CEILING FAN AND METHOD OF MANUFACTURE

Abstract

A fan having an outer circumferential support with a plurality of radial penetrations. An inner circumferential support having a plurality of radial penetrations. A plurality of blades, each coupled to the outer circumferential support and the inner circumferential support. A plurality of radial supports, each radial support extending through a penetration of the inner circumferential support and a penetration of the outer circumferential support.

Description

TECHNICAL FIELD

The present disclosure relates generally to ceiling fans, and more specifically to a ceiling fan having an improved design and method of manufacture.

BACKGROUND OF THE INVENTION

Ceiling fans are typically designed to reduce weight. As such, the use of extraneous ornamental features is typically avoided, because they add unnecessary weight.

SUMMARY OF THE INVENTION

A fan having an outer circumferential support with a plurality of radial penetrations. An inner circumferential support having a plurality of radial penetrations. A plurality of blades, each coupled to the outer circumferential support and the inner circumferential support. A plurality of radial supports, each radial support extending through a penetration of the inner circumferential support and a penetration of the outer circumferential support.

Other systems, methods, features, and advantages of the present disclosure will be or become apparent to one with skill in the art upon examination of the following drawings and detailed description. It is intended that all such additional systems, methods, features, and advantages be included within this description, be within the scope of the present disclosure, and be protected by the accompanying claims.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

Aspects of the disclosure can be better understood with reference to the following drawings. The components in the drawings may be to scale, but emphasis is placed upon clearly illustrating the principles of the present disclosure. Moreover, in the drawings, like reference numerals designate corresponding parts throughout the several views, and in which:

FIG. 1 is a diagram of a ceiling fan in accordance with an exemplary embodiment of the present disclosure;

FIG. 2 is a side view of fan from a first side, in accordance with an exemplary embodiment of the present disclosure;

FIGS. 3, 4 and 5 are second, third and fourth side views, respectively, showing additional circumferential positions around a ceiling fan;

FIG. 6 is a bottom view of a ceiling fan showing blades underneath an outer circumferential support, an inner circumferential support and a radial support;

FIG. 7 is a top view of a ceiling fan showing blades on top of an outer circumferential support, an inner circumferential support and a radial support;

FIG. 8 is a diagram of a hub in accordance with an exemplary embodiment of the present disclosure; and

FIG. 9 is a diagram of a hub in accordance with an exemplary embodiment of the present disclosure.

DETAILED DESCRIPTION OF THE INVENTION

In the description that follows, like parts are marked throughout the specification and drawings with the same reference numerals. The drawing figures may be to scale and certain components can be shown in generalized or schematic form and identified by commercial designations in the interest of clarity and conciseness.

FIG. 1 is a diagram of a ceiling fan 100 in accordance with an exemplary embodiment of the present disclosure. Ceiling fan 100 includes blades 102, outer circumferential support 104, inner circumferential support 106, radial supports 108 and hub 110, each of which can be fabricated from metal, polymers, wood or other suitable materials.

As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises” and/or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof. As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items. As used herein, phrases such as “between X and Y” and “between about X and Y” should be interpreted to include X and Y. As used herein, phrases such as “between about X and Y” mean “between about X and about Y.” As used herein, phrases such as “from about X to Y” mean “from about X to about Y.”

Blades 102 are coupled to outer circumferential support 104 and inner circumferential support 106 by nuts 114 or other suitable mechanical fasteners, such as rivets or welds. Radial supports 108 are inserted through a penetration in inner circumferential support 106, and attached to hub 110 by welding, rivets, bolts or other suitable fasteners, or can alternatively be fabricated from a single piece, such as by casting, extrusion or in other suitable manners. Each blade 102 can be fabricated separately and attached to outer circumferential port 104 and inner circumferential support 106 in a suitable manner, such as by attaching a first blade 102 to outer circumferential support 104 and inner circumferential support 106 with nuts 114 before attaching a second blade 102 in the next circumferentially adjacent position, by attaching blades 102 at opposite circumferential locations, by attaching four blades 102 at 90 degree offsets or in other suitable manners. In this manner, a single person can assemble fan 100 at a remote location, or can be assisted by one, two or more persons, who can each work in parallel on the assembly. Fan 100 can thus be easily shipped in pieces to an installation site and can then be assembled.

The shaft of motor 112 has a small circular mounting plate attached to it, about 2″ in diameter, which is also attached to a circular hub 110. Hub 110 has 6 holes in it, one for each radial support 108, and the radial supports 108 are attached with a nut onto hub 110. Each radial support 108 runs through a penetration in inner circumferential support 106 and into outer circumferential support 104 where it is attached with a nut onto the threaded end again. Because fan 100 is being used in a horizontal disposition instead of a vertical disposition, inner circumferential support 106 and outer circumferential support 104 can be fabricated from hollow tubing, which can be square so as to provide additional support. Furthermore, as fan 100 is being used for generating cooling instead of transmitting torque from winds to generate motive power (such as for typical applications of a windmill), the blades, 102, outer circumferential support 104 and inner circumferential support 106 can be fabricated from aluminum, polymers or other light metals or materials, so as to only weigh 40 pounds or less.

FIG. 2 is a side view of fan 100 from a first side, in accordance with an exemplary embodiment of the present disclosure. As shown in FIG. 2, each blade 102 has a leading edge 202 that extends outward from outer circumferential support 104, and an attachment edge 204 that is secured to outer circumferential support 104 by nut 114. FIG. 2 also shows motor 206, ceiling support 208 and base 210.

FIGS. 3, 4 and 5 are second, third and fourth side views, respectively, showing additional circumferential positions around fan 100. Because fan 100 is symmetric, each of FIGS. 3, 4 and 5 are identical.

