Patent ID: 12253099

DETAILED DESCRIPTION

The disclosure is related to a ceiling fan mounting system, which can be used, for example, in residential, agricultural, industrial, and commercial applications. More specifically, this disclosure relates to a ceiling fan mounting system utilizing a snap-on canopy mounting system. Such applications can be indoors, outdoors, or both. While this description is primarily directed toward a residential ceiling fan, it is also applicable to any environment utilizing fans or for cooling areas utilizing air movement.

As used herein, the term “set” or a “set” of elements can be any number of elements, including only one. All directional references (e.g., radial, axial, proximal, distal, upper, lower, upward, downward, left, right, lateral, front, back, top, bottom, above, below, vertical, horizontal, clockwise, counterclockwise, upstream, downstream, forward, aft, etc.) are only used for identification purposes to aid the reader's understanding of the present disclosure, and do not create limitations, particularly as to the position, orientation, or use of aspects of the disclosure described herein. Connection references (e.g., attached, coupled, connected, and joined) are to be construed broadly and can include intermediate members between a collection of elements and relative movement between elements unless otherwise indicated. As such, connection references do not necessarily infer that two elements are directly connected and in fixed relation to one another. The exemplary drawings are for purposes of illustration only and the dimensions, positions, order and relative sizes reflected in the drawings attached hereto can vary.

Referring toFIG.1, a ceiling fan assembly10comprises a ceiling fan20, surface bracket30, downrod40, and canopy50. The ceiling fan20is secured to a surface1, such as a ceiling or wall, by the downrod40and the surface bracket30. The surface bracket30is secured to the surface1in any desirable manner and the downrod40couples the ceiling fan20to the surface bracket30. The canopy50covers the surface bracket30and at least a portion of the interface of the surface bracket30and downrod40. The canopy50can function as one or both of an aesthetic covering for the mechanical and electrical connections for the surface bracket30and the surface1.

The ceiling fan20can comprise a motor21having a stationary motor shaft22, a rotor23, and a stator25. The motor shaft22can be secured to or integrated with the stator25. The rotor23is rotationally coupled to the motor shaft22by a bearing assembly (not shown) supported on the motor shaft22. The ceiling fan20further includes a plurality of blades24, which are directly coupled to the rotor23or indirectly coupled through a bracket, commonly referred to as a blade iron. The ceiling fan can still further include a motor adapter26that couples the motor shaft22to the downrod40.

The downrod40comprises a ball41affixed to one end of a tube42. The tube42can be of a fixed or adjustable length, such as a telescoping tube. The end of the tube42opposite the ball41is secured to the motor shaft22and/or the motor adapter26.

Referring toFIG.2, the surface bracket30has surface plate31from which is suspended a ball seat32by spaced arms33extending between the surface plate31and the ball seat32. The ball seat includes an open collar34, defining an opening35, which is oriented with the spaced arms33to define an inlet through which the tube42and ball41can pass.

The surface plate31has a plurality of openings for receiving fasteners, such as screws or bolts, to secure the surface plate31to the structure1or an electrical fixture, such as a junction box, with the structure1. The surface plate31is illustrated as wings36extending from the arms33but could be a continuous plate, which may or may not be flat. The flange37is illustrated as multiple discrete flanges37, but it could be a continuous flange37.

Each of the wings36has a flange37located between a pair of position tabs38. The flange37extends away from the wings36while the position tabs38extend laterally away from the wings36. While the wings36are illustrated as two, diametrically opposed wings36, there could be more than two spaced about the periphery of the surface bracket30.

Resilient bushings39can be affixed to the wings36and are sized to bear against the structure1when the surface bracket30is secured to the structure1. The bushings39function to stabilize the surface bracket against the surface and can conform to the structure1.

A set of snap springs60are mounted to the flanges37. It is contemplated there will be one snap spring60for each flange37but it is possible to mount more than one snap spring60to each flange37. The snap spring60comprises a base61, which is secured to the flange37, by a suitable fastener, such as a screw or bolt62passing through the base61and into a tapped opening in the flange37, which increases the ease of assembly.

