REINFORCED FAN BLADE CONSTRUCTION

Abstract

There is provided herein a reinforced fan blade construction which is reinforced at a proximal end thereof utilising a pair of opposing reinforcement brackets, typically metallic. In this way, the fan blade member may be manufactured from Acrylonitrile butadiene styrene (ABS) plastic or the like which is typically cheaper, lighter and easier to colour as opposed to other fan blade materials. Furthermore, plastic is noncorrosive allowing for outdoor application. The reinforcement brackets may comprise an elongate stem and an orthogonal cross piece. The orthogonal cross piece (which may be semicircular) may attached directly to the drive motor annulus such that inertial strain imparted thereon is spread along the elongate stem thereby reinforcing the proximal end of the fan blade.

Description

FIELD OF THE INVENTION

This invention relates generally to fan blades and more particularly, this invention relates to a reinforced fan blade construction.

BACKGROUND OF THE INVENTION

Ceiling fan blades comprise numerous shapes, configuration and materials for differing applications. Conventionally, ceiling fan blades may be metallic, plastic or particleboard composite.

The present invention seeks to provide fan blade construction, which will overcome or substantially ameliorate at least some of the deficiencies of the prior art, or to at least provide an alternative.

It is to be understood that, if any prior art information is referred to herein, such reference does not constitute an admission that the information forms part of the common general knowledge in the art, in Australia or any other country.

SUMMARY OF THE DISCLOSURE

There is provided herein a reinforced fan blade construction which is reinforced at a proximal end thereof utilising a pair of opposing reinforcement brackets, typically metallic. In this way, the fan blade member may be manufactured from Acrylonitrile butadiene styrene (ABS) plastic or the like which is typically cheaper, lighter and easier to colour as opposed to other fan blade materials. Furthermore, plastic is noncorrosive allowing for outdoor application.

Furthermore, the reinforcement of the fan blade construction allows for increased power without necessarily increasing the thickness of the fan blade member itself for reinforcement and the associated weight increase.

Furthermore, the present constructions and material used may allow for manufactured weight consistency within a tolerance of approximately 0.5g, being important for ceiling fan balancing.

Fan blades commonly used within industry are generally of unity construction and are not generally reinforced, let alone in the manner described herein.

The reinforcement brackets may comprise an elongate stem and an orthogonal cross piece. The orthogonal cross piece (which may be semicircular) may attached directly to the drive motor annulus such that inertial strain imparted thereon is spread along the elongate stem thereby reinforcing the proximal end of the fan blade.

The reinforcement brackets may be planar and, furthermore, the proximal end of the fan blade member may be shaped to define a correspondingly planar engagement piece against which the oppositely engaging reinforcement brackets may be riveted flush. The reinforcement brackets may press against the planar engagement piece so as to enhance the frictional engagement thereof, thereby spreading the strain substantially along the entire planar engagement piece as opposed to at the river points alone.

The proximal end of the fan blade member may further be shaped to define an upper predominance and an under recess. The upper predominance may locate the brackets upwardly to make allowance for the recess. An aesthetic under covering may lie flush within the recess. The covering may similarly comprise proximal attachment apertures but may have a distal end devoid of apertures for aesthetic purposes. In this way, the present reinforced construction is not aesthetically compromised when viewed from beneath.

In embodiments, the fan blade member may comprise a trailing edge pitch transition close to the proximal end thereof. As such, the elongate members of the reinforcement brackets may extend into the pitch transition area. As such, in an embodiment, the proximal end of the fan blade member may be further shaped to define an elongate prow standing proud from the predominance. The prow supports the planar engagement piece therealong and comprises lateral edges that fall away to the predominance.

As such, with the foregoing in mind, in accordance with one aspect, there is provided a reinforced fan blade construction comprising: an elongate fan blade member defining a distal end and an opposite proximal attachment end; and upper and lower reinforcing brackets engaged oppositely through the proximal end for reinforcement.

The reinforcement brackets may be planar.

The proximal end may be shaped to may define a planar engagement piece against which the respective upper and lower planar reinforcement brackets lie flush.

The planar engagement piece and the reinforcing brackets may define corresponding rivet accommodation apertures and wherein the brackets may be riveted to the planar engagement piece.

