Patent Document

This invention is a Continuation in part of Ser. No. 09/405,676 filed Sep. 24, 1999, now U.S. Pat. No. 6,352,411 which is a Continuation-In-Part of application Ser. No. 09/200,607 filed on Nov. 30, 1998, now U.S. Pat. No. 6,171,059 which is a Divisional of Ser. No. 08/851,501 filed May 5, 1997, now U.S. Pat. No. 6,010,306, all by the same inventors and assignee as the subject application which are all incorporated by reference, and this invention relates to ceiling fans, and in particular to ceiling fans having reversible blades that hook on and fold out to locked positions during assembly, and this invention is related to pending application Ser. No. 09/989,827 filed Nov. 21, 2001 which is a Divisional of Ser. No. 09/708,291 filed Nov. 8, 2000, now U.S. Pat. No. 6,336,792 which is a Divisional of Ser. No. 09/200,607 filed Nov. 30, 1998, now U.S. Pat. No. 6,171,059 which is a Divisional of Ser. No. 08/851,501 filed May 5, 1997, now U.S. Pat. No. 6,010,306, all by the same inventors and assignee as the subject application which are all incorporated by reference, and this invention relates to U.S. Pat. No. 6,213,716 to Bucher et al., the same inventors and assignees, which is incorporated by reference. 
    
    
     BACKGROUND AND PRIOR ART 
     Conventional ceiling fans that are shipped in cartons have separate packing materials such as foam inserts for the many components that must be assembled by the installer to hang the ceiling fan. For example, ceiling fan blades are generally shipped in detached positions and are fastened onto the motors and ceiling fan arms by screw type fasteners during the assembly process, a practice having many inherent problems. 
     A single conventional ceiling fan blade has often required some five screw type fasteners to attach the blade to the motor/arm of the ceiling fan. Thus, a five blade ceiling fan can have some twenty five screw type fasteners just for attaching the fan blades to the motor and arm assembly. Clearly, problems occur when any of this small screw type fasteners become lost and/or missing during the assembly process. 
     In addition to having multiple loose parts, a typical installer must follow a tedious process in order to assemble and hang the ceiling fan. In FIG. 1, a conventional ceiling fan motor housing  10  has a rotor component  20  that rotates about a central axis within a motor housing  10 , which in turn is connected to a hanger assembly  5  that is attached beneath a ceiling  2 . A plurality of fan blades  30  can be connected to the rotor  20  by mounting arms  40 . Each mounting arm  40  has one end  42  connected to an end  32  of each fan blade  30 , and an opposite second end  44  having at least two through-holes  45  therethrough, so that conventional screw type fasteners  50  can pass through the through-holes  45  to mateably thread into threaded holes  25  in the bottom of rotor  20 . 
     It is usual in many ceiling fan installation directions to have the installer first connect and hang the motor housing  10 , rotor  20  and hanger assembly  5  to a ceiling by having the installer standing on a raised platform such as a ladder or stool. Next, the installation directions have the installer attach the blades  30  to their respective mounting arms/motor connectors  40 . Finally, a last step is to connect the blade  30  and respective mounting arm  40  to the rotor  20  on the motor housing  10 . 
     This final assembly step takes great dexterity, patience, balance and time for the installer. In order for a single person  60  to be able to complete this final step, the installer  60  needs to hold in one hand  62  the fan blade  30  and already attached mounting arm  40 , and to position a screwdriver  70  to the heads of the screws  50  with the other hand  64 . The installer must be able to balance the mounting screws  50  on the tip of the screw driver  70 , insert the screws upwardly through the holes  44  in the mounting arm, making sure not to accidentally drop the screws  50  and then screw the screws  50  into the mating holes  25  on the rotor  20  all while still holding the blade  30  and arm  40 . This assembly requires the installer to have to constantly hold both hands  62  and  64  raised high above their head, while again standing on the ladder or stool. 
     This tedious traditional process of assembly and installation causes many potential problems. First, the screw type fasteners can and do accidentally fall and become lost causing more time and expense to finish the installation. The installer  60  often has to constantly reposition the blade  30  and arm  40  in order to be able to properly line up the through-holes  45  in the mounting arms  40  with their respective mating holes  25  in the bottom of rotor  20 . Also, the blade  30  and mounting arm  40  have been known to fall on and cause injury to the installer  60  during assembly. Furthermore, the installers can lose their balance and injure themselves by falling off the ladder or stool. 