FIG. 6 is a bottom view of fan 100 showing blades 102 underneath outer circumferential support 104, inner circumferential support 106 and radial support 108. As shown in FIG. 6, each radial support 108 is coupled to hub 110 (not explicitly shown), and is then inserted through a penetration in inner circumferential support 106 and a corresponding penetration in outer circumferential support 104 and is then secured by a nut 114 to outer circumferential support 104.

FIG. 7 is a top view of fan 100 showing blades 102 on top of outer circumferential support 104, inner circumferential support 106 and radial supports 108. As shown in FIG. 6, each radial support 108 is coupled to hub 110, and is then inserted through a penetration in inner circumferential support 106 and a corresponding penetration in outer circumferential support 104 and is then secured by a nut 114 to outer circumferential support 104. Each blade is attached to outer circumferential support 104 and inner circumferential support 106 by a single bolt or other suitable attachment at the leading edge.

FIG. 8 is a diagram of a hub 110 in accordance with an exemplary embodiment of the present disclosure. Hub 110 includes nuts 802, which are coupled to threads 804 of radial support 108. In one exemplary embodiment, each radial support 108 is inserted through a hole in hub 110, and nut 802 is then threaded on. Hub 110 further includes a shaft hole 808 and four support screw holes 806 that are used to couple the motor shaft to hub 110.

FIG. 9 is a diagram of a hub 110 in accordance with an exemplary embodiment of the present disclosure. Hub 110 includes nuts 802, which are coupled to threads 804 of radial support 108. Radial supports 108 are threaded through penetrations in outer circumferential support 04 and inner circumferential support 106, and are also coupled to outer circumferential support 104 by nuts 114.

It should be emphasized that the above-described embodiments are merely examples of possible implementations. Many variations and modifications may be made to the above-described embodiments without departing from the principles of the present disclosure. All such modifications and variations are intended to be included herein within the scope of this disclosure and protected by the following claims.

Claims

1. A fan comprising:

an outer circumferential support having a plurality of radial penetrations;

an inner circumferential support having a plurality of radial penetrations;

a plurality of blades, each coupled to the outer circumferential support and the inner circumferential support; and

a plurality of radial supports, each radial support extending through a penetration of the inner circumferential support and a penetration of the outer circumferential support.

2. The fan of claim 1 wherein the outer circumferential support is fabricated from aluminum.

3. The fan of claim 1 wherein the outer circumferential support is fabricated from hollow aluminum tubing.

4. The fan of claim 1 wherein the outer circumferential support is fabricated from hollow aluminum tubing having a square cross-section.

5. The fan of claim 1 wherein the inner circumferential support is fabricated from aluminum.

6. The fan of claim 1 wherein the inner circumferential support is fabricated from hollow aluminum tubing.

7. The fan of claim 1 wherein the inner circumferential support is fabricated from hollow aluminum tubing having a square cross-section.

8. The fan of claim 1 wherein each blade is fabricated from aluminum.

9. The fan of claim 1 wherein each blade is fabricated from aluminum and is coupled to the inner radial support by a bolt.

10. The fan of claim 1 wherein each blade is fabricated from aluminum and is coupled to the outer radial support by a bolt.

11. The fan of claim 1 further comprising a fan motor coupled to the plurality of radial supports.

12. The fan of claim 1 further comprising:

a fan motor coupled to a circular hub; and

wherein the plurality of radial supports are coupled to the circular hub.

13. A method of manufacturing a fan comprising:

threading a plurality of radial supports through penetrations in an inner circumferential support and penetrations in an outer circumferential support;

securing the plurality of radial supports to the outer circumferential support;

securing the plurality of radial supports to a fan motor; and

securing a plurality of fan blades to the inner circumferential support and the outer circumferential support.

14. The method of claim 13 wherein securing the plurality of radial supports to the fan motor comprises securing the fan motor to a circular hub.

15. The method of claim 13 wherein securing the plurality of radial supports to the fan motor comprises:

securing the fan motor to a circular hub; and

securing the plurality of radial supports to the circular hub.

16. The method of claim 13 wherein securing the plurality of radial supports to the outer circumferential support comprises bolting each of the radial supports to the outer circumferential support.

17. The method of claim 13 wherein securing the plurality of fan blades to the inner circumferential support and the outer circumferential support comprises bolting each of the fan blades to the inner circumferential support and the outer circumferential support.

18. A method of fabricating a fan that has an outer circumferential support having a plurality of radial penetrations, an inner circumferential support having a plurality of radial penetrations, a plurality of blades, each coupled to the outer circumferential support and the inner circumferential support, a plurality of radial supports, each radial support extending through a penetration of the inner circumferential support and a penetration of the outer circumferential support, wherein the outer circumferential support is fabricated from hollow aluminum tubing having a square cross-section, wherein the inner circumferential support is fabricated from hollow aluminum tubing having a square cross-section, wherein each blade is fabricated from aluminum and is coupled to the inner radial support and the outer radial support by a bolt, a fan motor coupled to a circular hub and wherein the plurality of radial supports are coupled to the circular hub, the method comprising:

threading a plurality of radial supports through penetrations in an inner circumferential support and penetrations in an outer circumferential support;

securing the plurality of radial supports to the outer circumferential support;

securing the plurality of radial supports to a fan motor;

securing a plurality of fan blades to the inner circumferential support and the outer circumferential support;

wherein securing the plurality of radial supports to the fan motor comprises:

securing the fan motor to a circular hub; and

securing the plurality of radial supports to the circular hub;

wherein securing the plurality of radial supports to the outer circumferential support comprises bolting each of the radial supports to the outer circumferential support; and

wherein securing the plurality of fan blades to the inner circumferential support and the outer circumferential support comprises bolting each of the fan blades to the inner circumferential support and the outer circumferential support.