CEILING FAN MOTOR ADAPTER

Abstract

A method and apparatus for mounting a ceiling fan motor to a structure by mounting a motor shaft to a downrod with a motor adapter. The motor shaft mounts to the motor adapter with a press-fit. The motor shaft can extend beyond the motor adapter press-fit within the motor adapter such that the extended portion of the motor shaft can be swaged to provide a mounting redundancy. The motor can be encased with a motor housing, such that the motor adapter minimally extends from the motor housing, obstructing the motor adapter from view. The downrod can insertably mount to the motor adapter with a snug fit reducing fan wobble and with a set screw inserted along a ratcheting fastener to secure loosening of the set screw. A cap is slidably disposed over the downrod to cover the portion of the motor adapter extending beyond the motor housing.

Description

CROSS-REFERENCE TO RELATED APPLICATION(S)

This application claims priority to U.S. Provisional Patent Application No. 62/270,210, filed Dec. 21, 2015, and to U.S. Provisional Patent Application No. 62/428,188, filed Nov. 30, 2016, both of which are incorporated herein by reference in their entirety.

BACKGROUND OF THE INVENTION

Typical ceiling fans are electrically powered, being electrically coupled to a building electrical supply. The ceiling fans comprise an electric motor that is suspended beneath a ceiling by a hollow downrod through which electrical wires extend from the building electrical supply to the motor. An annular array of fan blades are coupled to the motor by blade irons such that the blades can rotate about the motor, pushing a flow of air. Ceiling fans typically utilize a motor adapter to couple the motor to the downrod. A portion of the motor adapter is often exposed to the exterior, while the motor is hidden by a motor housing. Downrods commonly couple to the motor adapter by inserting the downrod into the motor adapter and securing the two with locking pin or a screw through complementary apertures in each member. With this design, however, the weight of the ceiling fan rests upon the locking pin, often resulting in ceiling fan swing, noise, or wobble.

BRIEF DESCRIPTION OF THE INVENTION

In one aspect, the disclosure relates to a ceiling fan comprising a motor having a motor shaft with the motor shaft having an outer diameter, a plurality of blades coupled to the motor, a downrod having an outer diameter and a pair of downrod mounting apertures, a mounting fastener and a motor adapter. The motor adapter mounts the motor to the downrod at the motor shaft and comprises an upper portion with a first inner surface defining an upper cavity and with a pair of fastener apertures therein, and a lower portion with a second inner surface to define a lower cavity. The motor shaft mounts to the motor adapter by inserting the motor shaft into the lower cavity with a press-fit and the downrod mounts to the motor adapter by inserting the downrod into the upper cavity and inserting the mounting fastener through the pair of fastener apertures and the downrod mounting aperture.

In another aspect, the disclosure relates to a method for mounting a ceiling fan to a structure comprising: (1) providing a motor with a motor shaft, a motor adapter, and a downrod; (2) mounting the motor shaft to the motor adapter with a press-fit by inserting the motor shaft into the motor adapter; (3) mounting the downrod to the motor adapter by inserting the downrod into the motor adapter; (4) fastening the downrod to the motor adapter with a mounting fastener; and (5) coupling the downrod to a structure.

In yet another aspect, the disclosure relates to a method of coupling a motor shaft to a motor adapter for a ceiling fan with a reciprocating fixture, including (1) attaching the motor adapter to a first fitting on the fixture, (2) attaching the motor shaft to a second fitting on the fixture, (3) press-fitting a portion of the motor shaft within the motor adapter by reciprocating the fixture, and (4) swaging an end of the motor shaft within the motor adapter.

In yet another aspect, the disclosure relates to a machining fixture to couple a motor shaft to a motor adapter for a ceiling fan includes a frame including an upper plate and a lower plate slidably coupled to one another by opposing rods. A motor adapter mount assembly is provided on the upper plate including a hub to receive the motor adapter. A motor shaft mount assembly is provided on the lower plate including a central aperture to receive the motor shaft. The upper plate is actuable about the rods to press fit the motor shaft provided in the motor shaft mount assembly to the motor adapter provided in the motor mount assembly.

BRIEF DESCRIPTION OF THE DRAWINGS

In the drawings:

FIG. 1 is a perspective view of a ceiling fan motor with a mounted motor adapter.

FIG. 2 is a cross-sectional view of the ceiling fan motor of FIG. 1 with a top portion of the motor housing.

FIG. 3 is a perspective view of the motor adapter assembly.

FIG. 4 is a cross-sectional view of the motor adapter assembly of FIG. 3.

FIG. 5 is a cross-sectional view of a motor adapter of the motor adapter assembly of FIG. 3

FIG. 6 is an exploded view of the motor adapter assembly of FIG. 3.

FIG. 7 is a perspective view of the motor adapter with a ratcheting fastener.

FIGS. 8A-8C are perspective, side, and sectional views of another exemplary motor adapter.

