Patent ID: 12234833

DETAILED DESCRIPTION

The disclosure herein is directed to systems, methods, and other devices related to an apparatus and methods for attaching and detaching blades to a motor housing of a ceiling fan. In particular by inserting an end of a blade into a blade snap-fit holding attachment. The blade snap-fit holding attachment can be mounted directly or indirectly to a rotor of the motor for the ceiling fan. The indirect mounting can include an intervening blade iron coupling the snap-fit holding attachment to the rotor. In one aspect the blade holding attachment includes catch plate defining a root gap with ramped surfaces, causing a spring plate to lift and springs of the spring plate to compress. Upon compression, locking posts align with mounting holes in the blades, and the springs bias the catch plate down to lock the blade in place.

In another aspect, the blade snap-fit holding attachment includes a living hinge and a snap fit connector with ramped pins. When the blade is inserted, the snap fit connector pivots along the living hinge, and when the ramped pins align with the mounting holes, the pins snap into the holes, locking the blade in place. In this case, the material memory in the living hinge causes the plate to snap down and lock the blade in place.

Screwing blades onto a ceiling mounted motor results in visible screws. Ceiling fans run under continuous vibration conditions where the screws can loosen causing the blades to become loose or sag. Furthermore, cleaning ceiling fan blades can be messy where dirt and dust fall on furniture and the flooring beneath the ceiling fan. Current techniques have relied on manually holding brushes to the blades themselves which inherently tires the muscles in the cleaner's neck, shoulders, arms and hands. The blade holding attachment described herein allows for easy detachment and reattachment for cleaning blades. Furthermore, the blades described herein can be reversible and/or replaceable, allowing for a décor change without replacing an entire ceiling fan.

FIG.1is a bottom view perspective drawing of a ceiling fan10. The ceiling fan10includes a motor housing11removed from the ceiling fan to illustrate a motor12, with an inner stator and an outer rotor. The housing11can rotate with the rotor or remain stationary to the rotor. As illustrated, the housing rotates with the rotor. At least one blade iron14is mounted to the motor12. A blade holding attachment16can be mounted to the at least one blade iron14. It is further contemplated that the at least one blade iron14and the blade holding attachment16are one piece. At least one blade18is attached to the at least one blade iron14with the blade holding attachment16. Each blade18extends from a root20received by the blade holding attachment16to a tip22. The housing11can include at least one slot21for through which the blade18extends from the motor12through the motor housing11. In one aspect, each blade18is reversible, where the blade has first and second opposing surfaces23a,23band can be secured to the blade holding attachment16with either surface facing up or down.

Turning toFIG.2, the blade holding attachment16according to an aspect of the disclosure herein is illustrated. The blade holding attachment16includes a snap-fit connector24. The snap-fit connector24includes a first element26and a second element28spaced from the first element26to define a root gap30. The root20of the blade can be a key with the root gap30defining a keyway. In other words, the root20functions as a key that is received in the root gap30. The blade18can be sized a key width (denoted “W1”) less than a blade width (denoted “Wb”) at the root20. The key width W1 corresponds with a keyway width (denoted “W2”) defined by the root gap30. The root20of the blade18includes a set of root openings44, illustrated as two thru holes50.

The first element26can be a bottom plate32integrally formed with and defining the blade iron14. The bottom plate32can extend between a mounting end34and a bottom lip36and include a bottom horizontal section38therebetween. The bottom horizontal section38defines at least a portion of an insertion path40for the root20of the blade18. The bottom lip36bends down away from the bottom horizontal section38for guiding the root20along the insertion path40.

The second element28can be a top plate42including a top horizontal section48and a top lip46. The second element28is movably mounted to the first element26between a first position56and a second position58(FIG.3) to provide for the movement of the biased snap-fit connector24. The second element28is further from the first element26in the first position56. The top horizontal section48defines another portion of the insertion path40. The top lip46bends up away from the top horizontal section48for guiding the root20along the insertion path40. A set of biased snap pins52extend from the top horizontal section48of the second element28into the root gap30and move with the second element28. Each snap pin of the set of biased snap pins52includes a ramped surface54. The set of biased snap pins52correspond to the set of root openings44to define complementary pairs of snap pins52and thru holes50.