Each reinforcement bracket may comprise an elongate stem and a cross piece.

The elongate stem may define a plurality of rivet attachment apertures.

The cross piece may define a plurality of attachment fastener apertures.

The cross piece may be semicircular.

The upper surface of the proximal end may define a predominance and a corresponding undersurface of the proximal end may define a recess and wherein the upper enforcement brackets locates on or within the predominance and the lower reinforcement bracket locates within the recess.

The reinforced fan blade construction may further comprise an under covering for covering the recess.

The under covering may comprise a cross-section conforming to that of the recess.

The under covering may be configured to lie flush when in the recess.

The covering may comprise proximal fastener attachment apertures.

The covering may define a distal end and wherein the distal end may be devoid of fastener apertures.

An upper surface of the distal end may comprise a centreboard comprising a linear edge for abutting against a corresponding undersurface of the adjacent lower attachment bracket.

The proximal end further may define a prow, the prow supporting the planar engagement piece therein and comprising lateral edges which fall away to the predominance.

The prow extends into a trailing edge pitch transition.

The recess may comprise a cross-section conforming to that of the reinforcement bracket.

The covering may comprise a cross-section conforming to that of the reinforcement bracket.

The fan blade member may comprise Acrylonitrile butadiene styrene (ABS) plastic.

Other aspects of the invention are also disclosed.

BRIEF DESCRIPTION OF THE DRAWINGS

Notwithstanding any other forms which may fall within the scope of the present invention, preferred embodiments of the disclosure will now be described, by way of example only, with reference to the accompanying drawings in which:

FIG. 1 shows an exploded bottom perspective view of a fan blade construction in accordance with a first embodiment;

FIG. 2 shows a cross-sectional elevation view of the fan blade of FIG. 1;

FIG. 3 shows an exploded top perspective view of the fan blade construction of FIG. 1;

FIG. 4 shows an exploded bottom perspective view of the proximal end of the fan blade construction of FIG. 1;

FIG. 5 shows an exploded top perspective view of the proximal end of the fan blade construction of FIG. 1;

FIG. 6 shows a cross-sectional elevation view of the proximal end of the fan blade construction of FIG. 1;

FIG. 7 shows an exploded bottom perspective view of a fan blade construction in accordance with a further embodiment;

FIG. 8 shows a cross-sectional elevation view of the fan blade of FIG. 7;

FIG. 9 shows an exploded top perspective view of the fan blade construction of FIG. 7;

FIG. 10 shows an exploded bottom perspective view of the proximal end of the fan blade construction of FIG. 7;

FIG. 11 shows an exploded top perspective view of the proximal end of the fan blade construction of FIG. 7; and

FIG. 12 shows a cross-sectional elevation view of the fan blade of FIG. 7.

DESCRIPTION OF EMBODIMENTS

FIGS. 1-3 show a reinforced fan blade construction 100 in accordance with a first embodiment. FIG. 1 shows a bottom perspective exploded view, FIG. 2 shows a side cross-sectional elevation view and FIG. 3 shows a top perspective exploded view.

The fan blade construction 100 comprises a fan blade member 101 being elongate and defining a distal end and a proximal attachment end.

The proximal end may attach to a fan blade motor in the manner described herein.

The fan blade member 101 defines a leading-edge 110 and a trailing edge 111 with respect to the direction of rotational motion.

The construction 100 comprises upper and lower reinforcement brackets 102 that engage opposite upper and lower surfaces of the proximal end of the fan blade member 101 for reinforcement.

FIGS. 4 and 5 show magnified respective bottom and top perspective views of the fan blade construction 100 in further detail.

The upper and lower reinforcing brackets 102 generally comprise a stronger material than that of the fan blade member 101. In embodiments, the fan blade member 101 is plastic and the brackets 102 are metallic. In alternative embodiments, the fan blade member 101 may comprise particleboard composite.

The reinforcing brackets 102 may be planar and may comprise a plurality of rivet apertures 119 therethrough through which rivets 105 are engaged. Each rivet 105 passes through a corresponding aperture 119 through the upper bracket 102, the proximal end of the fan blade member 101 and the lower bracket 102.