FIG. 8D is a perspective view of another exemplary motor adapter.

FIG. 9 is a front view of a fixture for press-fitting a motor adapter to a motor shaft.

FIG. 10 is an enlarged view of a hub of the fixture of FIG. 9 for holding the motor adapter during press-fitting operations.

FIG. 11 is a front view of the fixture of FIG. 9 having an attached motor adapter and motor shaft.

FIG. 12 is a front view of the fixture of FIG. 11 in a compressed position with the motor adapter press fit to the motor shaft.

FIG. 13 is a front view of the fixture of FIG. 12 in a decompressed position with the motor adapter press fit to the motor shaft.

FIG. 14 is a front view of the fixture of FIG. 9, having a motor attached to the motor shaft.

FIG. 15 is a perspective view of the press-fit coupled motor adapter and motor shaft of FIG. 13.

DESCRIPTION OF EMBODIMENTS OF THE INVENTION

The described embodiments of the present invention are directed to mounting a ceiling fan to a structure, and in particular to a ceiling fan motor adapter. For purposes of illustration, the present invention will be described with respect to an exemplary ceiling fan motor. It will be understood, however, that the invention is not so limited and can have general applicability in all ceiling fan or mounting applications, such lighting or suspension for industrial, commercial, and residential applications. It can also have application to ceiling fans comprising multiple motors or angularly oriented motors.

FIG. 1 is a top perspective view of a ceiling fan 10 illustrating a ceiling fan motor 12 with a motor housing 14 shown in phantom surrounding the motor 12. The motor 12 has a motor casing 16 comprising an upper casing 18 and a lower casing 20. A motor shaft 22 extends vertically from and couples to the motor 12 for mounting the motor 12. A motor adapter 24 couples to the motor 12 at the motor shaft 22 opposite of the motor 12. A downrod 26 couples to the motor adapter 24, effectively coupling the downrod 26 to the motor 12 through the intermediate motor adapter 24 and the motor shaft 22. The downrod 26 can couple to the ceiling or a structure, such as beams or rafters, at a mount such as a hanger bracket (not shown). Thus, the motor 12 can be suspended from the ceiling or structure. The downrod 26 can further comprise a cap 28 for covering the motor adapter 24 as well as securing the downrod 26 at the motor adapter 24.

Turning to FIG. 2, a cross-section of the ceiling fan 10 of FIG. 1 illustrates the internal components of the motor 12 as they mount to the motor shaft 22. The motor cover 14 as shown is exemplary, illustrating only a top portion of the motor cover 14 surrounding a portion of the motor adapter 24, the motor shaft 22, and the motor 12, and should not be understood as limiting.

The motor 12 further comprises a stator 40 and a rotor 42. A plurality of bearings 44 are disposed between the motor shaft 22 and the upper casing 18 and the lower casing 20. The motor casing 16 can mount to the rotor 42 by a plurality of fasteners 48 such as screws, permitting the motor casing 16 and the rotor 42 attached thereto to rotate about the motor shaft 22. Additionally, a plurality of wiring can be fed from the structure, through the downrod 26, the motor adapter 24, and the motor shaft 22 to provide electricity to the motor 12 for operations. A plurality of fan blades can mount to the rotor 42 such that the fan blades rotate about the motor 12 during operating of the ceiling fan 10.

The motor shaft 22 couples to the stator 40 and extends above the motor 12. The motor shaft 22 is static, such that movement does not occur and the rotor 42 rotates about the motor shaft 22. The motor shaft 22 mounts within the motor adapter 24. The motor adapter 24 provides for connecting the motor shaft 22 to the downrod 26 as well as a mounting surface for the motor housing 14. The motor housing 14 can rest on and mount to the motor adapter 24 with one or more fasteners 50 such as a screw. The motor shaft 22 can mount within motor adapter 24 encased within or external to the motor housing 14.

The motor adapter 24 mounts to the downrod 26 with a mounting fastener such as a set screw 52. Additional mounting fasteners can include but are not limited to screws, bolts, pins, etc. The downrod 26 mounts within the motor adapter 24, and can be disposed adjacent to the upper end of the motor shaft 22.

The motor shaft 22, motor adapter 24, downrod 26, and cap 28 collectively form a mounting assembly 60, which is illustrated in detail in FIG. 3. The motor mounting assembly 60 is provided for securely mounting the motor 12 to a structure or ceiling as well as providing a secure fit preventing unwanted swing, wobble, or noise associated with typical ceiling fan mounts.

The motor shaft 22 is a hollow member having a cylindrical shape with varying diameters to define a lower portion 62, a middle portion 64, and an upper portion 66. While the diameters defined by the portions 62, 64, 66 varies, the hollow interior of the motor shaft 22 can have a consistent diameter along the length of the motor shaft 22. The portions 62, 64, 66 can have a step-wise definition to define the portions 62, 64, 66 and can further have one or more apertures 70 for mounting elements to the motor shaft 22 or for running wiring to provide electrical connectivity.

