Patent ID: 12234839

DESCRIPTION OF EMBODIMENTS OF THE INVENTION

The described embodiments of the present invention are directed to systems, methods, and other devices related to a ceiling fan.

FIG.1Aillustrates a top perspective view of a ceiling fan10. The ceiling fan10includes a ceiling mount structure12for mounting to a ceiling (not shown) or a structure, having a downrod assembly14extending therefrom. The downrod assembly14couples to a motor assembly16. A plurality of blade holders18couple the blades20to the motor assembly16. While five blades20and five blade holders18are shown, any number of blades20and blade holders18are contemplated. Optionally, a plurality of guy wires22can be used to mount to the downrod assembly14to the ceiling separate from the ceiling mount structure12. As used herein, the ceiling or structure can be any structure from which the ceiling fan can suspend from or mount. For example, the ceiling can be the ceiling of a building, factory, or farm building.

FIG.1Bis a close-up view of the downrod assembly14and motor assembly16. The ceiling mount structure12includes a mount plate13having two upper plates15for securing the ceiling mount structure12to the building with a bolted assembly. A support cable or wiring harness302and wiring conduit342extending from within the downrod assembly14underneath the mount plate13for coupling the ceiling fan10to the structure and an electrical power supply, respectively. An electrical connector303can be connected to the motor assembly16by a wiring harness302. The wiring conduit342terminates in an electrical connector343. A downrod plate50couples the downrod assembly14to the motor assembly16. The downrod assembly14further includes a guy wire fitting58for coupling the guy wires22to the downrod assembly14utilizing a set of turnbuckles80. A motor housing198includes a plurality of mounts204for coupling the blades20to the motor assembly16with the blade holders18.

FIG.1Cillustrates a portion of a retention system300, while the remaining portion is internal of the motor assembly16. The retention system300includes a retainer plate310disposed along the bottom of the motor housing198, providing a redundant suspension for suspending the ceiling fan10from the ceiling or structure. Additionally, the bottom of the mount plate13includes two integral tabs24for mounting the plate to a fastener19. The fastener19couples the mount plate13to the downrod assembly14at the swivel mount36. The tabs24are formed in the mount plate13during manufacture, as compared to welding of the tabs24, which reduces cost while improving reliability of the tabs24during fan operation. A central gap is provided between the tabs24providing for electrical connections to enter the downrod14.

FIG.1Dis an exploded view illustrating the combination of components comprising the downrod assembly14and the motor assembly16. The downrod assembly14includes a hollow rod30having a swivel mount36for coupling the downrod assembly14to the ceiling mount structure12. The guy wire fitting58mounts around the hollow rod30. A downrod plate50mounts to the downrod assembly14opposite of the swivel mount36. The downrod plate50couples to a shaft coupler52for coupling the downrod assembly14to the motor assembly16. The motor assembly16includes the motor housing198split into an upper housing portion200and a lower housing portion230. A non-rotating motor shaft90is disposed within the motor housing198for supporting a stator232, upper bearing272, and lower bearing274. A retainer nut92can be used to secure the motor shaft90to the downrod assembly14at the shaft coupler52. A spring member282can be disposed between the lower bearing274and the lower motor housing portion230. A rotor234mounts to the upper and lower motor housing portions200,230, such that the motor housing198can rotate about the non-rotating motor shaft90. The retention system300further includes the support cable302and retention rod304for suspending the retainer plate310from the structure. The retainer plate310can mount to the non-rotating motor shaft90and rest below the lower housing portion230to provide a redundant support for both the non-rotating and rotating elements of the motor assembly16. A wiring harness340can extend through the motor shaft90, and out through the center of the motor shaft90for supplying an electric current to the stator232.

Looking atFIG.2A, the downrod assembly14comprises the hollow rod30having an upper end32configured to mount to the ceiling via the ceiling mount structure12ofFIG.1. A lower end34, disposed opposite of the upper end32, mounts the downrod assembly14to the motor assembly16. The upper end32includes the swivel mount36mounted to the hollow rod30. The swivel mount36can include two extensions40defining a clevis with each extension40having a mounting aperture42. The mounting aperture42can be aligned to accept the insertion of a fastener, such as a pin, for pivotally coupling the upper end32to the ceiling mount structure12.

The lower end34can include the downrod plate50and shaft coupler52. The downrod plate50can mount to the hollow rod30, such as by welding, or can be integral with the hollow rod30. The shaft coupler52can couple to the downrod plate50with a plurality of fasteners54such as screws or bolts. The guy wire fitting58can be a disk60that can secure around the hollow rod30, between the upper and lower ends32,34, and can have one or more openings62for mounting the guy wires22ofFIG.1.

Looking now atFIG.2B, an exploded view shows the separated parts of the downrod assembly14. The guy wire fitting58can weld to the hollow rod30, or can be machined as part of the hollow rod30. The guy wire fitting58can alternatively include an inner ring70and an outer ring72, having the openings62disposed between the rings70,72. The turnbuckles80have hooks82that can extend through and couple to the outer ring72through the openings62. The turnbuckles80can couple the downrod assembly14to the ceiling via the guy wires22for providing additional support for the ceiling fan10and reducing vibration or gyroscopic movement of the ceiling fan10during operation.

The downrod plate50and the shaft coupler52can include a plurality of fastener openings74adapted to accept the insertion of the fasteners54for coupling the downrod plate50and the shaft coupler52. The fasteners54can thread into one or more of the downrod plate50and shaft coupler52or can utilize a secondary fastener such as a nut to secure the downrod plate50and shaft coupler52together. The shaft coupler52can be in the form of a collar76having a central opening78. Looking atFIG.2C, the collar76can be threaded to couple to a tapped upper end of the motor shaft90, mounting the downrod assembly14to the motor assembly16. Further, the collar76or shaft coupler52can be indexed relative to the motor shaft90, such as being keyed to receive a keyway88on the motor shaft90.

Alternatively, as seen inFIG.2C, the threaded retainer92can be used to secure the shaft coupler52to the motor shaft90. Utilizing the threaded retainer92, in an alternative implementation, the collar76can slide over the motor shaft90having the retainer92thread onto the tapped portion of the motor shaft90to secure the shaft coupler52to the motor shaft90. The retainer92can have a diameter sized to fit within an upper opening96of the shaft coupler52. Complementary to the retainer92, an upper collar95can be used to secure the motor shaft90to the retainer nut92redundant to the threads. Additionally, a spring ring93can be inserted between the retainer nut92and the shaft coupler52to provide a biasing force between the two. The biasing force of the spring ring93secures the retainer nut92to the motor shaft90, prevented unwanted rotation of the two that may otherwise lead to unthreading. In another alternative example, both the shaft coupler52and the retainer92can be threaded to couple to the motor shaft90, providing additional support for mounting the downrod assembly14to the motor assembly16.

Alternative to the threaded fasteners54, the downrod plate50or the shaft coupler52can include tapped studs94or press studs, while the remaining downrod plate50or motor coupler52has openings74adapted to receive the tapped studs94. Nuts or other fasteners can thread or fit onto the tapped studs94to secure the downrod plate50and motor coupler52together.

It should be appreciated that the downrod assembly14is beneficial in suspending the motor assembly16from the ceiling, permitting the use of a non-rotating downrod assembly14and a non-rotating motor shaft90. The downrod plate50in combination with the shaft coupler52facilitates connection of the downrod assembly14to the motor assembly16. Additionally, the guy wire fitting58facilitates the connection of additional suspension elements to the downrod assembly14, such as guy wiring22, reducing vibration or movement associated with operation of the ceiling fan10. Additionally, the guy wiring provides an additional redundant suspension system in the event that the ceiling mount structure12fails.

It should be further appreciated that the tapped studs94or press studs facilitate alignment and mounting of the downrod plate50to the shaft coupler52. Additionally, the use of the retainer nut92facilitates slidable insertion of the motor shaft90into the shaft coupler52as well as can provide a redundant coupling for attaching the motor shaft90.

Turning now toFIG.3A, a top view of the blade20illustrates three mount holes100on a first end102and a second end104opposite of the first end102. The mount holes100can mount the blade to the motor assembly16. The blade20can further comprise a blade span106as the distance between the first end102and the furthest end of the second end104. The blade20can have an airfoil110cross section, as shown inFIG.3B, with a leading edge112and a trailing edge114defining a chord116as the straight line distance between the leading edge112and the trailing edge114. In one example, the blade chord116can be about seven inches (in.) and can be between six and eight inches. The airfoil110can be non-symmetrical and can have an interior chamber117.

The blade20can further include a pressure side118and a suction side120, having the pressure side118facing toward a ground surface below the ceiling fan10and the suction side120facing the ceiling from which the ceiling fan10is mounted. A blade thickness122can be the greatest distance between the pressure side118and the suction side120. The blade20, as seen inFIG.3C, can also be two-part, being the combination of a leading member130and a trailing member132coupled together.