A pair of posts60spaced from each other a distance equal to or greater than the keyway width W2 extend through the second element28and into the first element26each equidistant from a center (denoted “C”) of the insertion path40. The top horizontal section48can include post holes62. The bottom horizontal section38can include a pair of post openings64. The pair of posts60can be anchored in the post openings64and can be slideably received in the post holes62. The second element28can slide along the pair of posts60between the first position56and the second position58. A spring66, illustrated as a coil spring68can be encircle each post in the pair of posts60. The spring66is positioned to provide a biasing force (denoted “F”) on the second element28from the first position56toward the second position58.

When the blade root20is moved along the insertion path40into the root gap30, engagement with the ramped surfaces54cause the second element28to move into the first position56where the set of biased snap pins52moves out of the insertion path40until the thru holes50align with corresponding snap pins of the set of biased snap pins52.

Turning toFIG.3, a cross-section taken along line III-III ofFIG.2with the second element28in the second position58is illustrated. The biasing force F causes the set of biased snap pins52to be received in the set of root openings44as the second element28is forced into the second position58where the second element28is closer to the first element26than when in the first position56(FIG.2). The pair of posts60can be bolts70with a head72and a shank74including a threaded portion76and a smooth portion78. The threaded portion76can be anchored in the post openings64. The smooth portion78of the bolt70can allow for sliding of the pair of posts60through the post holes62. The coil spring68can wrap around the smooth portion78and extend between the head72and the second element28.

FIG.4is a perspective view of a blade holding attachment116according to another aspect of the disclosure herein is illustrated. The blade holding attachment116is similar to the blade holding attachment16; therefore, like parts of the blade holding attachment116will be identified with like numerals increased by 100, with it being understood that the description of the like parts of the blade holding attachment16applies to the blade holding attachment116, except where noted.

The blade holding attachment116includes a biased snap-fit connector124. The biased snap-fit connector124includes a first element126and a second element128spaced from the first element126to define a root gap130. A blade118includes a set of root openings144, illustrated as two thru holes150, located at a root120of the blade118.

The first element126can be integrally formed with and define a blade iron114. The first element126can be a modified Z-bracket180, where the blade iron114can define a first plane P1 and extend between a mounting end134and a connecting portion182. The connecting portion182can define a second plane P2 substantially perpendicular to the first plane P1. The first element126can further include a bottom horizontal section138extending from the connecting portion182to define a third plane P3 substantially perpendicular to the second plane P2. The third plane P3 is pitched at an angle with respect to first plane P1 defining a desired blade pitch. A bottom lip136can protrude from the bottom horizontal section138bending downward, away from the third plane P3.

The modified Z-bracket180can include a fourth plane P4 spaced from, on top of, and parallel to the third plane P3. Both the third plane P3 and the fourth plane P4 extending substantially perpendicular from the second plane P2. The bottom lip136can be bent away from the connecting portion182and have a first width (denoted “W1”) extending within the third plane. A set of resilient fingers184can extend from the connecting portion182within the fourth plane P4. The set of resilient fingers184can be spaced from and above the bottom horizontal section138to define an insertion path140between the set of resilient fingers184and the bottom horizontal section138for the root120of the blade118. The set of resilient fingers184can be spaced from each other a second width (denoted “W2”) greater than or equal to the first width W1. A set of top lips146can protrude from corresponding fingers of the set of resilient fingers184bending upward, away from the fourth plane P4.

