching the center portion of the fan blade to the rotating flange of the motor; and a light kit. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0015]      FIG. 1  is a perspective view of a first embodiment of a single-blade ceiling fan of the invention. 
           [0016]      FIG. 2  is a perspective view of a first embodiment of a fan motor useful in the invention. 
           [0017]      FIG. 3  is a perspective view of the fan motor of  FIG. 2  in combination with an attachment ring. 
           [0018]      FIG. 4  is an elevated perspective view of a first embodiment of a single integrated ceiling fan blade useful in the invention. 
           [0019]      FIG. 5  is an elevated perspective view of the central portion of the fan blade shown in  FIG. 4 . 
           [0020]      FIG. 6  is an elevated perspective view of the central portion of the fan blade of  FIG. 4  attached to the fan motor and attachment ring combination shown in  FIG. 3 . 
           [0021]      FIG. 7  is an elevated perspective view of an embodiment of an attachment ring useful in the invention. 
           [0022]      FIG. 8  is a perspective view of a portion of the bottom side of the attachment ring shown in  FIG. 7 . 
       
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENTS 
       [0023]      FIG. 1  illustrates a first embodiment of the inventive ceiling fan  1 . The embodiment illustrated in  FIG. 1  includes a single integrally formed fan blade  10 . The single integrally formed fan blade  10  includes two opposing wing portions  12   a  and  12   b  and a center portion  14 . Center portion  14  partially encloses the fan motor (not shown in  FIG. 1 ). A light kit  16  is attached to the ceiling fan and is located below the center portion  14 . In alternative embodiments, a cover plate (not shown) may be used in lieu of a light kit. A downrod  18  suspends the ceiling fan  1  from the ceiling. Any of a number of known ceiling connectors may be used to suspend the downrod  18  from a ceiling junction box or electrical connection point. The downrod defines an axis of rotation about which the fan motor rotates. Wing portions  12   a  and  12   b  extend radially outward from the axis of rotation. In the embodiment shown in  FIG. 1 , the wing portions  12   a  and  12   b  exhibit a twist, or change in blade angle of attack, along the length of the wing portions  12   a  and  12   b.  The twist shown in  FIG. 1 , however, is illustrative and not limiting of the invention. Alternative twists, sizes, and shapes of wing portions  12   a  and  12   b  are contemplated in this invention, provided that wing portions  12   a  and  12   b  are substantially equally weighted and configured to present substantially balanced air movement and rotation. For example, in one alternative embodiment, wing portions  12   a  and  12   b  may be flat, exhibiting no twist. Referring still to  FIG. 1 , placed above center portion  14  is a cap  20 . 
         [0024]      FIG. 4  illustrates fan blade  10 . As seen in  FIG. 4 , the center portion  14  of fan blade  10  includes a top layer  14   a  and a bottom layer  14   b.  Layer  14   a  extends upwardly from the top surface of fan blade  10  and layer  14   b  extends downwardly from the bottom of fan blade  10 . Center portion  14  further includes an open passageway  22 , the height of which is defined by the distance between layers  14   a  and  14   b.  Passageway  22  is formed by a circular opening in layer  14   a  which lies apart from and over a circular opening in layer  14   b.  In preferred embodiments, the height of passageway  22  is sufficient to substantially enclose a fan motor.  FIG. 5  illustrates the center portion  14  of fan blade  10 . Extending radially inward to passageway  22  from layer  14   a  are projections  24 . Projections  24  include fastener openings  26 . As shown in  FIG. 6 , screws  28  (or other appropriate fasteners) may be passed through fastener openings  26  to attach fan blade  10  onto a fan motor  30  or attachment ring  32  which is, in turn, attached to fan motor  30 . In some embodiments of the inventive ceiling fan, the entire fan blade  10  is made of a top and a bottom surface joined along all edges except at the interior edges of passageway  22 . In other embodiments, wing portions  12   a  and  12   b  may be formed from a single ply or layer of material to which a second ply is bonded at the center portion  14  permitting the formation of passageway  22 . 
         [0025]      FIG. 7  illustrate an attachment ring  32  which may be used in certain embodiments of the invention.  FIG. 7  is an elevated perspective view showing the top surface of the ring having a number of spaced holes  34  of varying size and configuration.  FIG. 2  illustrates a fan motor  30  having a rotating flange  36  which also includes a plurality of fastener openings  38  configured to receive screws or other appropriate fasteners. Rotating flange  36  further includes guide indentations  40  configured to receive guide posts (not shown in  FIG. 2 .)  FIG. 8  illustrates a portion of a bottom side of ring  32 . The bottom side of ring  32  includes guide posts  42  configured to interconnect with guide indentations  40  on rotating flange  36 .  FIG. 3  illustrates a fan motor  30  having a rotating flange  36  onto which ring  32  has been attached. 
         [0026]    Referring again to  FIG. 6 , a fan motor  10  having a rotating flange (not visible in  FIG. 6 ) onto which ring  32  has been attached is shown. Further shown in  FIG. 6  is the attachment of fan blade  10  onto ring  32  (and thereby the rotating flange) by threading a screw  28  through each fastener opening  26  into an appropriate opening in ring  32 . In alternative embodiments, fan blade  10  may be attached directly to rotating flange  36  without the use of a ring. Although screws  28  are illustrated as attaching fan blade  10  to ring  32 , it will be understood that other means for such attachment may be used. For example, center portion  14  could include downwardly projecting, contractable clips that would interlock with interlocking receiving members on the rotating flange or ring. In yet other embodiments, the means for attaching the center portion  14  of fan blade  10  onto the rotating flange, either directly or by attachment to a ring, may include hook and loop fasteners, adhesives, such as epoxy, rivets, cotter pins, and magnets. Once attached, fan blade  10  will rotate with the rotation of rotating flange  26 . 
         [0027]    In the embodiment shown in  FIG. 6 , a cap may be placed over the passageway  22 . An example of a cap  44  having a conelike shape is shown in  FIG. 9 . In alternative embodiments, cap  44  may have other shapes, such as a hemispheroid, ovoid, or polyhedral. 
         [0028]    The illustrated embodiments show the fan blade attachment means attaching to an upper surface of the rotating flange. However, in alternative embodiments, the fan blade attachment means may attach to a bottom and/or side surface of the rotating flange.

Technology Classification (CPC): 5