The blade thickness122can be adapted such that a thickness to chord ratio can be less than 0.14 and can be greater than 0.13. For example, the blade chord116can be 7.01 inches and the thickness122can be 0.97 inches having a thickness-to-chord ratio of 13.8% or 0.138. The blade chord116and thickness122can be changed relative to one another to maintain the thickness-to-chord ratio of about 13.8%. Furthermore, the blade20can adapted to rotate at a rotational speed defined by revolutions per minute (rpm). Rotational speed of the blade20can be dependent on the blade span106or total ceiling fan width. The total ceiling fan width can be the diameter defined by a circle defined by the outermost rotation of the blades20. In one example, fan10can have a total width of 24 feet having blade spans106of about 12 feet, a chord116of 7.01 inches, and a thickness122of 0.97 inches. The exemplary fan10can be adapted to rotate at a particular rotational speed to generate a particular volumetric flow rate or air speed

It should be understood that the dimensions of the blade span106, total fan width, blade chord116, and blade thickness122rotating at a determined rotational speed can be determinative of the maximum wind speed generated by the fan as well as volumetric flow rates. Alternatively, the wind speeds generated by the fan10can be determined based upon consumer preference, which can be determined by the need for fan-driven airflow. For example, a hotter or more stagnant environment will require a greater wind speed to maintain appropriate temperatures, while a cooler or open environment will require less wind speed to maintain temperatures. It can be appreciated, adapting the span106, chord116, thickness122, chord-to-thickness ratio, rotational speed, or otherwise can maximize efficiency of the fan10, by improving temperature management, volumetric airflow, or airspeed while minimizing energy consumption.

It should be appreciated that the blades20have a thickness-to-chord ratio of about 13.8% and include an airfoil shape to maximize efficiency of the blades20. The blade span106, chord116, thickness122, rotational speed, and pitch can be adapted to maximize efficiency, airspeed, and airflow volume during operation of the ceiling fan10.

Turning toFIG.4A, focusing on the blade holder18, the blade holder18includes a first end150and a second end152opposite of the first end150. The first end150can have a first cross section, such as circular cross-section140and the second end152can have second cross-section, such as elliptical cross section142. The first and second cross sections140,142can be different from one another, while it is also contemplated that they can be the same. Further, the height of the first cross-section140can be greater than that of the height of the second cross-section142. The cross-sections140,142can each define a cross-sectional area for the first and second ends150,152. The cross-sections140,142can have the same area, while the shapes are different. Alternatively, the cross-sectional areas for the shapes can differ. The first and second ends150,152can connect by a transition portion or transition section154. The transition section154can have a cross-section144transitioning from the first cross-section140to the second cross-section142, such as transitioning from the circle to the ellipse.

The blade holder18can comprise a single machined piece, or can be a combination of multiple parts, such as welding the first and second ends150,152to the transition section154. The second cross-section142can be formed by stamping from an initial shape. For example, the entire blade holder18can be machined having a circular cross-section. The second end152and part of the transition section154can be stamped or compressed to form the appropriate second cross-sections142,144.

The first end150can have a push-lock assembly156closing the first end150. The motor assembly16having the rotating blade hub, can have a first receiver which can comprise the blade hub ofFIG.5A. The second end152can have mounting apertures158complementary to the mount holes100of the blades20such that the second end152is received within the interior chamber117of the blade20operating as a second receiver. Thus, the blade20can couple to the motor assembly16utilizing the blade holder18. The interconnection between the blade20, blade holder18, and blade hub are further described below during the discussion ofFIG.5B.

The first end150includes an opening160for receiving the push-lock assembly156. The push-lock assembly156can further include an index157having a biased detent, such as a spring-loaded pin162extending radially from one side of the push-lock assembly156.

Turning toFIG.4B, illustrating the push-lock assembly156exploded from the body of the blade holder18, the push-lock assembly156mounts to the first end150at the opening160, such as by welding, and can mount relative to the blade holder18to orient the blade holder18at an angle relative to the pin162. For example, the second cross-section142at the second end152can define a major axis164. The push-lock assembly156can mount to the first end150to orient the pin162at an angle of five degrees offset from the major axis164. Thus, a blade20mounted to the second end152can be disposed at an angle offset by five degrees from the pin162and can define a pitch for the blades20upon mounting the blade holder18to the motor housing198. The pitch is the angle of attack of the blades20into the air to control the production of a flow of air through which the blades20sweep.

Looking atFIG.4C, an exploded view illustrates the components included with the push-lock assembly156. The push-lock assembly156includes a body170having an interior172. The interior172is defined by a top174and a bottom176of the body170, having two shelves178disposed between the top174and bottom176on either side of the interior172. Each shelf178includes a fastener aperture180. The top174includes a circular extension182adapted to be received at the opening160of the first end150for mounting thereto. An internal body184is sized to be received within the interior172of the body170. A pin interior186is disposed in the internal body184for receiving insertion of the pin162. The pin162includes a pin extension163. Insertion of the pin162into the pin interior186and insertion of the internal body184into the interior172positions the pin162extending out through the opposite end of the body170as shown inFIG.4B. A plate188positioned behind the internal body184secures a spring190behind pin162within the internal body184. The spring190is positioned around the pin extension163and sandwiched between the pin162and the plate188. The pin extension163has an arcuate surface shaped to abut the plate188. The arcuate surface of the pin extension163and a concave inner end189of the plate188provides for slight movement of the pin162beyond straight linear movement. This facilitates insertion of the pin162into the mounts204on the motor housing198during installation of the blade holders18. Additionally, the arcuate outer surface191of the plate188is complementary to the body170form a cylindrical outer surface for the push-lock assembly156. Fasteners192, such as screws can insert into second fastener apertures194within the plate188for mounting the plate188at the shelves178, securing the spring190behind the pin162within the body170, forming the completed push-lock assembly156seen inFIG.4B. The spring190permits actuation of the pin162for coupling the blade holder18to the motor assembly16with the push-lock assembly156.

It should be appreciated that the blade holders18facilitate mounting of the blades20to the motor assembly16. The size and shape of the blade holders18minimizes system weight while maximizing structural integrity, which improves overall efficiency. For example, the blade holder18can be thin walled steel to achieve the minimal weight and maximum integrity. The blade holders18, including the push-lock assembly156with the pin162, determines the blade pitch. Thus, based upon blade features such as span, the push-lock assembly156can be manufactured to orient the blades20at an optimal pitch to maximize efficiency without requiring such a determination by an installer or consumer.

FIG.5Ashows the upper portion200of the rotatable motor housing198comprising a portion of the outer shell for the motor assembly16. The upper portion200further comprises a blade hub202having a central hub203integral with the rotatable motor housing198. Upper portion200includes five mounts204for receiving the blade holders18to mount the blades20. While five mounts204are shown, any number of mounts204are contemplated. The upper portion200further includes a plurality of mounting apertures206for mounting to a lower portion (seeFIG.6) and has a central aperture208for mounting the motor assembly16to the downrod assembly14at the shaft coupler52ofFIG.2B or2C.

FIG.5Aalso shows a close-up view of one mount204. The mount204includes a split sleeve210defining a sleeve interior212. The split sleeve210has two sets of compression fittings214for tightening or loosening the split sleeve210. The split sleeve210and compression fittings214are integrally formed with the rotatable motor housing198. The split sleeve210further includes a slit216extending along one side of the longitudinal length of the mount204. The slit216terminates at a pin-lock aperture218and is sized to accept slidable insertion of the pin162of the push-lock assembly156ofFIGS.4A-4C. The pin-lock aperture218operates as a blade rotation stop to prevent rotation of an attached blade20about a longitudinal axis, which could otherwise change the blade pitch during operation.

Turning toFIG.5B, for connection of the blade20to the motor assembly16via the blade holder18, the push-lock assembly156is mounted on the first end150of the blade holder18having the pin162oriented at an angle to determine the pitch of the blade20. The mount204can be a first receiver for receiving the first end of the blade holder18. The pin162slides into the slit216and inboard of the compression fittings214, depressing the pin162within the push-lock assembly156. The first end150slides into the sleeve interior212unit the pin162is received within the slit216by rotating the blade holder18. After rotating, the blade holder18is moved inwardly until the pin162is received in the pin-lock aperture218and the spring190pushes the pin162outwardly, locking the blade holder18to the mount204. Alternatively, the blade holder18can be fully inserted into the mount204and rotated until the pin162is received in the pin-lock aperture218. Fasteners (not shown), such as a screw or bolt, insert into the compression fittings214of the mount204, tightening the compression fittings214of the split sleeve210to secure the blade holder18to the mount204and to prevent the pin162from sliding out of the pin-lock aperture218.

After insertion of the blade holder18into the motor housing198, the disposition of the pin162based upon mounting to the index157fixes the rotation of the circular first cross-section140and orients the second end152of the blade holder18at an angle relative to a horizontal plane, which can be defined, for example, relative to the horizontal plane such as the ceiling or floor of the structure to which the fan10mounts. Alternatively, the pin162can orient the blade20relative to the blade hub202.

The blade20can be a second receiver for receiving the second end152of the blade holder18, having the second receiver located within the interior of the blade20. The blade20can mount to the blade holder18sliding the blade20over the second end152and into the interior chamber117, and aligning the mount holes100with the mounting apertures158. Fasteners can secure the blade20to the blade holder18by utilizing mount holes100and mounting apertures158. The angular disposition of the second end152, based upon the orientation of the pin162and the push-lock assembly156defines the pitch of the blade20. For example, positioning the pin162at five degrees offset from the major axis164of the ellipse of as shown inFIG.4Bcan orient the pitch of the blade20at five degrees relative to the ceiling or floor of the structure.