The motor adapter 24 mounts around the upper portion 66 of the motor shaft 22, extending above the motor shaft 22. The motor adapter 24 comprises a lower portion 80 and an upper portion 82. The lower portion 80 is a cylindrical portion having a hollow center for receiving the motor shaft 22 and a cylindrical outer surface 84. A plurality of support structures 86 extend between the outer surface 84 and a motor housing mounting surface 88.

The motor housing mounting surface 88 comprises a wider diameter than the lower or upper portions 80, 82, and extends to a plurality of housing mounts 90, exemplarily illustrated as three housing mounts 90 for mounting to the fan motor housing 14. The particular shape of the inner housing mounts 90 can be keyed to receive a particular shape of the motor housing 14 for mounting to the motor adapter 24 to prevent vibrational noise typically associated with a loosely mounted motor housing 14.

The upper portion 82 extends from the motor housing mounting surface 88 opposite of the lower portion 80, comprising a cylindrical outer surface 96. The cylindrical outer surface 96 further comprises a flat portion 98 adapted to receive the set screw 52.

To assemble the downrod 26 to the motor adapter 24, the downrod 26 inserts into the upper portion 82. The cap 28 is disposed around the downrod 26 such that the cap 28 can be slid along the outer surface of the downrod 26. The cap 28 comprises cylindrical cap body 100 with a flat cap portion 102, such that the cap 28 is keyed to slide over the upper portion 82 of the motor adapter 24, having the flat portion 98 and the flat cap portion 102 aligned. As such, the cap 28 secures the set screw 52 in place and provides an aesthetically pleasing transition between the motor adapter 24 and the downrod 26.

Turning to FIG. 4, a cross-sectional view of FIG. 3 best illustrates the connections between the motor shaft 22, the motor adapter 24, and the downrod 26. As can be appreciated, the motor shaft 22 extends through the lower portion 80 into a lower cavity 110 defined by a cylindrical first inner wall 112. The motor shaft 22 couples to the motor adapter 24 within the lower cavity 110 by a press-fit, also commonly known as a friction fit or an interference fit. As such, the outer diameter of the upper portion 66 of the motor shaft 22 is wider than the diameter of the first inner wall 112 of the motor adapter 24 to achieve the press-fit. For example, the inner diameter of the first inner wall 112 can be 0.0005 inches smaller than the outer diameter of the motor shaft 22. The manufacturer can complete mounting of the motor shaft 22 to the motor adapter 24 in order to complete the press-fit.

An end 114 of the motor shaft 22 can extend above the lower portion 80 and into the upper portion 82. The end 114 can be swaged to comprise a wider inner diameter than the rest of the motor shaft 22, such that the end 114 defines an annular lip over a bottom surface 116 of the motor adapter 24. The swaged end 114 provides a redundant interference for securing the motor shaft 22 to the motor adapter 24.

The upper portion 82 can comprise a cylindrical inner surface 118 to define an upper cavity 120 within the upper portion 82. When the downrod 26 is inserted into the motor adapter 24, the outer surface of the downrod 26 and the inner surface 118 of the motor adapter 24 can be adapted to have a snug fit. A snug fit can comprise, for example, an inner diameter, defined by the inner surface 118, of 1.070 inches and an outer diameter for the outer surface of the downrod 26 of 1.065 inches. Thus, an exemplary diameter gap of 0.005 inches can define the snug fit between the downrod 26 and the motor adapter 24. The consumer or end user can assemble the downrod 26 to the motor adapter 24, whereas the manufacturer can complete the press-fit discussed previously. The snug fit is advantageous for mounting the downrod 26 to the motor adapter 24, eliminating the shaking, wobbling, vibration, or noise typical to ceiling fans with a large gap between the downrod 26 and the motor adapter 24 often secured with a pin-lock system.

Additionally, the upper portion 82 can be adapted to have a slim-line design, only slightly protruding above the motor housing 14, or not at all. As such, the motor adapter 24 can be designed to receive a portion of the downrod 26 into the motor housing 14, protruding only enough to permit fastening of the downrod 26 to the motor adapter 24. Alternatively, the motor housing 14 can be mounted to the motor 12 after coupling the downrod 26 to the motor adapter 24, such that the downrod 26 mounts to the motor adapter 24 within the motor housing 14. Thus, the slim-line design eliminates the need for an adapter cover between the motor housing 14 and the downrod 26 as the consumer is unable to see the motor adapter 24 from below the ceiling fan. Eliminating the need for an adapter cover reduces cost and weight, as well as eliminates a potential source for rattling or noise during fan operation.