     The use of screws has other inherent problems as to their appearance. The screw type fasteners are often visible from those looking up at the running ceiling fans. Visible screws are unsightly and further detract from the appearance of the ceiling fan itself. 
     Still additional problems have been known to occur after installation of the screw type fasteners. For example, uneven tightening of each of the plural screw type fasteners that connect the blades to the mounting arms has resulted in wobble effects when the ceiling fan is running. 
     Another problem occurs as a result of the need to clean blades over time in order to remove dirt and dust buildup. Current techniques have relied on manually holding brushes to the ceiling fan attached blades themselves which inherently tires the muscles in the cleaner&#39;s back, neck, shoulders, arms and hands. Furthermore, this messy cleaning operation with brushes while the blades are attached to the ceiling fan mounted motor often results in dirt and debris falling on both the cleaner and furniture and flooring below the ceiling fan. 
     Another problem occurs when the ceiling fan is taken down to be reboxed. In order to be repackaged, each and every component must be disassembled, a time consuming endeavor, which also can result in many loose parts becoming misplaced and lost over time. 
     Various solutions to changing some of the traditional attachment methods have been proposed that have additional problems. U.S. Pat. No. 5,944,486 to Hodgkins, Jr. describes an “Interchangeable Fan Blade System”, title. However, generally all of the embodiments shown require some screw type fasteners be used that still would have many of the problems described above. Furthermore, the slots shown in FIGS. 2,  3  and  9 , and adapter plates shown in FIGS. 5A-5G would have problems in fixably securing the blades to the adapters so that the blades would not wobble nor rattle when being run during a ceiling fan use. For example, the hook arm in FIG. 5D would not by itself adequately secure the fan blades in position by solely relying on a “centrifugal force.” Besides the wobble and rattle problems, each time the ceiling fan stops the hooked on blades can potentially fall off and become damaged as well as injure those beneath the ceiling fan. Similarly the “pin” supported blades of FIG. 5F would also wobble and rattle for not being properly secured to the mounting arms. In addition, these “pins” can inherently become loose and cause the blades to possibly fall off, become damaged and possibly injure those beneath the ceiling fan. Thus, the need exists for solutions to the above problems. 
     SUMMARY OF THE INVENTION 
     A first objective of the subject invention is to provide ceiling fan blades that can be easily and quickly attached onto a ceiling fan mounted motor without using removable fasteners such as screws and the like. 
     The second objective of the subject invention is to provide mountable ceiling fan blades that become instantly aligned when being mounted. 
     The third objective of the subject invention is to provide ceiling fan blades that do not rattle nor wobble when being run on a ceiling fan. 
     The fourth objective of the subject invention is to provide ceiling fan blades that can be reversibly hung without using removable fasteners such as screws and the like. 
     Two embodiments of hook and fold blades are included. Both embodiments include a ceiling fan motor having a rotating member, a first mount attached to the rotating member, a first fan blade having a first interior end portion and a first exterior end portion, a first hook portion which hooks the first mount to the first interior end portion, and a lock portion for restricting lateral movement between the first mount and the first interior end portion, wherein gravity and centrifugal force further locks the first fan blade to the first mount. The first mount can be on the first fan blade arm, or on a portion of a rotor on the motor. The locking portion can include edges having a cavity therebetween, wherein a portion of the first hook portion becomes positioned and locked within the cavity. One embodiment has the first hook portion attached to and extending outward away from the first interior portion of the first blade. Another embodiment has the first hook portion attached to and extending outward away from the first mount attached to the rotating member. The first hook portion can be attached to the first interior portion of the first blade and extending to the first exterior portion of the first blade. The first hook portion can be attached to the first mount toward the rotating member. The blades can be reversible in at least one of the embodiments. 
     For both embodiments there is a novel method of attaching the ceiling fan blades without using any removable fasteners, that includes the steps of hooking one end of a fan blade to a mount attached to a ceiling fan motor, and locking the fan blade to the ceiling fan motor with at least one technique to eliminate any lateral movement between the fan blade and the mount. The techniques can include either or both inserting a narrow body portion to be tightly fit or mateably fit between two raised edges/walls/arms, and/or positioning a raised ridge type portion into a mateably receiving indentation. 
     Further objects and advantages of this invention will be apparent from the following detailed description of a presently preferred embodiment that is illustrated schematically in the accompanying drawings. 