During operation, a torque generated by the motor assembly16can define the rotational speed for the fan10. The rotational speed of the fan10in combination with the blade pitch can determine a volumetric flow rate for air movement by the fan10. The volumetric flow rate can be the volume of air moved by the fan10during operation based upon the motor torque and the blade pitch. The blade span106can proportionally increase or decrease the volumetric flow rate, as a longer blade20generates greater airflow and a shorter blade20generates less. However, greater motor torque is required to drive a longer blade20at the desired rotational speed as compared to a shorter blade. In order to maximize flow rates while operating within the capabilities of the motor to generate torque, the blade pitch can be predetermined during manufacture based upon the span106of the blades20. For example, for a blade span106of about 12 feet or a total diameter of 24 feet, the pin162can be oriented to define a blade pitch of 8 degrees, while a blade span106of about 6 feet or total diameter of 12 feet can have a blade pitch of 12 degrees. Thus, the fan having a smaller area through which the blades sweep can have a greater pitch to drive a greater volume of airflow within the motor operational capabilities. It should be understood that the blade spans, fan diameters, and blade pitches as described are exemplary, illustrating that the blade pitch can be determined by fan diameter in order to maximize volumetric airflow or airspeed based upon operational capabilities of the motor.

Thus, mounting the push-lock assembly156to orient the pin162at the predetermined blade pitch angle can facilitate orienting the blades20at a pitch based upon the blade span106to maximize volumetric flow rate within motor torque capabilities. As such, the need for a consumer or installer to determine the proper pitch or attempt to properly orient the blades20at a pitch to maximize flow rate is eliminated. This elimination is due to supplying each fan blade20with a corresponding blade holder18having the predetermined blade pitch angle. It should be understood that the pitch is independent of the blade span106. The pitch can be any angle and the blade span106can be any length. It should be appreciated, however, that determining pitch based upon span106is beneficial to maximizing volumetric airflow based upon capabilities of the motor such as torque.

It should be appreciated that the blade hub202facilitates attachment and improves security of the blade holders18. The split sleeve210and pin-lock aperture218accurately aligns blade pitch among all mounted blades20. The compression fittings214secure the blade holders18to the blade hub202with easy tightening of mechanical fasteners. The integral mounts204with the rotating blade hub202enables rotational operation without requiring additional elements for rotating the blades20.

FIG.6illustrates an exploded view of the motor assembly16comprising the upper portion200of the motor housing198and the lower portion230of the motor housing198for encasing the stator232and rotor234. The stator232can including a coil winding of conductive material and the rotor234can include a plurality of magnets240. Alternatively, the stator232can include the magnets240and the rotor234can include a winding. The upper and lower portions200,230can couple and rotate together to define the rotating motor housing198. The lower portion230can include a set of stabilizing ribs236, providing increased structural integrity for the lower portion230, and it is contemplated that the upper portion200can include the same. The upper and lower portions200,230can further include a magnet seat238as an annular surface for supporting the plurality of magnets240mounted to the rotor234or forming a portion of the rotor234. The magnet seat238can include complementary channels formed in each of the upper and lower portions200,230of the motor housing198to collectively form the magnet seat238. The magnets240can be permanent magnets or an electromagnet comprising a motor winding. The rotor234and upper and lower portions200,230can have a plurality of mount holes242for mounting the rotor234to motor housing198utilizing, for example, mechanical fasteners such as a screw or bolt. The upper and lower portions200,230can each have an edge243. The horizontal edges243can abut one another when mounting the upper and lower portions200,230. Alternatively, the upper and lower portions200,230can be space by a gap (not shown) between the edges243, exposing a portion of the rotor234through the gap.

During operation, electric current is provided to the stator232causing the rotor234to rotate about the stator232. By mounting the rotor234to the upper and lower portions200,230, the motor housing198can rotate about stator232, rotating any blade holders18and blades20attached thereto.

It should be appreciated that the motor housing198is a clamshell style housing having upper and lower portions200,230for mounting directly to the rotor234for rotating the entire motor housing198, blade hub202, and blades20coupled thereto. The motor housing198enables a rotor234and stator232combination to be housed within the motor assembly16suspended from the downrod assembly14without requiring a motor assembly16to be completely rotationally mounted. Operational wear, vibration, and wobble are minimized while lifetime is increased.

Referring now toFIG.7A, an alternative motor assembly400is illustrated including a rotatable housing portion402having an upper portion404and a lower portion406forming the rotatable housing portion402. A rotating blade hub408is included on the rotatable housing portion402and can be integral with the upper portion404. At least one blade mount410is provided on the blade hub408, such as five blade mounts410in one example. Each blade mount410includes a pin aperture412and at least one fastener aperture414. The pin aperture412can be substantially similar to the pin-lock aperture218ofFIG.5A, in one example.

The blade mounts410can define a substantially cylindrical cavity420. A channel422can be formed in the blade mounts410such that the cavity420includes an enlarged portion424at the channel422. In one example, the channel422can be used to guide the pin162toward the pin aperture412for locking the blade holder18to the motor assembly400at the blade mount410.

The fastener apertures414can each include an inserted fastener432. The fastener432, for example, can be any suitable fastener, such as a setscrew or grub screw. The fastener apertures414are disposed in a face434. The fastener apertures414extend from the face434through the blade mounts410to the cavity420. Additionally, a plurality of housing fasteners436can be used to secure the upper portion404to the lower portion406, as well as securing a rotor through mount holes similar to that ofFIG.6.

Referring now toFIG.7B, an exploded view illustrates a set of two fasteners432and two saddles430. The fastener432and the saddle430can be separate or integral, or coupled permitting rotation of the fastener432without rotating the saddle430. The saddles430include a curved surface438opposite of the fastener432and a post439. The fastener432can have a hollow interior437, adapted to receive the post439and enabling rotation of the fastener432about the post439.

The face434can be offset from a vertical axis416at an angle418from a face axis419. The angle418can be any suitable angle, such as 20 degrees in one non-limiting example, in order to align the fastener apertures414radially to the center of the cavity420. Furthermore, the angled face434provides easy access to the fasteners432in the fastener apertures414by a user.

Referring now toFIG.7C, in operation, the user can tighten or loosen the saddle430within the cavity420by tightening or loosening the fastener432. A user inserts the blade holder18, such as that ofFIG.5B, into the blade mount410. The pin162on the blade holder18aligns along the channel422and the blade holder18inserts until the pin162secures in the pin aperture412.

After insertion of the blade holder18, the fastener432can be used to tighten the saddle430against the first end150of the blade holder18inserted within the blade mount cavity420. The tightened saddle430abuts the blade holder18at the curved surface438to apply pressure to the first end150of the inserted blade holder18to provide a secondary securing means for the blade holder18.

The saddle430is oriented at the angle418, such as the 20-degree angle, as defined by the face434, and can orient the saddle430radially from the center of the blade holder18. The radial orientation of the saddle430against the inserted blade holder18prevents rotation of the blade holder18based upon the insertion force from the saddle430. This radial insertion further prevents rotational movement of the pin162inserted within the pin aperture412against the blade mount410, which can tend to otherwise crack the blade holder18.

It should be appreciated that the motor assembly400and the blade hub408can be substantially similar to the motor assembly16and blade hub202ofFIG.5B, for accepting the insertion of a blade holder18for coupling the blade20to the motor assembly400. The saddles430provide for a secondary retention system for the blade hub408, as well as can reduce vibration, noise, or wobble of the ceiling fan, which can increase overall fan efficiency.

FIG.8Ais one example of the non-rotating motor shaft90. The motor shaft90includes an upper end252and a lower end254having a hollow interior256. The exterior surface of the upper end252includes a threaded connection258for coupling a collar which can include the shaft coupler52ofFIG.2B, the retainer nut92ofFIG.2C, or a combination of both. A keyed recess260can be disposed at the upper end252for alignment with the shaft coupler52at coupling. The motor shaft90can further include an upper collar262and a lower collar264, with the upper collar262having an increased outer diameter and the lower collar264having a further increased outer diameter, being greater than that of the upper collar262. The upper collar262includes a step-wise increase in outer diameter for the motor shaft90defining an annular upper bearing stop266. The upper collar262further includes a wiring opening269. The lower collar264includes a further step-wise diameter increase from the upper collar262, defining a stator stop268for supporting the stator winding232. Underneath the lower collar264is a step-wise decrease in diameter defining a lower bearing stop270.

As shown inFIG.8B, the upper and lower bearings272,274are disposed on the upper bearing stop266and the lower bearing stop270, respectively. The upper and lower bearing stops266,270are formed within the motor shaft90for positioning the bearings272,274against the motor shaft90and permitting rotation of the motor housing198about the non-rotating motor shaft90.