The motor adapter 24 can further comprise a weep hole 122. The weep hole 122 is disposed in a junction between the bottom surface 116 and the second inner surface 118 of the upper portion 82 providing fluid communication between the upper cavity 120 and the external surface of the motor adapter 24. Where liquid or fluid can enter the motor adapter 24 through the junction between the downrod 26 and the motor adapter 24, the excess liquid or fluid can drain to the bottom of the upper portion 82 and flow out of the motor adapter 24 through the weep hole 122 without the fluid contacting internal wiring extending through the motor mounting assembly 60. The weep hole 122 further permits outdoor use for the ceiling fan utilizing the motor mounting assembly 60.

Turning to FIG. 5, an isolated, cross-sectional view of the motor adapter best illustrates the lower cavity 110 and the upper cavity 120 without the inserted motor shaft 22 and the downrod 26. As such, the cavities 110, 120 are in fluid communication with one another such that the inserted hollow downrod 26 and motor shaft 22 can provide for internal wiring providing electricity to the motor 12. Furthermore, without the set screw 52, the upper portion 82 comprises two fastener apertures for receiving the set screw 52 for securing the downrod 26 to the motor adapter 24. As can be appreciated, the swaged portion of the motor shaft 22 will be disposed in the upper cavity 120 adjacent the bottom surface 116.

Turning to FIG. 6, an exploded view illustrates the set screw 52 and a ratcheting fastener 132. The set screw 52 has an elongated smooth surface at the middle, with a threaded end and a keyed end opposite of the threaded end. The upper portion 82 of the motor adapter 24 further comprises a set of fastener apertures 124, disposed radially opposite of one another. After the downrod 26 is inserted into the motor adapter 24, the set screw 52 can be inserted through one fastener aperture 124, through a set of downrod holes 126, and out through the other fastener aperture 124. The fastener apertures 124 can further be defined into an insertion aperture 136 and a reception aperture 138. The insertion aperture 136 can be identified by the flat portion 98 disposed on the outer surface 96 of the motor adapter 24. The reception aperture 138 can be identified by the ratcheting fastener 132 disposed adjacent to the reception aperture 138.

Turning to FIG. 7, the ratcheting fastener 132 is mounted to a second flat portion 140. The second flat portion 140 is partially recessed into the outer surface 96 of the motor adapter 24 such that the ratcheting fastener 132 can mount to the second flat portion without extending beyond the outer surface 96. The ratcheting fastener 132 comprises an arcuate extension 142 which partially coves the reception aperture 138. During insertion of the set screw 52 through the reception aperture 138, the threaded portion of the set screw 52 can be pushed over or screwed over the ratcheting fastener 132. Once fully inserted, the set screw 52 is prevented from sliding out of the fastener apertures 124 by the ratcheting fastener 132 securing the set screw 52 in place at the threads.

In another embodiment, the invention can comprise a method for mounting a ceiling fan to a structure. The method can comprise providing a motor with a motor shaft, a motor adapter, and a downrod, such as those described herein. The method can include (1) press-fitting the motor shaft into the motor adapter, (2) inserting the downrod into the motor adapter, (3) fastening the downrod to the motor adapter, and (4) securing the downrod to the structure. The motor shaft is mounted to the motor adapter with a press-fit by inserting the motor shaft into the motor adapter and the downrod is mounted to the motor adapter by inserting the downrod into the motor adapter. The motor adapter can further comprise an upper cavity for receiving the downrod and a lower cavity for receiving the motor shaft. The press-fit can be defined by the outer diameter of the motor shaft being greater than the diameter of the lower cavity by about 0.0005 inches, for example. The downrod can insert into the to the upper cavity of the motor adapter with a slim fit defined by the outer diameter of the downrod being smaller than the diameter of the upper cavity by about 0.005 inches. The downrod can be fastened to the motor adapter with a mounting fastener, such as a pin or a set screw 52 as described herein. The mounting fastener can further be secured to the motor adapter with a ratcheting fastener and a cap can be slidably disposed along the downrod to cover the top of the motor adapter adjacent to the downrod. The motor can mount to the structure by coupling the downrod to the structure. Such mounting can be accomplished by seating a ball at an opposite end of the downrod in a hanger bracket, for example.

Additionally, the method can include securing a motor housing to the motor adapter, such as mounting the motor housing at the housing mounts 90. The method can further include swaging the motor shaft within the motor adapter. After press-fitting the motor shaft into the motor adapter, and end of the motor shaft can extend through the motor adapter into the upper cavity. The extending portion can be swaged to have a width greater than the lower cavity to provide a redundancy beyond the press-fit attachment of the motor shaft. In one aspect, swaging and press-fitting the motor shaft to the motor coupler can occur during the same action.

As can be appreciated, the motor adapter provides for improved mounting of a motor shaft to a downrod. The press-fit in combination with the swaged top portion of the motor shaft provides a secure fit as well as reduces the tendency for vibrations, swaying, or noise associated with typical fan mounts. Additionally, the threaded connections common for mounting motor shafts to motor adapters is removed, preventing potential loosening of the connection. Finally, the swaged top portion provides a redundancy for securing the motor shaft to the motor adapter.