One or more locating feet63extend from the base61. The locating feet include a first segment64, second segment65, and a reverse turn66. The first segment64extends away from the flange37while the second segment65extends toward the flange37because of the reverse turn66. While the first and second segments64,65are shown extending upwardly, in addition to either toward or away from the base, the snap spring60could be designed such that the first and second segments64,65extend downwardly.

It is contemplated that the snap spring60will be formed from a single piece of resilient material, such as a thin plate of metal, like spring steel, which is cut and then bent into the configuration as seen in the drawings. However, it is possible form the snap spring60in other ways, such as injection molding from plastic, or 3-D printing from plastic or metal.

While the surface plate31is shown in a two-wing configuration, it is contemplated the that the surface plate31could be a continuous structure, such as, for example, a disk or plate. In a disk or plate configuration, the flange37could be continuous about the periphery of the disk or plate, with the snap springs60mounted at different peripheral locations along the flange37. The shape of the disk or plate could be circular or some other desired shape. The disk or plate need not be flat.

FIG.3is a perspective view of the canopy50, which has a bottom wall51, with an opening52for receiving the downrod40, a peripheral wall53extending upwardly from the bottom wall51. The peripheral wall53terminates in an open top54. A pocket55is provided in the peripheral wall53. The pocket55is sized to receive the snap springs60. The pocket55can be a recess56in the peripheral wall53. The recess56can be formed as rib57in the peripheral wall53, with the inner surface of the rib57forming a channel that defines the recess56. The channel has a concave cross section when seen from the interior of the canopy50. The recess56includes an upper shoulder59and a lower shoulder58. The recess56and corresponding channel is illustrated as a continuous recess about the peripheral wall. However, the recess56could be discrete recesses that are located according to the snap springs60. The diameter of the canopy peripheral wall53is greater below the recess56than above the recess56.

FIG.4shows the relationship of the snap spring60to the pocket55when the canopy50is affixed to the surface bracket30. As is seen, the reverse turn66is received within the pocket55, with the reverse turn66and/or the second segment65bearing against the upper shoulder59.

The recess56and snap spring60have similar or complementary cross-sectional shapes as seen inFIG.4. The first segment64is longer than the second segment65, which is similar to the shapes of the lower shoulder58and upper shoulder59. Similarly, the first segment64is longer and at a steeper angle than the second segment65as is the lower shoulder58to the upper shoulder59.

FIGS.5and6illustrate the interface between the snap spring60and the flange37. The base61includes tabs71that wrap around at least a portion of the edge of the flange37. The tabs71retard clockwise rotation of the base61about and axis looking down the centerline of the fastener62. The tabs71, along with the base61, retard rotation about a vertical axis passing through the centerline of the fastener. The tabs71thereby help retard the base61from twisting, especially when the fastener62is installed, which helps maintain the level of the locating feet63such they will more easily be received with the pocket55.

The snap spring60is shaped such that the unflexed outer diameter defined by the reverse turn66is slightly larger than the diameter of the recess56, which leads to the locating feet63being sprung and flexed when received within the recess56, which aids in holding the canopy50to the surface bracket30, since the locating feet63are biased into the recess56. When the canopy is secured to the surface bracket30, the second segment65will bear against and support the upper shoulder59to help hold the canopy in the desired position. At the same time, the reverse turn66is biased into the recess56to further aid in holding the position of the canopy.

To remove the canopy50from the surface bracket30, a downward force must be applied to the canopy50, with the magnitude of the downward force being great enough to deflect the snap spring60and permit the removal of the canopy50.

To the extent not already described, the different features and structures of the various features can be used in combination as desired. That one feature is not illustrated in all of the aspects of the disclosure is not meant to be construed that it cannot be, but is done for brevity of description. Thus, the various features of the different aspects described herein can be mixed and matched as desired to form new features or aspects thereof, whether or not the new aspects or features are expressly described. All combinations or permutations of features described herein are covered by this disclosure.

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