    
    
     BRIEF DESCRIPTION OF THE FIGURES 
     FIG. 1 shows a prior art view of a blade with mounting arm attached to a ceiling fan motor and rotor. 
     FIG. 2A is a perspective view of a first embodiment of the hook and fold ceiling fan blade with a blade ready to be attached to a motor/arm. 
     FIG. 2B is a top view of FIG. 2A along arrow T. 
     FIG. 2C is a side cross-sectional view of FIG. 2B along arrows A—A. 
     FIG. 3 is another view of FIG. 2C with the hook starting to be inserted about the pin. 
     FIG. 4 is another view of FIG. 3 with the hook being fully wrapped about the pin. 
     FIG. 5 is another view of FIG. 4 with the blade in a folded down position. 
     FIG. 6 is a perspective view of the preceding figures in a fully attached state. 
     FIG. 7A is a perspective view of a second embodiment of the hook and fold ceiling fan blade with the blade ready to be attached to a motor/arm. 
     FIG. 7B is a top view of FIG. 7A along arrow S. 
     FIG. 7C is a side cross-sectional view of FIG. 7B along arrows B—B. 
     FIG. 8 is another view of FIG. 7C with the hook starting to be inserted about the pin. 
     FIG. 9 is another view of FIG. 8 with the hook being fully wrapped about the pin. 
     FIG. 10 is another view of FIG. 9 with the blade in a folded down position. 
     FIG. 11 is a perspective view of the second embodiment in a fully attached state. 
     FIG. 12A is a perspective view of the lower medallion cover of the second embodiment. 
     FIG. 12B is a top view of the cover of FIG. 12A along arrow X 1 . 
     FIG. 12C is a side view of the cover of FIG. 12B along arrow X 2 . 
     FIG. 13A is a perspective view of the upper medallion cover of FIGS. 7A-11 without pin support arms. 
     FIG. 13B is a top view of the cover of FIG. 13A along arrow Y 1 . 
     FIG. 13C is a side view of the cover of FIG. 13B along arrow Y 2 . 
     FIG. 14A is a perspective view of the arm and hook connector of the second embodiment. 
     FIG. 14B is a top view of FIG. 14A along arrow Z 1 . 
     FIG. 14C is a side view of FIG. 14B along arrow Z 2 . 
     FIG. 14D is a bottom view of FIG. 14C along arrow Z 4 . 
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT 
     Before explaining the disclosed embodiment of the present invention in detail it is to be understood that the invention is not limited in its application to the details of the particular arrangement shown since the invention is capable of other embodiments. Also, the terminology used herein is for the purpose of description and not of limitation. 
     First Embodiment 
     This invention is related to U.S. Pat. No. 6,010,306 to Bucher et al. and U.S. Pat. No. 6,171,059 to Bucher et al.; and U.S. Pat. No. 6,213,716 to Bucher et al., each having the same inventors and assignee as the subject invention and each being incorporated by reference. 
     FIG. 2A is a perspective view of a first embodiment  100  of the hook and fold ceiling fan blade with a blade  1110  ready to be attached to a motor/arm  140 . FIG. 2B is a top view of FIG. 2A along arrow T. FIG. 2C is a side cross-sectional view of FIG. 2B along arrows A—A. Referring to FIGS. 2A-2C, ceiling fan blade  110  can have a medallion cover  112 , attached thereon with fasteners  112 , such as screws, and the like. Attached to the medallion  112  can be a connector section  120  having two raised wall type members  122 ,  124  with a pin member  123  connected attached therebetween. The bottom of connector  120  has an upper bottom surface  126 , which steps down at  127  to a lower bottom surface  128 . A raised ridge type member  129  is positioned in front of wall members  122 ,  124 . A ceiling fan motor arm  140  has one end  142  that can be attached to a motor/rotor  50  such as that shown in FIG.  1 . Arm  140  can be a solid member or be hollow or have an open upper surface such as a half cylinder. The outer dimensions of the arm can be of any desired shape, such as but not limited to cylindrical, rectangular, and the like. The opposite end  144  of arm  140  can include a hook connector  130 , having a hook portion  132  and a mid narrow raised body portion  134  that attaches the hook portion  132  to the arm  140 . Hook connector  130  can be formed with arm  140  or be separately attached at end  136  by conventional fasteners such as screws, and the like. On the underside of hook connector  130  can be an indentation  135 . 