FIGS. 8A-8C show another exemplary motor adapter 200. Referring to FIG. 8A, the motor adapter 200 includes an upper portion 202 and a lower portion 204, adapted to receive a downrod and a motor shaft, respectively. An upper cavity 206 is formed in the upper portion having two channels 208 formed on opposing sides of the cavity 206. Extended portions 209 are formed in the upper portion 202 respective of the channels 208. An insertion aperture 210 can be disposed in the upper portion 202 at the extended portions 209 for accepting the insertion of a fastener, such as a pin or a screw, for example. Additional threaded apertures 211 can be disposed in the upper portion 202 fluidly coupling the interior of the upper portion 202 the exterior of the adapter 200. The upper portion 202 can include a diameter 212 sized to receive a downrod that is about 0.005 inches smaller than the diameter 206, to form the snug-fit as described herein. Alternatively, it is contemplated that the diameter is greater than 0.005 inches wider than a downrod, such as 0.040 inches or more. The greater the difference between diameter 212 and the downrod, the easier it will be for an installer to slide the downrod into the upper portion 202. Additionally, with the snug fit, manufacture defects can cause difficulty with installation. With a wider diameter, such difficulty can be minimized. The upper portion 202 can include a diameter 212 slightly larger that of an expected downrod. The threaded apertures 211 are intended to accept an inserted fastener that is tightened against the inserted downrod to compensate for any vibration, swaying, noise, or similar effect, resultant of the gap differential at the upper portion 202 and the downrod. The extended portions 209 can provide for improved support for a fastener extending through the insertion aperture 210 to couple the downrod. The extended portions 209 form the channels 208 while maintaining a uniform thickness for the wall of the upper portion 202. The channel 208 provides space between the extended portion 209 and an inserted downrod for supporting a permanent or semi-permanent fastener to couple the downrod to the motor adapter 200. The space of the channel 208 provides room, for example, to support a depressible member for removal of a semi-permanent fastener. At least one weep hole 214 is provided in the upper cavity 206, providing for draining any potential liquid flowing into the upper cavity 206. Such a weep hole 214 can be beneficial for use in wet or outdoor environments.

An annular ring 218 can extend around the exterior of the motor adapter 200 at the junction between the upper and lower portions 202, 204. One or more housing mounts 220, shown as three housing mounts 220, can extend further from the ring 218. Fastener apertures 222 are provided in the housing mounts 220 facilitating mounting of the motor adapter 200 to a motor housing. The housing mounts 200 include a partial wall 224. The partial wall 224 can be adapted to fit a particular motor housing, while reducing overall material and weight of the motor adapter 200, also reducing costs.

Referring now to FIG. 8B, illustrating a side view of the motor adapter 200, the lower portion 204 is seen extending from the ring 218 opposite of the upper portion 202. Arms 230 extend from the exterior of the lower portion 204 to the housing mounts 220 to structurally support the housing mounts 220, as well as support a motor housing mounted to the motor adapter 200 at the housing mounts 220. A weep channel 232 is formed in the exterior of the lower portion 204 providing egress for liquid draining through the weep hole 214 to the exterior of the motor adapter 200.

Referring now to FIG. 8C, a cross-sectional view taken across section VIII C of FIG. 8B shows a lower cavity 234 in fluid communication with the upper cavity 206. The lower cavity 234 can include a diameter 236 less than that of the upper cavity 204, while it is contemplated that the upper and lower cavities 204, 234 can have any diameter as is desirable. The diameter 236 can be sized to be smaller than the diameter of a motor shaft, requiring a press-fit connection for insertion of the motor shaft into the lower cavity 234, such as shown and described in regards to FIG. 4. The lower cavity 234 is open to the upper cavity 206 to provide for the extension of an inserted motor shaft into the upper cavity 206 through the lower cavity 234. Such an extension of the motor shaft can be swaged within the upper cavity 204 to secure the motor shaft within the upper cavity 206 and to the motor adapter 200. Such an example is shown in FIG. 4.

Referring now to FIG. 8D, an alternative motor adapter 240 is shown. The motor adapter 240 can be substantially similar to the motor adapter 200 of FIGS. 8A-8C. As such similar numerals will be used to identify similar elements, and the discussion of FIG. 8D will be limited to the differences from the motor adapter 200 of FIGS. 8A-8C. The upper portion 202 includes an outer wall 242 defining the upper cavity 206, and has a rounded upper edge 244.