The attachment brackets 102 and the proximal end of the fan blade may further comprise attachment fastener apertures 109 through which attachment fasteners may be located to attach the proximal end to the drive motor in use.

The fan blade construction 100 may be manufactured with the rivets 105 in place and wherein, during installation, attachment fasteners may be located through the corresponding attachment fastener apertures 109.

In the particular embodiments shown, the bracket 102 may comprise an elongate stem 106 and a generally orthogonal cross piece 107. The elongate stem 106 spreads the inertial strain along the proximal end of the fan blade member 101 for reinforcement. Furthermore, the orthogonal cross piece 107 allows for attachment to the drive motor.

The orthogonal cross piece 107 may be semicircular so as to conform to the periphery of a drive motor annulus.

The cross-sectional elevation view of FIG. 6 shows the manner of engagement of the reinforcement brackets 102 to the proximal end of the fan blade member 101.

As can be seen, the fan blade member 101 may be shaped to define a planar engagement piece 118 against which the opposing reinforcement brackets 102 lie flush. The rivets 105 pass through the upper and lower reinforcement brackets 102 and the planar engagement piece 118.

The rivets 105 may press the reinforcement brackets 102 against the planar engagement piece 118 to facilitate the frictional engagement thereof and substantially evenly distribute the strain across the entire length of the planar engagement piece 118 as opposed to at the rivets 105 alone.

Referring to FIGS. 4 and 5, the proximal end of the fan blade member 101 may be shaped to comprise a predominance 114. Furthermore, the corresponding undersurface of the proximal end of the fan blade 101 may comprise a recess 116.

The predominance 114 and the recess 116 may locate the brackets 102 more upwardly so as to allow their aesthetic covering from a viewpoint beneath by way of a flush mount cover 104.

The trailing edge 111 may be pitched downwardly behind the leading-edge 110. In this regard, the fan blade member 101 may comprise a proximal end pitch transition 113. As such, the stems 106 of the reinforcement brackets 102 may extend into the pitch transition 113.

As such, the proximal end of the fan blade member 101 may be shaped to define a prow 115 standing proud from the predominance 114 which extends the planar engagement piece 118 across the pitch transition 113.

The prow 115 may be elongate to supports the corresponding planar engagement piece 118 there along. Lateral edges of the prow 115 fall away to the predominance 114.

As can be appreciated from the cross-sectional elevation view of FIG. 6, the prow 115 allows the planar engagement piece 118 and the surrounding reinforcement brackets 102 to extend into the pitch transition 113.

As can also be appreciated from FIG. 6, the construction of the proximal end is yet relatively narrow so as to be ideal for insertion within fan engagements slots of motor housings. Yet furthermore, the prow 115 is located centrally and above, being aesthetically out of sight from beneath.

As is shown in FIG. 4, the recess 116 may comprise an entrance port 117 conforming in cross-sectional shape to the reinforcement bracket 102 which leads up to the planar engagement piece 118.

As alluded to above, the construction 100 may comprise a covering 104 conforming in cross-sectional shape with the recess 116 and configured to lie flush when recessed within the recess 116.

The covering 104 may comprise a plurality of attachment fastener apertures 109 corresponding in location with those of the reinforcement brackets 102. However, the distal end 118 of the covering 104 may be devoid of attachment fastener apertures 109 for aesthetic purposes.

FIG. 5 shows the upper surface of the covering 104 comprising a prominent centreboard 118 comprising a linear edge which abuts against the corresponding lower surface of the adjacent bracket 102 to hold the distal end 118 of the covering 104 at the correct flush level.

FIGS. 7-9 show a fan blade construction 200 in accordance with a further embodiment.

The fan blade construction 200 similarly comprises the upper and lower reinforcement brackets 102 covered with an under covering 104.

However, as is apparent, the fan blade member 101 comprises differing dimensions to those of the fan blade construction 100 of the first embodiment. In this regard, the pitch transition 113 may be located further away from the proximal end of the fan blade member 101 and therefore the fan blade construction 200 of the second embodiment is shaped differently. Alternatively, the fan blade member 101 may be devoid of a pitch transition, rather being planar and engage angularly by the motor.