     The subject invention can be assembled by initially hanging the ceiling fan motor as shown in FIG. 1, with the blades to be attached thereafter. The method of attaching the blade  110  to the motor/arm of the ceiling fan  140  will be described in reference to FIGS.  2 C and  3 - 4 . 
     An installer can initially orient the blade  110  off axis to the longitudinal axis L, of the motor arm  140 . FIG. 3 the hook portion  132  starting to be inserted about the pin  123 . Next, the installer can pull or push the blade  110  in the direction of arrow P so that the hook portion  132  is fully attached. FIG. 4 is another view of FIG. 3 with the hook being fully wrapped about the pin. Finally, the blade  110  is folded down in the direction of arrow R. FIG. 5 is another view of FIG. 4 with the blade in a folded down position with the blade  110  in the same plane as the axis L of the arm  140 . FIG. 6 is a perspective view of the final folded down position of the blade  110 . 
     The two different techniques of locking the blade  110  to the arm  130  will now be discussed in reference to FIGS. 2A,  2 B,  5  and  6 . The narrow body portion  134  of hook connector  130  slides into and becomes sandwiched between the raised edges  122 ,  124  of connector  120 . A tight sized space between edges  122 ,  124  allows for a tight fit when the narrow body portion  134  of hook connector  130  has been placed therein. The bottom uneven surface  134  of hook connector  130  abuts against the inner step surface  127  and inner lower bottom surface  128  of connector  120  to complete the first locking technique. A second locking technique occurs when raised ridge member  129  of connector  120  can become mateably seated into the indentation groove  135  of hook connector  130  locking the blade  110  to the arm  140 . A tight and/or snap fit between the raised ridge member  129  and indentation groove  135  can also be used. Either or both locking techniques described will restrict any lateral (side-to-side) movement of the blade  110  relative to the arm  140 . Although, the two locking techniques are shown the invention can be practiced with either one. Using both locking techniques acts as an extra safety feature to lock the blade  110  to the motor/arm  140 . 
     Second Embodiment 
     A second embodiment of the subject invention hook and lock blades will be described in reference to FIGS. 7A-14D. FIG. 7A is a perspective view of a second embodiment  200  of the hook and fold ceiling fan blade invention with the blade  210  ready to be attached to a motor/arm  240 . FIG. 7B is a top view of FIG. 7A along arrow S. FIG. 7C is a side cross-sectional view of FIG. 7B along arrows B—B. 
     FIG. 12A is a perspective view of the lower medallion cover  212 B of the second embodiment  200 . FIG. 12B is a top view of the cover  212 B of FIG. 12A along arrow X 1 . FIG. 12C is a side view of the cover  212 B of FIG. 12B along arrow X 2 . Referring to FIGS. 12A-12C, medallion cover  212 B can include two arms  222  and  224  attached to and extending from a rear portion so that a rotation pin  223  can be fixably inserted into mounting holes  221 ,  225  so that pin  223  can be fixably attached to both arms  222  and  224 . 
     FIG. 13A is a perspective view of the upper medallion cover  212 A of FIGS. 7A-11 without pin support arms. FIG. 13B is a top view of the cover  212 A of FIG. 13A along arrow Y 1 . FIG. 13C is a side view of the cover  212 A of FIG. 13B along arrow Y 2 . 
     The upper medallion cover  212 A can be attached to the lower medallion cover  212 B by positioning and sandwiching both covers  212 A and  212 B about an end portion of the blade  210  and using press fit type fasteners  213 A,  213 B, where for example male prong portions  213 A can be press fit into female receivers  213 B holding the medallion covers  212 A and  212 B to blade  210 . Alternatively, conventional screw type fasteners can be substituted for fasteners  213 A and  213 B. The two sided medallion covers  212 A,  212 B allow the second embodiment to be able to reverse the blade  210  during use. Thus, a blade  210  can be used that has different colors (i.e. black on one side and white on other side, wood grain on one side and solid color on other side, and the like) 
     FIG. 14A is a perspective view of the arm  240  and hook connector  230  of the second embodiment  200 . FIG. 14B is a top view of FIG. 14A along arrow Z 1 . FIG. 14C is a side view of FIG. 14B along arrow Z 2 . FIG. 14D is a bottom view of FIG. 14C along arrow Z 4 . Referring to FIGS. 14A-14D, hook connector  230  includes a hook portion  232  facing toward the motor end  242  of arm  240 , with the hook portion attached by fasteners  233  such as screws and the like, to a narrow raised body portion  234  with a uneven surface  236  facing toward the blades  210 . The hook connector  230  can be fixably attached to the arm  240  by being molded into the arm, or attached by conventional fasteners (not shown) such as screws and the like. 