Looking atFIG.8C, showing a cross-section of a portion of the motor assembly16illustrates the combination of the components associated with the non-rotating motor shaft90. The non-rotating motor shaft90is disposed within the motor housing198having the bearings272,274disposed in the upper and lower bearing stops266,270. A spacer280can be placed between the upper bearings272and the stator providing additional support during operation. The stator232rests on the stator stop268and fixes the position of the stator232relative to the motor shaft90. The rotor234surrounds the stator232and mounts between the upper portion200of the motor housing198and the lower motor housing portion230on the magnet seat238. Fixing the stator232on the stator stop268fixes the position of the stator232relative to the rotor234to fix the air gap between the two. The upper portion200further includes an upper bearing seat284abutting the upper bearing272above the upper bearing stop266. The lower portion230further comprises a lower bearing seat286abutting the lower bearing274below the lower bearing stop270. The upper and lower bearing seats284,286operate to sandwich the bearings272,274between the upper and lower bearing stops266,270, respectively, fixing the bearings in place during operation. During operation, rotation of the rotor234about the stator232rotates the motor housing198and the blade holders18attached thereto, rotating the blades20of the ceiling fan10.

The shaft coupler52mounts to the upper end252of the motor shaft90, such as by the threaded connection258. The shaft coupler52couples to the downrod plate50, utilizing the fasteners54or press studs. The downrod plate50couples to the downrod assembly14or is integral with the downrod assembly14, mounting the downrod assembly14to the motor shaft90via the shaft coupler52. Thus, the downrod assembly14suspends the motor shaft90from the structure or ceiling. During operation, the rotor234, motor housing198including the upper and lower portions200,230, the mounts204, blade holders18, and blades20can all rotate about the motor shaft90around the bearings272,274while the motor shaft90, stator232, downrod plate50, motor coupler52, and downrod assembly14remain fixed and are non-rotating.

The motor shaft90can further include a weep hole288. The weep hole288can be disposed below the opening269, as electrical wiring can be provided through the opening269. In operation, such as in weather heavy environments where rain, snow, or precipitation is common, such as in a farming environment, the weep hole288can protect the wiring at the opening269. In one example, rain may run into the interior of the motor shaft90. The motor shaft90can fill with the rainwater. The weep hole288provides for draining of the rainwater from the interior of the motor shaft90before the water can rise to the electronics, providing for outdoor or weathered operation of the ceiling fan.

The motor assembly16further includes one or more spring members282, such as a spring or spring finger, disposed underneath the lower bearings274between the lower bearings274and the lower motor housing portion230permitting rotation of the spring member282with the rotation of the lower motor housing portion230. The spring members282provide a downward force against the lower portion230of the motor housing198at the lower bearing seat286, which is transferred to the upper housing portion200, providing a downward force by the upper motor housing portion200against the upper bearings272at the upper bearing seat284. During operation, the blades20push a volume of air downward, also providing an upward force for the motor assembly16. The spring members282providing a balancing force to combat the forces generated during operation maintaining fan balance. Thus, the weight of the rotor234, mounted to the motor housing198, is transferred through the upper bearing272to the motor shaft90and is not borne by the motor housing198alone.

It should be appreciated that the non-rotating motor shaft90facilitates coupling of the motor assembly16to the downrod assembly14. The motor shaft90, including the upper bearing stop266, stator stop268, and the lower bearing stop270, facilitates alignment of the bearings272,274and operates in combination with the motor housing198to secure the bearings in place between the stops266,268and the bearing seats284,286to reduce vibration and movement, such as wobble of the fan10during operation while permitting a rotating motor housing198. The bearing stops266,270and the stator stop268fix the positions of the bearings272,274and stator232relative to the motor housing198and the rotor234. Mounting the rotor234to the motor housing198fixes the rotor234relative to the stator232, bearings272,274, and the motor shaft90. Fixing these positions fixes an air gap between the stator232and rotor234, determining operational efficiency of the motor while maintaining stability during operation.

Additionally, the spring member282creates a preload against the lower portion230of the motor housing198to equalize position of the rotating motor housing198during operation, which further reduces vibration and movement of the fan10.

Looking now atFIG.9A, the retention system300includes the support cable302coupled to the retaining rod304by a fastener306. The support cable302can mount to a ceiling or a structure, such that the retention system300can provide a redundancy to prevent falling or collapse of the ceiling fan10in the event that the initial ceiling mount structure12fails. The fastener306, for example, can be a bolt having an aperture307for securing with a pin308, or alternatively, can be a screw and nut system. Opposite of the support cable302, the retaining rod304can couple to the retainer plate310which includes an outer portion312and an inner portion314. The inner portion314includes an offset opening316for accepting insertion of the retaining rod304. The inner portion314has mounting holes318for mounting to the motor shaft90.

InFIG.9B, an exploded view illustrates the interconnection of the retention system300. A mount end320of the retaining rod304can insert through the opening316in the retainer plate310, with the opening316shaped to accept the shape of the mount end320. The mount end320can include a flattened surface with a mount hole322adapted to be received by a clevis324on one end of the support cable302. The retaining rod304, opposite of the mount end320, includes a cap326that abuts the bottom of the retainer plate310. The bottom of the retainer plate310includes a recessed portion (seeFIG.11A) adapted to receive the cap326.

It should be appreciated that the retention system300provides a redundancy in the event that the initial ceiling mount structure12fails. The retaining rod304disposed within the downrod assembly14and the motor shaft90coupled to the retainer plate310can permit continued rotation of the fan10during such a failure event. The continued rotation allows the fan10to slow down without further damage to internal components as well as supporting the fan10from falling. Without the ability for continued rotation, the internal components can otherwise contact one another, damaging the fan10, its components, or otherwise causing the fan10to fall despite redundant measures to prevent such a fall.

Turning toFIG.10A, the wiring harness340is illustrated having the wiring conduit342, a body344, and electrical wiring leads346. The wiring conduit342extends from the body344, electrically coupling the body344to a structure power supply. The wiring leads346, which can comprise live wires348and a ground wire350electrically couple to the stator232for powering the stator232to drive the rotor234during operation of the ceiling fan10. It should be appreciated that the wiring harness340separates the ground wire350from the live wires348preventing the potential for a short.

Looking atFIG.10B, the wiring harness340can slide into the stator232. The wiring harness340can terminate at the electrical connector343facilitating plug-in connection of the wiring harness340during installation of the fan10. The stator232can have a central aperture360having a slot362sized to receive the body344of the wiring harness340. Inserting the body344into the slot362positions the wiring leads346along the bottom of the stator232to provide power to the stator232.

Similarly, the opening269of the motor shaft90is sized to receive an end364of the body344, permitting the wiring conduit342to extend through the interior256of the motor shaft90. Thus, the wiring conduit342can extend through the interior256of the motor shaft90, having the end364inserted in the opening269. The combined motor shaft90and wiring harness340can be inserted into the stator232, having the extending body344of the wiring harness340inserted into the slot362of the stator232, providing the wiring leads346to the stator232.

It should be appreciated that the wiring harness340provides a power source to the stator232internal of and through the non-rotating motor shaft90. Additionally, the disposition of the motor shaft90and the retainer system300separates the retaining rod304from the wiring harness340, minimizing the possibility for electrical shorts or wear during operation by rubbing the two together.

Looking atFIG.11A, a cross-sectional view illustrates the combined motor shaft90, retention rod304, retainer plate310, and wiring harness340. The retainer plate310mounts to the motor shaft90by aligning the mounting holes318with complementary fastener apertures370within the motor shaft90. The offset orientation of the opening316within the retainer plate310positions the retaining rod304toward one side of the interior256of the motor shaft90. The retainer plate310mounts to the motor shaft90positioning the opening316of the retainer plate310on an opposite side as the opening269within the motor shaft90. As such, the wiring harness340positions on the opposite side of the interior256of the motor shaft90from the retaining rod304, spacing the two from one another and preventing any potential contact, which might otherwise short the wiring harness340or wear against one another during operation.

Turning toFIG.11B, the combination of the motor assembly16can be appreciated. From the bottom, the retaining rod304inserts through the retainer plate310until the cap326abuts the inner portion314of the retainer plate310. The inner portion314mounts to the bottom of the motor shaft90, through an aperture380in the lower motor housing portion230. The motor shaft90is non-rotating, and therefore the retainer plate310is non-rotating and is spaced from the lower motor housing portion230to permit rotation of the motor housing portion230during operation. The wiring harness340inserts into the opening269of the motor shaft90, having the wiring conduit342extending up through the interior256of the motor shaft90. The lower bearings274position at the lower bearing stop270, fixing the lower bearings274between the motor shaft90and the lower bearing seat286. The spring members282(FIG.8C) can be positioned between the bottom of the lower bearings274and the lower motor housing portion230providing a downward force upon the lower motor housing portion230. The rotor234and stator232can position around the motor shaft90, resting the rotor234on the magnet seat238of the lower housing portion230and resting the stator232on the stator stop268of the motor shaft90. The upper bearings272can position on the upper bearing stop266, having the upper bearing seat284fixing the upper bearings272against the motor shaft90. The upper housing portion200can mount to the lower housing portion230with a plurality of fasteners through the rotor234, encasing the rotor234, stator232, motor shaft90, bearings272,274, and wiring harness340. The support cable302can be coupled to the mount end320of the retaining rod304extending through the top of the upper motor housing portion200at the clevis324. The shaft coupler52is disposed around the support cable302and couples to the motor shaft90. The shaft coupler52can mount to the downrod plate50, suspending the motor assembly16from the downrod assembly14and the structure.