The second element128can include a top plate142defining a living hinge194in a top horizontal section148. The top plate142extending parallel to the fourth plane P4 on top of the set of resilient fingers184to define another portion of the insertion path140when in the top horizontal section148. A set of biased snap pins152extend from the top horizontal section148of the second element128into the root gap130. The set of biased snap pins152correspond to the set of root openings144to define complementary pairs of snap pins152and thru holes150. The set of biased snap pins152extend toward the bottom horizontal section138between the set of resilient fingers184. Each snap pin of the set of biased snap pins152includes a ramped surface154.

Further, a pair of sidewalls186extend from the top horizontal section148parallel to and spaced from corresponding snap pins in the set of biased snap pins152to form finger slots188. When the top plate142mounted to the modified Z-bracket180, the set of resilient fingers184are received in corresponding finger slots188. The second element128can further include a back plate190extending parallel to the second plane P2 and abutting the connecting portion182.

FIG.5is a cross-section taken along line V-V ofFIG.4when the biased snap-fit connector124is in a receiving position156angled with respect to the horizontal position148. The back plate190can be mounted, and or otherwise secured, to the connecting portion182by a fastener, by way of non-limiting example a bolt192. The top plate142defining the living hinge194is moveable. When the root120of the blade118is moved into the insertion path140, the root120comes in contact with the ramped surface154of the set of biased snap pins152. The ramped surface154is angled to face the blade118. The ramped surface154along with the living hinge194enables the top plate142to pivot upward when the root120is in contact with the ramped surface154to define the receiving position156. The top plate142pivots along the living hinge194toward the bottom lip136of the first element126by a movement (denoted “M”) of the root120into the insertion path140.

FIG.6is a cross-section taken along line V-V ofFIG.4when the biased snap-fit connector124is in a closed position158. It can more clearly be seen that the set of biased snap pins152can further include a front surface154fand a bottom surface154b, with the ramped surface154extending between the front surface154fand the bottom surface154b. The front surface154fis perpendicular to the insertion path140and the bottom surface154bis parallel to the insertion path140when the set of biased snap pins152are fully received in the set of root openings144. Further, as shown, when in the closed position158the bottom surface154bcan be spaced from the bottom lip136of the first element126.

FIG.7is a perspective exploded view of a blade holding attachment216according to another aspect of the disclosure herein is illustrated. The blade holding attachment216is similar to the blade holding attachment116; therefore, like parts of the blade holding attachment216will be identified with like numerals increased by 100, with it being understood that the description of the like parts of the blade holding attachment116applies to the blade holding attachment216, except where noted.

The blade holding attachment216includes a biased snap-fit connector224. The biased snap-fit connector224includes a first element226and a second element228. The first element226includes a resilient finger284spaced from a bottom horizontal section238to define a root gap230. A blade218includes a set of root openings244, illustrated as two thru holes250, located at a root220of the blade218.

The first element226can be integrally formed with and define a blade iron214. The first element226can be a modified Z-bracket280, where the blade iron214can define a first plane P1 and extend between a mounting end234and a connecting portion282. The connecting portion282can define a second plane P2 substantially perpendicular to the first plane P1. The bottom horizontal section238can extend from the connecting portion282to define a third plane P3 substantially perpendicular to the second plane P2. The third plane P3 is pitched at an angle with respect to first plane P1 defining a desired blade pitch. A bottom lip236can protrude from the bottom horizontal section238bending downward, away from the third plane P3. The bottom horizontal section238can be split into a first section238aand a second section238bspaced from the first section238aa third width (denoted “W3”).

The modified Z-bracket280can include a fourth plane P4 spaced from, on top of, and parallel to the third plane P3. A resilient finger284can extend from the connecting portion282within the fourth plane P4. The resilient finger284can be spaced from and above the bottom horizontal section238to define an insertion path240between the resilient finger284and the bottom horizontal section238for the root220of the blade218. The resilient finger284has a fourth width (denoted “W4”) equal to or greater than the third width W3. A top lip246can protrude from the resilient finger284bending upward, away from the fourth plane P4.