     The second embodiment  200  of the subject invention can be assembled by initially hanging the ceiling fan motor as shown in FIG. 1, with the blades to be attached thereafter. The method of attaching the blade  210  to the motor/arm  240  of the ceiling fan will be described in reference to FIGS.  7 C and  8 - 10 . 
     An installer can initially orient the blade  210  off axis to the longitudinal axis L, of the motor arm  240 . FIG. 8 is another view of FIG. 7C with the hook portion  232  starting to be inserted about the pin  223 . Next, the installer can pull or push the blade  210  in the direction of arrow Q so that the hook portion  232  is fully attached. FIG. 9 is another view of FIG. 8 with the hook portion  232  being fully wrapped about the pin  223 . Finally, the blade  210  is folded down in the direction of arrow S. FIG. 10 is another view of FIG. 9 with the blade  210  in a folded down position with the blade  210  in the same plane as the axis L of the arm  240 . FIG. 11 is a perspective view of the second embodiment  200  in a fully attached state. 
     Similar to the first embodiment  100 , there is at least one locking techniques for locking the blade  210  to the arm  240 . The narrow body portion  234  of hook connector  230  slides between and becomes sandwiched in the space between the two arms  222 ,  224  of connector  220 . A tight sized space between arms  222 ,  224  allows for a tight fit when the narrow body portion  234  of hook connector  230  has been placed therein. The bottom surface  245  (shown more clearly in FIG. 14D) on both sides of narrow body portion  234  of hook connector  230  abuts against the bottom of the arms  222 ,  224  of connector  220  to complete the locking step. Although not shown a second locking technique similar to the one described in reference to the first embodiment can also be used in the second embodiment. For example, a raised ridge and mateable indentation can be on either the rear surface  236  of hook connector  230  and surface  228 (FIG.  12 B), respectively, and vice versa. 
     While the preferred embodiments describe attaching ceiling fan blades while the motor has been previously hung on a ceiling, the blades can be attached before the motor is hung so that the entire ceiling fan and blades can be hung together from the ceiling. 
     Although the preferred embodiments show the arms of the motor having hook connectors thereon, the rotating portion of the motor such as the rotor can have the hook connectors thereon instead of the arms. Still additionally, the blade ends can have the hook connectors thereon. Still additionally, a portion of the blades can protrude therefrom with hook connectors. Still additionally, the lock connectors can be located on portions of the rotor adjacent to the motor, the lock connectors can be located on the blade ends, and on protruding portions of the blades. Additionally, the hook and lock members can be integrated to be inside of the edges of the rotor, inside of the outer edges of the blade, and the like. 
     Although the preferred embodiments show the hook and lock connectors on the upper surface portions of the blades and arms, the hook and loop connectors can be positioned on the sides of these components, or on the bottom of these components, as needed. 
     While the locking techniques are shown with one component on one member and another component on another member, the component locations can be switched and their locations can be varied as desired and needed for the particular application used. 
     Additionally, the hook and lock blades can be easily removed by reversing any of the assembly steps described in reference to the embodiments described above. 
     Although the hook connectors and lock connectors are shown as being formed from separate piece components, the hook and lock connectors can include less and more components, and also be formed from injection molded plastic and the like, where the components are formed with the rotors or the arms or the blades or on protruding portions of the blades, and the like. For example, although some fasteners are shown for some of the pre-attached components in the preceding figures, some or all of these fasteners can be eliminated as needed by techniques such as injection molded plastics, and the like. 
     The subject invention can also be packed and stored in similar boxes and packaging as U.S. Pat. No. 6,213,716 to Bucher et al., the same assignees and inventors as that of the subject invention. For example, the blades of the subject invention can be stored vertically with their interior ends adjacent to the rotor/motor of the ceiling fans. Additionally, the subject invention fan blades can be laid in a sandwich pattern above, below or both above and below the motor component in a packing box. 
     While the invention has been described, disclosed, illustrated and shown in various terms of certain embodiments or modifications which it has presumed in practice, the scope of the invention is not intended to be, nor should it be deemed to be, limited thereby and such other modifications or embodiments as may be suggested by the teachings herein are particularly reserved especially as they fall within the breadth and scope of the claims here appended.

Technology Category: 2