In operation, a power supply is provided to the stator232via the wiring harness340, inducing rotation of the rotor234. The rotor234couples to the motor housing198and rotates about the stator232, rotating the blade holders18and the blades20attached thereto.

It should be appreciated that the ceiling fan10as described herein provides a number of advantages. These advantages can be combined into one embodiment or utilized individually in any particular embodiment. The following are examples of some of the advantages. The downrod assembly14utilizes the downrod plate50to mount to the shaft coupler52for mounting to the motor shaft90. The combination of the downrod plate50and shaft coupler52facilitates mounting of the downrod assembly14to the motor shaft90for suspending the motor assembly16from the ceiling. Additionally, the downrod plate50and shaft coupler52permit the motor shaft90to be non-rotating without requiring the downrod assembly14or the entire motor assembly16to rotate. Furthermore, the downrod assembly14includes the guy wire fitting58for mounting the downrod assembly14to the ceiling separate from the initial ceiling mount structure12. Additionally, the non-rotating nature of the downrod assembly14facilitates the mounting of the guy wire fitting58directly to the downrod assembly14without requiring a separate non-rotating element for mounting to guy wires22. The guy wiring system provides a redundancy in the event the fan10can fall from ceiling mount structure as well as reduces operational vibration and gyroscopic tilt.

Furthermore, the tapped studs94or press studs facilitate alignment and mounting of the downrod plate50to the shaft coupler52. The studs94permit the downrod assembly14to quickly mount to the motor shaft90via the shaft coupler52. Additionally, the use of the retainer nut92facilitates slidable insertion of the motor shaft90, into the shaft coupler52as well as can provide a redundant coupling for attaching the motor shaft90to the shaft coupler52.

Further still, the blades20can have a thickness-to-chord ratio of about 13.8% and include an airfoil shape to maximize efficiency of the blades20. Furthermore, the blade span106, chord116, thickness122, rotational speed, and pitch can be adapted to maximize efficiency, airspeed, and airflow volume during operation of the ceiling fan10.

Further still, the blade holders18including the cross-sections140,142at the first and second ends150,152facilitating mounting of the blades20to the mounts204. The size and shape of the blade holders18minimizes system weight while maximizing structural integrity, which improves overall efficiency. The blade holders18include the push-lock assembly156with the pin162, which determines the blade pitch. Thus, based upon blade features such as span, the push-lock assembly156can be manufactured to orient the blades20at an optimal pitch to maximize efficiency without requiring such a determination by an installer or consumer.

Further still, the blade hub202, having multiple mounts204, facilitates attachment and improves security of the blade holders18. The split sleeve210and pin-lock aperture218accurately aligns blade pitch among all mounted blades20. The compression fittings214facilitate securing the blade holders18to the blade hub202with tightening of mechanical fasteners. The integral mounts204with the rotating blade hub202enables rotational operation without additional elements for rotating the blades20.

Further still, the motor housing198is a clamshell style housing having upper and lower portions200,230for mounting directly to the rotor234for rotating the entire motor housing198, blade hub202, and blades20coupled thereto. The motor housing198enables a rotor234and stator232combination to be housed within the motor assembly16. Thus, the motor housing198can rotate to drive the blades20without requiring rotation of the entire motor assembly16. Operational wear, vibration, and wobble are minimized while lifetime is increased.

Further still, the non-rotating motor shaft90facilitates coupling of the motor assembly16to the downrod assembly14. The motor shaft90, including the upper bearing stop266, stator stop268, and the lower bearing stop270facilitates alignment of the bearings272,274and operates in combination with the motor housing198to secure the bearings in place between the stops266,268and the bearing seats284,286to reduce vibration and wobble of the fan10during operation while permitting a rotating motor housing198. The stator stop268in combination with mounting the rotor234to the motor housing198fixes the air gap between the stator232and the rotor234to determine operational efficiency and maintain operational stability of the motor assembly16. Additionally, the spring member282creates a preload against the lower portion230of the motor housing198to equalize position of the rotating motor housing198during operation, which further reduces vibration and wobble of the fan10as well as offsets the upward force generated by rotation of the fan blades20.

Further still, the retention system300provides a redundancy in the event that the initial ceiling mount structure12fails. The retaining rod304disposed within the downrod assembly14and the motor shaft90, coupled to the retainer plate310permits continued rotation of the fan10during such a failure event. The continued rotation allows the fan to slow down without further damage to internal components as well as supporting the fan10from falling. Without the ability for continued rotation, the internal components can otherwise contact one another, damaging the fan10, its components, or otherwise causing the fan10to fall despite redundant measures to prevent such a fall.

Further still, the wiring harness340provides a power source to the stator232internal of and through the non-rotating motor shaft90. Additionally, the disposition of the motor shaft90, and the retainer system300separates the retaining rod304from the wiring harness340, minimizing the possibility for electrical shorts or wear during operation by rubbing the two against one another.

Further still, the combination of elements provides for utilizing a non-rotating motor shaft90with a non-rotating downrod assembly14, having the motor assembly16suspended from the downrod assembly14. The combination of elements disclosed herein maximizes fan efficiency, while providing redundancies in the event that the fan10might fall, which can occur in an industrial environment due to typical industrial operations, which can hit the fan10. Furthermore, the fan10as disclosed facilitates installation having easily interconnectable elements. Additionally, the overall vibration and wobble of the fan10is reduced, further increasing efficiency while minimizing noise and power consumption.

Referring now toFIG.12, another exemplary ceiling fan510is illustrated. The ceiling fan510includes a motor housing512. A central aperture520can be formed in the center of the motor housing512and extending through the motor housing512. The motor housing512can operate as a rotating blade hub for mounting a set of blades514, shown as four blades, and can mount to the motor housing512via mount struts516. The blades514can be similar to the blades as described herein, such as the blades20described inFIGS.3A-3C, for example. A set of hub sockets518can be formed in the motor housing512adapted to couple the mount struts516for mounting the blades514to the motor housing512.

FIG.13illustrates an enlarged view of the motor housing512ofFIG.12. The motor housing512can have an upper surface530. The hub sockets518can have a bottom wall532with tapered walls534extending between the upper surface530and the bottom wall532. The bottom wall532can be horizontal. The tapered walls534can have a variable cross-sectional area, defining an interior wall536extending as a neck538terminating at a throat540. A mouth542extends from the throat540to a terminal edge544of the motor housing512. Fasteners546can couple the mount struts516to the motor housing512and the blades514to the mount struts516. As shown, two fasteners546couple each mount strut516to the motor housing512and two fasteners546couple each blade514to each complementary mount strut516. While two fasteners546are shown at each position, any number of fasteners is contemplated. The fasteners546can be any suitable fastener, such as a screw or bolt in non-limiting examples.

The ceiling fan510further includes a motor shaft550disposed within and partially extending from the motor housing512for coupling to a motor interior of the motor housing512. A nut598redundantly fastens the motor housing512to the motor shaft550. A shaft coupler552couples to the motor shaft550for suspending the ceiling fan510. Additionally, a secondary suspension system554is visible for redundantly suspending the ceiling fan510from a structure via the motor shaft550.

Referring now toFIG.14, a cross-section of the ceiling fan510taken along section XIV-XIV ofFIG.13. Fasteners560couple an upper motor housing portion562and a lower motor housing portion564to form the motor housing512. The upper and lower motor housing portions562,564encase a motor assembly566including a fixed stator568and a rotor570rotatable about the stator568. The stator is non-rotating and slidably couples to the motor shaft550. The fasteners560couple the rotor570to the motor housing512such that the motor housing512rotates with the rotor570. The stator568fixes to the motor shaft550such that the motor shaft550is non-rotating. The rotor570, the motor housing512, and any other rotating portions of the ceiling fan encased within the motor housing512can define a rotor assembly, which rotates about the motor shaft550.

The motor shaft550can include an upper shoulder556and a lower shoulder558. Two bearings572slidably mount to the motor shaft550to permit rotation of the motor housing512about the motor shaft550. The bearings572abut the rotor assembly at the motor housing516. The upper bearing572can position at the upper shoulder556and the lower bearing572can position at the lower shoulder558. Each bearing572includes an inner housing574and an outer housing576encasing a set of bearing balls578. As such, the outer housing576can rotate with the motor housing512via the bearing balls578while the inner housing574can remain stationary at the motor shaft550.

The bearings572, which rest on the shoulders556,558, can support the motor assembly566. As such, the shaft coupler552can suspend the motor shaft550from a building and the motor shaft550can support the remaining portions of the ceiling fan510, including the motor assembly566, or any blades attached thereto.

A set of spacers580slidably mount to the motor shaft550. The spacers580can space the bearings572from the stator568. The spacers580can position against the inner housing574of the bearing and the stator568as non-rotating elements. The upper spacer380can circumscribed the upper shoulder556. The spacers580fix the sliding location of the first and second bearings572relative to the stator along the motor shaft550. As such, the stator568is compressively retained between the first and second spacers580and the bearings572compressively retain the spacers580, and thus the stator568. The spacers580maintain the bearings572positioned against the motor housing512to minimize wobble or vibration of the motor assembly566. On the opposite side of the lower bearing572, a spring member582is provided to load the bearings572against the motor housing512. The spring member582can position against the outer housing576of the bearing572between the housing512, between two rotating parts. As such, the spring member582can be a rotating member as well. The spring member582also minimizes wobble or vibration emanating from the motor assembly566. At the bottom of the lower motor housing564, a plate583can fasten to the motor housing512to encase the motor assembly566at the bottom.