The second element228can include a top plate242defining a top horizontal section248extending parallel to the fourth plane P4 on top of the resilient finger284. A set of biased snap pins252extend from the top horizontal section248of the second element228.

A pair of posts260spaced from each other a distance greater than the third width W3 extend from the second element228each equidistant from a center (denoted “C”) of the insertion path240. The bottom horizontal section238can include a pair of post openings264. The pair of posts260can extend through the pair of post openings264. Each of the pair of posts260can include a threaded insertion hole265.

A flat spring296can be positioned to provide a biasing force (denoted “F”) on the bottom horizontal section238and in turn the second element228in reaction to a force exerted on a ramped surface254of the set of biased snap pins252from the root220of the blade218when inserted along the insertion path240. The flat spring296can include a pair of spring openings298that when assembled align with the pair of post openings264. The pair of posts260can be anchored in the pair of spring openings298via, by way of non-limiting example a bolt299received within the threaded insertion hole265.

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

A ceiling fan comprising a motor housing having at least one blade iron; at least one blade extending from a root to a tip, and having a set of multiple, spaced, through openings at the root; and a snap-fit connector securing the at least one blade to the blade iron and comprising a first element and a second element, which is spaced from the first element to define a root gap defining an insertion path for the root of the blade, a set of biased snap pins corresponding to the set of through openings to define complementary pairs of snap pins and through openings, wherein at least one of the first and second elements is integrally formed as part of the blade iron, and when the blade root is moved along the insertion path, the set of biased snap pins moves out of the insertion path until the through openings align with the set of biased snap pins, which are then biased into the through openings.

The ceiling fan of any preceding clause wherein the first element is integrally formed with the blade iron.

The ceiling fan of any preceding clause wherein the biased snap pins are coupled second element, which is movably mounted to the first element to provide for the movement of the biased snap pins.

The ceiling fan of any preceding clause wherein the second element is moveable between first and second positions, with the first position closer to the first element than the second position.

The ceiling fan of any preceding clause wherein the second element is biased from the second position toward the first position.

The ceiling fan of any preceding clause wherein the second element slides along a pair of posts extending from the first element, with a spring provided on each of the posts in the pair of posts to bias the second element from the second position toward the first position.

The ceiling fan of any preceding clause wherein the pair of posts comprise bolts, having a head and threaded shank, threaded into the first element.

The ceiling fan of any preceding clause wherein each spring is a coil spring encircling the threaded shank and extending between the head and the second element.

The ceiling fan of any preceding clause wherein the second element comprises a pair of posts slidably received within corresponding post openings in the first element.

The ceiling fan of any preceding clause further comprising a spring carried by the first element and coupled to the pair of posts to bias the second element from the second position to the first position.

The ceiling fan of any preceding clause wherein the spring comprises a flat spring.

The ceiling fan of any preceding clause wherein the flat spring is located on an opposite side of the first element as the second element.

The ceiling fan of any preceding clause wherein the second element comprises a set of root openings, which are paired with the set of biased snap pins to form corresponding complementary pairs of snap pins and thru holes.

The ceiling fan of any preceding clause wherein the fingers comprise a living hinge, which the fingers pivot about when the biased snap pins move.

The ceiling fan of any preceding clause wherein the fingers are secured to the blade iron.

The ceiling fan of any preceding clause wherein the biased snap pins comprise a ramped surface facing the blade root as the blade is moved along the insertion path.

The ceiling fan of any preceding clause wherein the biased snap pins further comprising a front surface and a bottom surface, with the ramped surface extending between the front surface and the bottom surface.

The ceiling fan of any preceding clause wherein the front surface is perpendicular to the insertion path and the bottom surface is parallel to the insertion path.

The ceiling fan of any preceding clause wherein the biased snap pins extend only partially into the through openings.

The ceiling fan of any preceding clause wherein the blade is reversible, wherein the blade has first and second opposing surfaces and can be secured to the biased snap-fit connection with the first surface either facing up or down.

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.