Specifically, referring now to FIGS. 10-11, the predominance 114 may narrower and/or less accentuated as is shown in FIG. 11. Furthermore, as can be seen from FIG. 10, the recess 116 may conform in cross-sectional shape to the bracket 102. Furthermore, so too may the covering 104 conform in cross-sectional shape to the bracket 102.

As can be appreciated from FIG. 12, the fan blade construction 200 of the second embodiment further yet comprises the planar engagement piece 118 between the opposing reinforcement brackets 102 for reinforcement.

The foregoing description, for purposes of explanation, used specific nomenclature to provide a thorough understanding of the invention. However, it will be apparent to one skilled in the art that specific details are not required in order to practice the invention. Thus, the foregoing descriptions of specific embodiments of the invention are presented for purposes of illustration and description. They are not intended to be exhaustive or to limit the invention to the precise forms disclosed; obviously, many modifications and variations are possible in view of the above teachings. The embodiments were chosen and described in order to best explain the principles of the invention and its practical applications, they thereby enable others skilled in the art to best utilize the invention and various embodiments with various modifications as are suited to the particular use contemplated. It is intended that the following claims and their equivalents define the scope of the invention.

Claims

1. A reinforced fan blade construction comprising:

an elongate fan blade member defining a distal end and an opposite proximal attachment end; and

upper and lower reinforcing brackets engaged oppositely through the proximal end for reinforcement.

2. A reinforced fan blade construction as claimed in claim 2, wherein the reinforcement brackets are planar.

3. A reinforced fan blade construction as claimed in claim 2, wherein the proximal end is shaped to define a planar engagement piece against which the respective upper and lower planar reinforcement brackets lie flush.

4. A reinforced fan blade construction as claimed in claim 3, wherein the planar engagement piece and the reinforcing brackets define corresponding rivet accommodation apertures and wherein the brackets are riveted to the planar engagement piece.

5. A reinforced fan blade construction as claimed in claim 2, wherein each reinforcement bracket comprises an elongate stem and a cross piece.

6. A reinforced fan blade construction as claimed in claim 5, wherein the elongate stem defines a plurality of rivet attachment apertures.

7. A reinforced fan blade construction as claimed in claim 5, wherein the cross piece defines a plurality of attachment fastener apertures.

8. A reinforced fan blade construction as claimed in claim 8, wherein the cross piece is semicircular.

9. A reinforced fan blade construction as claimed in claim 3, wherein the upper surface of the proximal end defines a predominance and a corresponding undersurface of the proximal end defines a recess and wherein the upper enforcement brackets locates on or within the predominance and the lower reinforcement bracket locates within the recess.

10. A reinforced fan blade construction as claimed in claim 9, further comprising an under covering for covering the recess.

11. A reinforced fan blade construction as claimed in claim 10, wherein the under covering comprises a cross-section conforming to that of the recess.

12. A reinforced fan blade construction as claimed in claim 10, wherein the under covering is configured to lie flush when in the recess.

13. A reinforced fan blade construction as claimed in claim 12, wherein the covering comprises proximal fastener attachment apertures.

14. A reinforced fan blade construction as claimed in claim 13, wherein the covering defines a distal end and wherein the distal end is devoid of fastener apertures.

15. A reinforced fan blade construction as claimed in claim 12, wherein an upper surface of the distal end comprises a centreboard comprising a linear edge for abutting against a corresponding undersurface of the adjacent lower attachment bracket.

16. A reinforced fan blade construction as claimed in claim 2, wherein the proximal end further defines a prow, the prow supporting the planar engagement piece therein and comprising lateral edges which fall away to the predominance.

17. A reinforced fan blade construction as claimed in claim 18, wherein the prow extends into a trailing edge pitch transition.

18. A reinforced fan blade construction as claimed in claim 9, wherein the recess comprises a cross-section conforming to that of the reinforcement bracket.

19. A reinforced fan blade construction as claimed in claim 18, wherein the covering comprises a cross-section conforming to that of the reinforcement bracket.

20. A reinforced fan blade construction as claimed in claim 1, wherein the fan blade member comprises Acrylonitrile butadiene styrene (ABS) plastic.