An electrical aperture584is provided in the motor shaft550with an electrical conduit586extending through the electrical aperture584. The electrical conduit586can provide electrical power to the stator568for powering the motor assembly566to drive the rotor570.

The shaft coupler552couples to the motor shaft550for suspending the ceiling fan510from a structure. A pin aperture588is formed in the motor shaft550with a seat590provided in the interior of the motor shaft550opposite of the pin aperture588. Alternatively, the seat590can be an additional pin aperture588extending through the motor shaft550. A retainer pin592inserts through the pin aperture588and secures in the seat590. A retainer rod594can attach to the pin592and includes a retainer aperture596. The retainer aperture596can secure to a redundancy system, such as a wire cord extending through a connected downrod, for example. As such, the retainer rod594can couple to the motor shaft550via the retainer pin592in the pin aperture588and the seat590.

A nut598with a lock washer600can be provided around the top of the motor shaft550within the shaft coupler552. The nut598can redundantly secure the shaft coupler552to the motor shaft550. Additionally,598, the nut598can secure the pin592within the pin aperture588.

The combination of the pin592, the retainer aperture596, and the nut598can define the secondary suspension system554. The secondary suspension system554provides a redundant mount for the ceiling fan510. As the secondary suspension system554mounts to non-rotation portions of the ceiling fan510, such as the motor shaft550, redundant operation of the secondary suspension system554permits continued rotation of the ceiling fan510during user, minimizing potential damage to the ceiling fan510during operation of the secondary suspension system554.

FIG.15is an exploded view of the components shown inFIG.14, including exploded mount struts516. In assembly, the motor assembly566can couple to the motor shaft550. The electrical conduit586ofFIG.14can be installed within the motor shaft550to the motor assembly566. Spacers580can be installed along the motor shaft550on either side of the motor assembly566. Bearings572can be installed on either side of the spacers580. At the bottom, the spring member582can be positioned against the bearing572. At the top, the shaft coupler552and the secondary suspension system554can be mounted above the motor shaft550. The mount struts516can mount to the motor housing512for mounting blades.

Turning now toFIG.16, an exemplary mount strut516is shown. The mount strut516can be hollow, and made of steel, for example, reducing weight while maintaining structural integrity. The mount strut516includes a first portion as a hub portion610and a second portion as a blade portion612. The hub portion610and the blade portion612can have a cross-sectional area that is non-constant along the length of the strut516, while it is contemplated that the cross-sectional area can be constant. The hub portion610can mount to the motor housing512ofFIG.15and the blade portion612can mount to the blades514ofFIG.12. A set of mount aperture616can be formed in the mount strut516, shown as two aperture616in each portion610,612. A twist614is formed in the mount strut516. The twist614orients the mount strut516such that the hub portion610and the blade portion612are rotationally offset from one another by an offset angle616. The offset can be between 1-degree and 45-degrees, for example. The offset angle616can be used to orient a blade attached to the mount strut516at a pitch angle or angle of attach relative to a chord of the blade. The twist614enables flat, flush mounting of the hub and blade portions610,612against the horizontal bottom wall532(FIG.13) and the blade514, respectively. The particular offset angle616can be tailored based upon particular ceiling fan510to maximize efficiency. For example, the offset angle616can be increased or decreased based upon the length of the blades, or the rotational speed of the ceiling fan510, for example.

It should be appreciated that the ceiling fan510and related components described inFIGS.12-16provide for a ceiling fan having improved efficiency. The ceiling fan510provides for maximizing air movement while minimizing energy costs. Additionally, the secondary suspension system554provides for a redundant mounting system for the fan. The components are optimized to reduce weight to further improve efficiency and minimize the weight tax on a suspending structure.

FIG.17illustrates a blade holder, which can be the blade holder18as described herein, with an alternative push-lock assembly650for mounting the blade holder18to a ceiling fan motor housing, such as the motor hub, such as the motor housing198ofFIG.2. The push-lock assembly650includes an end cap652including a pin aperture654. A pin656is provided in the pin aperture654. The blade holder18includes a spring pin aperture658. A spring pin660is provided in the spring pin aperture658. The spring pin660couples the push-lock assembly650to the blade holder18. At assembly, the push-lock assembly650can insert into the blade holder18and the spring pin660can insert into the spring pin aperture658to secure the push-lock assembly650to the blade holder18.

Referring now toFIG.18, the end cap652is shown in dashed-line to provide a view of the interior assembly of the push-lock assembly650. The end cap652further includes a lock end670and a mount end672. The mount end672includes smaller diameter than the lock end670permitting insertion into the blade iron18(FIG.17). The mount end672also has a pair of opposing apertures674for receiving the spring pin660.

Within the lock end670is a pin assembly676. The pin assembly676includes the pin656, a spring680and a washer682. A seat684is formed in the interior of the lock end670as part of the end cap652. The washer682can seat at the seat684to secure the spring680at the seat684. The spring680abuts the pin656opposite of the seat684and the washer682. The pin656further includes a pin end686and an actuation end688. The actuation end688includes a widened diameter and abuts the spring680. As such, the pin656can actuate via the spring680to move the pin end686in and out of the pin aperture654.

In operation, the pin656can actuate via the spring680to retract during insertion of the push-lock assembly650for coupling the blade holder18(FIG.17) to a ceiling fan or motor housing. At insertion, the pin656retracts into the end cap652. At full insertion, the pin656will extend into a receiving aperture, such as that of the pin lock218ofFIG.5A. In such a receiving aperture, the push-lock assembly650attaches to the ceiling fan to mount the blade holder18. A blade, such as that described herein, can mount to the opposing end of the blade holder18to mount the blade to the ceiling fan.

The push-lock assembly650as described provides for a strengthened assembly for coupling a blade holder to a ceiling fan or motor housing. The push-lock assembly650also provides for a simple assembly, which facilitates slidable insertion of the blade holder18to mount to the motor housing. Removal of such a blade holder18is also simplified by depression of the pin656and slidable removal of the blade holder18. Thus, it should be appreciated that the push-lock assembly provides for a simplified assembly for mounting a blade and blade iron to a ceiling fan, reducing cost and providing for ease of use by a user or installer.

In addition to the concepts covered by the claims, the following concepts can also provide for the basis for claims in any possible combination:

A ceiling fan comprising: a motor assembly having a non-rotating motor shaft and a rotating blade hub rotating about the non-rotating shaft; multiple blades mounted to the rotating blade hub; and a downrod having an upper end configured to mount to a structure to a lower end mounted to the non-rotating motor shaft.

A ceiling fan assembly further comprises a shaft coupler coupled to the non-rotating motor shaft and a downrod plate coupled to the lower end of the downrod, wherein the shaft coupler and downrod plate are secured to each other.

A ceiling fan assembly wherein the shaft coupler located above the rotating blade hub.

A ceiling fan assembly wherein the shaft coupler located on an upper end of the non-rotating motor shaft.

A ceiling fan assembly wherein the shaft coupler comprises a collar having a central opening that receives the non-rotating motor shaft.

A ceiling fan assembly wherein the collar slides over the non-rotating motor shaft.

A ceiling fan assembly wherein the collar slides over the non-rotating motor shaft.

A ceiling fan assembly wherein the collar is indexed relative to the non-rotating motor shaft.

A ceiling fan assembly wherein the index comprises one of the collar and the non-rotating motor shaft comprises a key and the other comprises a keyway that receives the key.

A ceiling fan assembly further comprising a retaining nut threaded onto a portion of the non-rotating motor shaft.

A ceiling fan assembly wherein at least one of the shaft coupler and the downrod plate has tapped studs and the other of the at least one shaft coupler and downrod plate has openings for receiving the tapped studs.

A ceiling fan assembly further comprising nuts threaded onto the tapped studs to secure together the shaft coupler and the downrod plate.

A ceiling fan assembly further comprising a guy wire fitting mounted to the downrod.

A ceiling fan assembly wherein the guy wire fitting is located above the lower end of the downrod.

A ceiling fan assembly wherein the guy wire fitting comprises a disk having multiple openings.

A ceiling fan assembly wherein the disk has an inner ring and an outer ring, with the openings lying between the inner and outer rings.

A ceiling fan assembly further comprising at least one turnbuckle having a hook extending through one of the openings and hooked to the outer ring.

A ceiling fan assembly wherein the disk is welded to the downrod.

A ceiling fan comprising: a motor assembly having a rotating blade hub; multiple blades mounted to the rotating blade hub; a downrod having an upper end configured to mount to a structure and a lower end mounted to the motor assembly; and a guy wire fitting mounted to the downrod.

A ceiling fan assembly wherein the guy wire fitting is located above the lower end of the downrod.

A ceiling fan assembly wherein the guy wire fitting comprises a disk having multiple openings.

A ceiling fan assembly wherein the disk has an inner ring and an outer ring with the openings lying between the inner and outer rings.

A ceiling fan assembly further comprising at least one turnbuckle having a hook extending through one of the openings and hooked to the outer ring.

A ceiling fan assembly wherein the disk is welded to the downrod.