As can be appreciated by comparison to FIG. 8A, the extended portion 209 defining the channels 208 on either side of the upper portion 202 has been removed. However, the diameter 212 among the adapters 200, 240 of FIGS. 8A and 8D remains the same. As such, it should be appreciated that the particular design of the upper portion 202 can be adapted or varied based upon the particular implementation of the motor adapter. For example, a particular fastener may be needed to mount a downrod to the motor adapter 240. As such, the upper portion 202 of the motor adapter 240 may need to be tailored to the fastener to attach the two, which may be limited by the particular fan. A fan may include a particular motor housing, where mounting of the motor housing may require the additional space provided in the design of FIG. 8D. Additionally, each separate design may be beneficial for reducing fan wobble, vibration, or noise based upon the particular fan.

Referring now to FIG. 9, a fixture 250 can include a frame 252 having an upper plate 254 and a lower plate 256 with opposing rods 258 including springs 259 connecting the upper plate 254 to the lower plate 256. Upper mounts 260 can secure the rods 258 to the upper plate 254 and lower mounts 262 can secure the rods 258 to the lower plate 256. The springs 259 support the upper plate 254 above the lower plate 256 at the upper and lower mounts 260, 262 along the rods 258. Two additional rods 264 extend from the lower plate 256, terminating prior to the upper plate 254.

A motor adapter mount assembly 270 is included on the upper plate 254 facing the lower plate 256. The motor adapter mount assembly 270 includes a base 272 with a hub 274 having a swaging finger 276 extending from the hub 274. An arm 278 including a bearing 280 is provided adjacent the hub 274. The bearing 280 can be any actuable element adapted to secure an element to the hub 274, such as the motor adapter 200, 240 of FIGS. 8A-8D. An alignment member 282 is further provided adjacent the hub 274 including a housing mount aperture 284.

A motor shaft mount assembly 286 is included on the lower plate 256 including a central aperture 288 sized to receive a motor shaft. A bottom 290 of the central aperture 288 is provided to secure an inserted motor shaft at one terminal end. An opening 289 of the motor shaft mount assembly 286 at the central aperture 288 provides for nesting of an assembled motor, including motor wiring extending below the motor. The opening 289 can provide room for such motor wiring extending through the central aperture 288. The motor shaft mount assembly 286 further includes an upper terminal surface 292 facing the motor adapter mount assembly 270.

A drive 294 including a drive rod 296 can mount to the upper plate 254. The drive 294 can communicatively and operably couple to a controller 298. The drive 294 can actuate the upper plate 254 along the rods 258 relative to the lower plate 256.

Referring now to FIG. 10, illustrating an enlarged view of the motor adapter mount assembly 270, includes an exploded motor adapter 200. While the motor adapter 200 is illustrated in FIGS. 10-15 as the motor adapter 200 of FIGS. 8A-8C, it should be understood that the motor adapter can be any motor adapter 24, 200, 240 described herein. The hub 274 is sized to slidably receive the motor adapter 200, inserting the hub 274 into the upper cavity 206. Upon insertion, the swaging finger 276 extends through the upper cavity 206 into the lower cavity 234. The bearing 280 on the end of the arm 278 is positioned such that a frictional force of the bearing 280 against the upper portion 202 secures insertion of the motor adapter 200 onto to hub 274. While described as a bearing 280, the bearing 280 can alternatively be any flexure or flexible element enabling sliding insertion of the motor adapter 200 along the hub 274 and then effectively holding the motor adapter 200 in place. Such a holding can be accomplished, for example, by a frictional force to prevent the motor adapter 200 from falling off the hub 274. The alignment member 282 includes the housing mount aperture 284 to receive one of the housing mounts 220 upon insertion of the hub 274 into the upper cavity 206. Reception of the housing mount 220 into the housing mount aperture 284 aligns the motor adapter 200 in the desired position, as well as prevents unwanted rotation of the motor adapter during fitting operations.

Referring now to FIG. 11, a front view of the fixture of FIG. 9 is illustrated including the motor adapter 200 releasably attached to the motor adapter mount assembly 270 and a motor shaft 310 provided in the central aperture 288 of the motor shaft mount assembly 286. One housing mount 220 of the motor adapter 200 has been inserted into the housing mount aperture 284 of the alignment member 282. The motor shaft 310 includes one or more rings 312, shown as two rings 312, for aligning or seating elements at the motor shaft 310. For example, the lower ring 312 rests against the upper terminal surface 292 of the motor shaft mount assembly 286. Additionally, the rings 312 are useful for mounting ceiling fan components, such as a rotor or stator in non-limiting examples.

In the position shown, one end 314 of the motor shaft 310 is aligned with the motor adapter 200, and particularly the lower cavity 234 (FIG. 8C) of the motor adapter 200. In operation, the controller 298 can operate the drive 294 to actuate the frame 252, driving the upper plate toward the lower plate 256 along the rods 258 and compressing the spring 259. Arrows 316 illustrate such movement.