A ceiling fan comprising: a motor assembly having a rotating blade hub and a downrod mount; multiple blades mounted to the rotating blade hub; a downrod having an upper end configured to mount to a structure and a lower end having a mount motor; and multiple studs provided in one of the downrod mount or the motor mount and corresponding openings provided in the other of the downrod mount or the motor mount, with the studs being received within the openings to aid in securing the downrod to the motor assembly.

A ceiling fan further comprising a motor assembly plate coupled to the motor assembly and a downrod plate coupled to the lower end of the downrod, wherein the studs are provided on one of the motor assembly plate or the downrod plate and the openings are provided in the other of the motor assembly plate and the downrod plate.

A ceiling fan wherein the motor assembly comprises a non-rotating shaft about which the rotating blade hub rotates and which has a shaft coupler forming the motor assembly plate.

A ceiling fan wherein the shaft coupler is located above the rotating blade hub.

A ceiling fan wherein the shaft coupler is located on an upper end of the non-rotating motor shaft.

A ceiling fan wherein the shaft coupler comprises a collar having a central opening that receives the non-rotating motor shaft.

A ceiling fan wherein the collar slides over the non-rotating shaft.

A ceiling fan wherein the collar is indexed relative to the non-rotating shaft.

A ceiling fan wherein the index comprises one of the collar and non-rotating shaft comprises a key and the other comprises a keyway that receives the key.

A ceiling fan further comprising a retaining nut threaded onto a tapped portion of the non-rotating motor shaft.

A ceiling fan wherein the studs are tapped studs.

A ceiling fan further comprising nuts threaded onto the tapped studs to secure together the shaft coupler and the downrod plate.

A ceiling fan comprising: a motor assembly having a rotating blade hub with a first receiver; at least one fan blade having a second receiver; and a blade holder having a first end with a first cross-section and a second end with a second cross-section different from the first cross-section, with the first end received within the first receiver and the second end receiving within the second receiver to couple the blade to the blade hub.

A ceiling fan assembly wherein the first and second cross-sections have a height and a width and the height of the second cross-section is less than the height of the first cross-section.

A ceiling fan assembly wherein the first and second cross-sections have the same area.

A ceiling fan assembly wherein the first and second cross-sections are not the same.

A ceiling fan assembly wherein the area of the second cross-section is greater than the area of the first cross-section.

A ceiling fan assembly wherein the first cross-section is a circle and the second cross-section is an ellipse.

A ceiling fan assembly wherein the blade holder comprises a circular section defining the circle, an elliptical section defining the ellipse, and a transition section connecting the circular and elliptical sections, with the transition section transition from a circular to an elliptical shape.

A ceiling fan assembly wherein the blade holder is a single piece.

A ceiling fan assembly wherein the blade holder is formed by stamping.

A ceiling fan assembly wherein the elliptical section has multiple mounting openings.

A ceiling fan assembly wherein the second receiver is located within an interior of the blade and the elliptical section is received within the second receiver.

A ceiling fan assembly wherein fasteners extend through the multiple openings and the blade.

A ceiling fan assembly wherein the first receiver comprises at least one sleeve and the circular section is received within the sleeve.

A ceiling fan assembly further comprising an index fixing the rotational position of the circular section relative to the sleeve.

A ceiling fan assembly wherein the index comprises a biased detent.

A ceiling fan assembly wherein the biased detent comprises a biased pin on one of the circular section and the sleeve and a recess receiving the pin on the other of the one of the circular section and the sleeve.

A ceiling fan assembly wherein the blade comprises a hollow interior and an open end, which form at least a portion of the second receiver.

A ceiling fan assembly wherein the first receiver comprises at least one split sleeve and the first end is received within the compressively retained by the at least one split sleeve.

A ceiling fan assembly further comprising an index fixing the rotational position of the blade relative to the blade hub.

A ceiling fan assembly further comprising mechanical fasteners passing through the blade and the second end to secure the blade to the blade holder.

An aspects of the disclosure described herein relate to a ceiling fan comprising: a motor assembly having a rotating blade hub; and at least one blade mount provided on the blade hub and having a split sleeve and a compression fitting closing the split sleeve.

A ceiling fan wherein the motor assembly comprises a rotatable housing portion and the blade hub is provided on the rotatable housing portion.

A ceiling fan wherein the motor assembly comprises a non-rotating motor shaft about which the rotatable housing portion rotates.

A ceiling fan wherein the blade hub is integrally formed with the rotatable housing portion.

A ceiling fan wherein the split sleeve and compression fittings are integrally formed with the rotatable housing portion.

A ceiling fan wherein the motor assembly comprises upper and lower motor housings and one of the upper and lower motor housings forms the rotatable housing portion.

A ceiling fan further comprising a pair of axially-spaced compression fittings closing the split sleeve.

A ceiling fan wherein the compression fitting is integrally formed with the split sleeve.

A ceiling fan wherein the compression fitting comprises a split ring.

A ceiling fan further comprising a rotation index.

A ceiling fan of wherein the rotation index comprises a detent in the sleeve.

A ceiling fan wherein the detent is aligned with the split in the split sleeve.

A ceiling fan wherein the detent is inboard of the compression fitting.

A ceiling fan wherein the at least one blade mount comprises multiple blade mounts radially spaced about the blade hub.

A ceiling fan wherein the motor assembly comprises a rotating housing portion having a central hub and the blade mounts extend radially form the hub.

A ceiling fan wherein the motor assembly comprises a non-rotating shaft and the hub circumscribes and rotates about the non-rotating shaft.

A ceiling fan wherein the motor assembly comprises upper and lower motor housings, one of which forms the rotating housing portion.

A ceiling fan wherein the blade mounts are integrally formed with the one of the upper and lower motor housings.

A ceiling fan comprising: an upper motor housing; a lower motor housings; and a magnet seat formed in a portion of the upper and lower housing configured to seat a rotor and mount the rotor to the upper and lower motor housings.

A ceiling fan wherein the magnets comprise a permanent magnet.

A ceiling fan wherein the magnet comprises an electromagnet.

A ceiling fan wherein the electromagnet comprises a motor winding.

A ceiling fan wherein the magnet seat comprises confronting channels formed in each of the upper and lower housings, which collectively form the magnet seat when the upper and lower housings are secured together.

A ceiling fan wherein the upper and lower housings are secured together by mechanical fasteners.

A ceiling fan wherein at least one of the upper or lower housings rotates to define a rotating housing.

A ceiling fan further comprising a blade assembly coupled to the blade mount.

A ceiling fan wherein the blade assembly comprises a blade and a blade holder coupling the blade to the blade holder.

A ceiling fan further comprising a non-rotating motor shaft about which the rotating housing rotates.

A ceiling fan wherein the rotating housing is rotatably mounted to the non-rotating motor shaft.

A ceiling fan further comprising a stator winding mounted to the non-rotating shaft and located within an interior defined by the upper and lower housings.

A ceiling fan wherein the magnets form a portion of a rotor for the motor.

A ceiling fan wherein the upper and lower housings rotate about non-rotating shaft.

A ceiling fan further comprising upper and lower bearings wherein the non-rotating shaft has upper and lower bearing stops for supporting the bearings against which the upper and lower housings correspondingly abut.

A ceiling fan wherein the upper and lower housings are biased against their corresponding housing seats.

A ceiling fan wherein the stator winding is fixed relative to the non-rotating shaft and with respect to the housing seats.

A ceiling fan assembly comprising: a non-rotating motor shaft with an upper and lower bearing stop; a stator mounted to the non-rotating motor shaft; a rotor surrounding the stator; a motor housing having an upper bearing seat spaced above the upper bearing stop and a lower bearing seat spaced below the lower bearing stop; an upper bearing seated within the upper bearing seat; a lower bearing seated within the lower bearing seat; and a downrod coupling provided on the non-rotating shaft; wherein when the ceiling fan assembly is suspended from a structure with the downrod coupling, the weight of the rotor presses the upper bearing against the upper bearing stop such that the weight of the rotor is transferred through the upper bearing to the non-rotating shaft.

A ceiling fan assembly further comprising a spring located within the lower bearing seat and biasing the lower bearing against the lower bearing stop.

A ceiling fan assembly wherein the non-rotating motor shaft is hollow and further comprising a retaining rod passing through the hollow motor shaft.

A ceiling fan assembly wherein a lower end of the retaining rod has a cap that abuts a retention plate adjacent to a lower portion of the non-rotating shaft.

A ceiling fan assembly wherein an upper end of the retaining rod is located above an upper end of the non-rotating shaft.

A ceiling fan assembly wherein the upper end of the retaining rod terminates in a clevis.

A ceiling fan assembly wherein the rotor comprises upper and lower housings, which are secured together, with the upper housing having the upper bearing seat and the lower housing having the lower bearing seat.

A ceiling fan assembly wherein the upper and lower housings define a magnet seat in which magnets for the rotor are located.

A ceiling fan assembly wherein magnet seat comprises confronting channels formed in each of the upper and lower housings.

A ceiling fan assembly wherein the upper and lower housings are secured together by mechanical fasteners.

A ceiling fan assembly further comprising multiple blade mounts provided on one of the upper and lower housing.

A ceiling fan assembly wherein the blade mounts comprise at least one split sleeve.