Referring to FIG. 12, the frame 252 has been compressed by the drive 294. Upon compression, the upper plate 254 rests upon terminal ends 318 of the additional rods 264, preventing excessive actuation. The motor shaft 310 has been coupled to the motor adapter 200. The diameter of the motor shaft 310 is larger than the diameter of the lower cavity 234 (FIG. 10). As such, a press-fit, or interference fit, is accomplished by the fixture 250 to couple the motor shaft 310 to the motor adapter 200 in the lower cavity 234.

At the same time, during the same compressive actuation by the drive 294, the end 314 of the motor shaft 310 is also received at the swaging finger 276. The swaging finger 276 inserts into the hollow motor shaft 310, swaging the end 314 of the motor shaft 310 extending through the lower cavity 234 and into the upper cavity 206. See the swaged end 114 of FIG. 4, for example.

The press-fit of the motor shaft 310 in the lower cavity 234 of the motor adapter 200 secures the motor shaft 310 to the motor adapter 200. The swaged end of the motor shaft 310 formed by the swaging finger 276 provides a redundancy for permanently securing the motor shaft 310 to the motor adapter 200. After press-fitting and swaging the motor shaft 310 to the motor adapter 200, the drive 294 can actuate the upper plate 254 in the opposite direction, decompressing the springs 259 along the rods 258, as shown by arrows 320.

Referring now to FIG. 13, showing the frame 252 of the fixture 250 returned to the initial position, as shown in FIG. 9. The motor shaft 310 has been removed from the motor shaft mount assembly 286, being coupled to the motor adapter 200 still attached to the motor adapter mount assembly 270. Alternatively, the motor adapter 200 may detach from the motor adapter mount assembly 270, leaving the motor shaft 310 in the motor shaft mount assembly 286. A user may remove the assembled motor adapter 200 and motor shaft 310 assembly for use with a desired ceiling fan. A downrod can be coupled to the motor adapter 200 to suspend the motor shaft 310 as well as any components mounted to the motor shaft 310 or the motor adapter 200.

Referring to FIG. 14, the fixture 250 is shown in an alternative example including a motor 322 mounted on the motor shaft 310 prior to coupling the motor shaft 310 to the motor adapter 200. The fixture 250 of FIG. 14 can be substantially similar or identical to the fixture 250 of FIGS. 9-13, only differing by way of attaching the motor 322 to the motor shaft 310 prior to mounting operations. As such, only the motor 322 and associated elements will be discussed with regard to FIG. 14, utilizing similar numerals as FIGS. 9-13. The motor 322 can mount to the motor shaft 310 prior to attaching the motor adapter 200. Additionally, the motor 322 can include motor wiring 324. The motor wiring 324, for example, can be for electrically coupling a light fixture or a switch housing. The central aperture 288 provides room for the extending motor wiring 324 while securing the motor shaft 310 at the motor shaft mount assembly 286.

Referring to FIG. 15, the final assembled motor shaft 310 and the motor adapter 200 is shown, being mechanically secured to one another with the press-fit and the swaged end of the motor shaft 310 extending into the upper cavity 206 of the motor adapter 200. It should be understood that in the example of FIG. 14, the assembly of FIG. 15 would include the motor 322.

A method of coupling a motor shaft to a motor adapter for a ceiling fan with a reciprocating fixture includes (1) attaching the motor adapter to a first fitting on the fixture, (2) attaching the motor shaft to a second fitting on the fixture, (3) press-fitting a portion of the motor shaft within the motor adapter by reciprocating the fixture, and (4) swaging an end of the motor shaft within the motor adapter.

Attaching the motor adapter to a first fitting on the fixture can include attaching the motor adapter 200 to the motor adapter mount assembly 270 as shown in FIGS. 10-11. Attaching the motor shaft to a second fitting on the fixture can include inserting the motor shaft 310 into the motor shaft mount assembly 286 as shown in FIG. 11. Press-fitting portion of the motor shaft within the motor adapter by reciprocating a fixture can include actuating the fixture 250 to press fit the motor shaft 310 into the motor adapter 200 as shown in FIGS. 11-12. Swaging an end of the motor shaft within the motor adapter can include swaging the end 314 of the motor shaft 310 with the swaging finger 276 during actuation of the fixture 250 as shown in FIGS. 11-12. The press-fitting and swaging steps can be performed at the same time, such as simultaneously or during the same actuating motion of the fixture 250.

Due to manufacturing tolerances, the diameter of the motor adapter to accept the downrod has been oversized to permit easy insertion of the downrod into the motor adapter. In order to compensate for any vibration, noise, or wobbling resultant of the oversized motor adapter, fastener apertures have been formed in the motor adapter to accept threaded fasteners to secure to the inserted downrod. Such threaded fasteners will minimize or prevent vibration, noise, or wobbling, otherwise resultant of the oversized fit.

Alternatively, it should be further appreciated that a snug-fit for the downrod to the motor adapter reduces the potential for movement or vibrations between the motor adapter and the downrod, further reducing noise or ceiling fan wobble.

It should be further understood that the recessed area of the motor adapter for accepting the downrod accepts the downrod into the area enclosed by the motor housing, defining a slim-line design such that the motor adapter does not extend beyond the motor housing to be visible to someone using the fan, making the fan more aesthetically pleasing.

It should be further understood that the ratcheting fastener in combination with the cap provide additional protection for the fastener used to secure the downrod to the motor adapter. The ratcheting fastener permits easy insertion of a standard set screw or other fastener while preventing it from loosening. The cap further protects the set screw from sliding out of the downrod-motor adapter connection, while providing an aesthetically pleasing transition between the motor housing and the downrod without the need for a motor cover common to ceiling fans utilizing a motor adapter.

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.

Claims

1. A ceiling fan comprising:

a motor having a motor shaft with the motor shaft having an outer diameter;

a plurality of blades coupled to the motor;

a downrod having an outer diameter and a pair of downrod mounting apertures;

a mounting fastener; and

a motor adapter defining a cavity having an inner diameter and a pair of fastener apertures;

wherein the motor shaft is located within the cavity and the outer diameter is greater than the inner diameter to form a press-fit connection between the motor shaft and the motor adapter, and the mounting fastener passes through the pairs of downrod mounting apertures and the fastener apertures.

2. The ceiling fan of claim 1 further comprising a motor housing encasing the motor and mounted to the motor adapter.

3. The ceiling fan of claim 2 wherein the motor housing is mounted to the motor adapter.

4. The ceiling fan of claim 3 further comprising a cap slidably disposed around the downrod wherein the cap slides along the downrod to cover the motor adapter extending above the motor housing.

5. The ceiling fan of claim 1 wherein the cavity further comprises an upper cavity and a lower cavity.

6. The ceiling fan of claim 5 wherein the outer diameter of the downrod is about 0.005 inches smaller than the diameter of the upper cavity.

7. The ceiling fan of claim 5 wherein the press-fit connection is defined by the outer diameter of the motor shaft being greater than the diameter of the lower cavity by about 0.0005 inches.

8. The ceiling fan of claim 5 wherein the motor shaft extends through the lower cavity and into the upper cavity.

9. The ceiling fan of claim 8 wherein an end of the motor shaft extending into the upper cavity is swaged.

10. The ceiling fan of claim 9 wherein the swaged end of the motor shaft defines a lip.

11. The ceiling fan of claim 1 further comprising a ratcheting fastener disposed adjacent to and extending partially over at least one of the fastener apertures.

12. The ceiling fan of claim 11 wherein the mounting fastener comprises a threaded portion and the ratcheting fastener threadably receives the threaded portion.

13. The ceiling fan of claim 1 further comprising a weep hole disposed within the motor adapter providing fluid communication between the cavity and a space external of the motor adapter.

14. A method for mounting a ceiling fan having a motor shaft, a motor adapter, and a downrod to a structure, the method comprising:

press-fitting the motor shaft into the motor adapter;

inserting the downrod into the motor adapter;

fastening the downrod to the motor adapter; and

securing the downrod to the structure.

15. The method of claim 14 further comprising ratcheting a fastener to secure the downrod to the motor adapter.

16. The method of claim 14 further comprising securing a motor housing to the motor adapter.

17. The method of claim 14 further comprising swaging the motor shaft within the motor adapter.

18. The method of claim 17 wherein swaging the motor shaft and press-fitting the motor shaft occur during the same action.

19. A method of coupling a motor shaft to a motor adapter for a ceiling fan with a reciprocating fixture, the method comprising:

attaching the motor adapter to a first fitting on the fixture;

attaching the motor shaft to a second fitting on the fixture;

press-fitting a portion of the motor shaft within the motor adapter by reciprocating the fixture; and

swaging an end of the motor shaft within the motor adapter.

20. The method of claim 19 wherein the swaging and press-fitting occur at the same time.

21. A machining fixture to couple a motor shaft to a motor adapter for a ceiling fan, the machining fixture comprising:

a frame including an upper plate and a lower plate slidably coupled to one another by opposing rods;

a motor adapter mount assembly provided on the upper plate including a hub to receive the motor adapter; and

a motor shaft mount assembly provided on the lower plate including a central aperture to receive the motor shaft;

wherein the upper plate is actuable along the rods to press fit the motor shaft provided in the motor shaft mount assembly to the motor adapter provided in the motor adapter mount assembly.

22. The machining fixture of claim 21 further comprising a swaging finger extending from the hub to swage an end of the motor shaft during press-fitting of the motor shaft to the motor adapter.

23. The machining fixture of claim 21 further comprising springs provided on the opposing rods.

24. The machining fixture of claim 21 further comprising a controller operatively coupled to the machining fixture for automating actuation of the upper plate.

25. The machining fixture of claim 21 wherein the motor adapter mount further comprises a bearing for securing the attached motor adapter to the motor adapter mount assembly.