A ceiling fan assembly wherein the blade mounts comprise at least two axially aligned split sleeves.

A ceiling fan assembly wherein the blade mounts further comprise a blade rotation stop.

A ceiling fan assembly wherein the non-rotating shaft has a stator stop located between the upper and lower bearing seats.

A ceiling fan assembly wherein the stator stop and the lower bearing seat are formed by one or more collars on the non-rotating shaft.

A ceiling fan assembly wherein the non-rotating motor shaft includes a weep hole.

A ceiling fan comprising: a motor assembly having a hollow, non-rotating motor shaft; and a retaining rod passing through the motor shaft; wherein the retaining rod provides a redundant mount system for the ceiling fan.

A ceiling fan further comprising a retention plate wherein the retaining rod secures retention plate and the retention plate is secured to the non-rotating motor shaft.

A ceiling fan wherein the non-rotating motor shaft is hollow and the retaining rod extends at least into the hollow of the non-rotating motor shaft.

A ceiling fan wherein a lower end of the retaining rod has a cap that abuts a lower portion of the non-rotating shaft.

A ceiling fan wherein an upper end of the retaining rod is located above an upper end of the non-rotating shaft.

A ceiling fan wherein the upper end of the retaining rod terminates in a clevis.

A ceiling fan further comprising a shaft coupler coupled to the non-rotating shaft and a downrod plate coupled to the lower end of the downrod, wherein the shaft coupler and downrod plate are secured to each other.

A ceiling fan wherein the shaft coupler is located on an upper end of the non-rotating motor shaft.

A ceiling fan wherein the shaft coupler comprises a collar having a central opening that receives the non-rotating motor shaft.

A ceiling fan wherein the collar slides over the non-rotating motor shaft.

A ceiling fan wherein the collar is indexed relative to the non-rotating motor shaft.

A ceiling fan wherein index comprises one of the collar and non-rotating motor shaft comprises a key and the other comprises a keyway that receives the key.

A ceiling fan further comprise a retaining nut threaded onto a tapped portion of the non-rotating motor shaft.

A ceiling fan wherein at least one of the shaft coupler and the downrod plate has tapped studs and the other of the at least one shaft coupler and downrod plate has openings for receiving the tapped studs.

A ceiling fan further comprising nuts threaded onto the tapped studs to secure together the shaft coupler and the downrod plate.

A ceiling fan comprising: a motor assembly having a non-rotating, hollow, motor shaft; a stator winding carried by the motor shaft; and a wiring harness passing through the hollow of the motor shaft and electrically coupled to the stator winding.

A ceiling fan further comprising a hollow down rod mounted to the motor shaft and the wiring harness passes through the hollow of the down rod and the non-rotating shaft.

A ceiling fan further comprising a retaining rod passing through the hollow downrod and secured to at least one of the non-rotating motor shaft and the motor assembly.

A ceiling fan further comprising a shaft coupler coupled to the non-rotating shaft and a downrod plate coupled to the lower end of the downrod, wherein the shaft coupler and downrod plate are secured to each other.

A ceiling fan wherein the shaft coupler is located on an upper end of the non-rotating motor shaft.

A ceiling fan further comprise a retaining nut threaded onto a tapped portion of the non-rotating motor shaft.

A ceiling fan wherein a lower end of the retaining rod has a cap that abuts a lower portion of the non-rotating shaft.

A ceiling fan wherein an upper end of the retaining rod is located above an upper end of the non-rotating shaft.

A ceiling fan wherein the upper end of the retaining rod terminates in a clevis.

A ceiling fan further comprising an exit passage extending from the hollow through an exterior of the motor shaft and the wiring harness passes through the exit passage.

A ceiling fan wherein the non-rotating shaft comprises a stator stop against which the stator winding rests.

A ceiling fan wherein the stator stop comprises a collar about the non-rotating shaft.

A ceiling fan comprising: a motor assembly having a rotating blade hub; a plurality of blades; at least one blade holder for mounting the plurality of blades to the blade hub; at least one blade mount provided on the blade hub for receiving the blade holder and having at least one fastener aperture and at least one pin aperture; at least one saddle disposed in the fastener aperture; and at least one fastener for selectively tightening or loosening the saddle.

A ceiling fan wherein the motor assembly comprises a rotatable housing portion and the blade hub is provided on the rotatable housing portion.

A ceiling fan wherein the motor assembly comprises a non-rotating motor shaft about which the rotatable housing portion rotates.

A ceiling fan wherein the blade hub is integrally formed with the rotatable housing portion.

A ceiling fan wherein the motor assembly comprises upper and lower motor housings and one of the upper and lower motor housings forms the rotatable housing portion.

A ceiling fan wherein the at least one blade mount comprises multiple blade mounts radially spaced about the blade hub.

A ceiling fan wherein the motor assembly comprises a rotating housing portion having a central hub and the blade mounts extend radially from the hub.

A ceiling fan wherein the motor assembly comprises a non-rotating shaft and the hub circumscribes and rotates about the non-rotating shaft.

A ceiling fan wherein the blade mounts extend radially from the motor shaft to collectively define a horizontal plane.

A ceiling fan wherein the fastener aperture is oriented at an angle relative to the horizontal plane.

A ceiling fan wherein the angle is 20 degrees.

A ceiling fan wherein the blade mount defines a cylindrical cavity and the fastener aperture extends radially from the cylindrical cavity.

A ceiling fan wherein the saddle is adapted to anchor the blade holder along the radial extension of the fastener aperture.

A ceiling fan wherein the motor assembly comprises upper and lower motor housings, one of which forms the rotating housing portion.

A ceiling fan wherein the blade mounts are integrally formed with the one of the upper and lower motor housings.

A ceiling fan wherein the at least one fastener is a set screw.

A ceiling fan wherein the blade mount further comprises an inlet, with a channel extending from the inlet to the pin aperture.

A ceiling fan wherein the saddles are aligned along the channel.

A ceiling fan wherein the at least one saddle includes two saddles.

A ceiling fan assembly comprising: a stator assembly having a non-rotating motor shaft and stator slidably and non-rotationally coupled to the non-rotating motor shaft; a rotor assembly; a first bearing slidably mounted to the non-rotating motor shaft and rotatably coupling the rotor assembly to the stator assembly; and a first spacer located between the first bearing and the stator assembly to fix the sliding location of the first bearing relative to the stator along the non-rotating motor shaft.

A ceiling fan assembly further comprising a second bearing and second spacer located on an opposite side of the stator than the first bearing and first spacer, with the second bearing slidably mounted to the non-rotating motor shaft, the second spacer located between the second bearing and the stator.

A ceiling fan assembly wherein the second bearing rotatably couples the rotor assembly to the stator assembly.

A ceiling fan assembly wherein the stator is compressively retained between the first and second spacers.

A ceiling fan assembly wherein the first and second spacers are compressively retained between the first and second bearings.

A ceiling fan assembly wherein the rotor assembly abuts at least one of the first and second bearings.

A ceiling fan assembly wherein the rotor assembly abuts both the first and second bearings.

A ceiling fan assembly wherein the rotor assembly comprises a housing abutting both the first and second bearings.

A ceiling fan assembly wherein the stator assembly is compressively retained by at least one of the first spacer and first bearing.

A ceiling fan assembly wherein the first spacer is compressively retained between the first bearing and the stator assembly.

A ceiling fan assembly wherein the rotor assembly abuts the first bearing.

A ceiling fan assembly wherein the first bearing is compressively retained between the rotor assembly and the first bearing.

A ceiling fan assembly wherein the rotor assembly comprises a housing that compressively retains the first bearing.

A ceiling fan assembly wherein the non-rotating motor shaft has a shoulder and at least one of the first bearing and first spacer abuts the shoulder.

A ceiling fan assembly wherein the first bearing abuts the shoulder.

A ceiling fan assembly wherein the spacer circumscribes the shoulder.

A ceiling fan assembly wherein the spacer is compressively retained between the bearing and the stator.

A ceiling fan comprising: a motor assembly having a rotating blade hub; at least one hub socket formed in the blade hub; a blade having a body with a blade socket and the body extending from a root to a tip to define a body span-wise axis and an airfoil cross-section defining a chord-wise axis; and a strut having a hub portion received within the hub socket and a blade portion received within the blade socket to couple the blade to the hub; wherein at least one of the blade portion is rotationally offset from the hub portion or the blade socket is rotationally offset from the blade such that the blade is provided with an angle of attack relative to the chord-wise axis when the blade portion is received within the blade socket.

A ceiling fan wherein the hub socket has a horizontally-oriented bottom wall.

A ceiling fan wherein the blade portion is rotationally offset from the hub portion.

A ceiling fan wherein the cross-sectional area of the strut is non-constant along the length of the strut.

A ceiling fan wherein the hub socket includes a bottom wall and the at least one fastener aperture is formed in the bottom wall.

A ceiling fan wherein the hub socket further comprises tapered walls between the bottom wall and the remainder of the blade hub.

A ceiling fan wherein the hub socket further includes a mouth at a terminal edge of the rotating blade hub.

A ceiling fan wherein the hub socket further includes a neck and the throat defined at an intersection of the mouth and the neck.

This written description uses examples to disclose the invention, including the best mode, and to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention 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.