AU2017203518B2

AU2017203518B2 - A ceiling fan assembly

Info

Publication number: AU2017203518B2
Application number: AU2017203518A
Authority: AU
Inventors: William Yu
Original assignee: Deka Australia Pty Ltd
Current assignee: Deka Australia Pty Ltd
Priority date: 2017-05-26
Filing date: 2017-05-26
Publication date: 2021-05-27
Anticipated expiration: 2037-05-26
Also published as: AU2021103062A4; AU2017203518A1; AU2021107556A4; AU2021103062B4

Abstract

There is provided a ceiling fan assembly comprising: a motor assembly hung from a downrod, the motor assembly defining a peripheral flange comprising a plurality of radial flange affixation apertures for the receipt of fan blade fastening fasteners therethrough for the securement of fan blades thereto, the affixation apertures each having a longitudinal axis perpendicular with a rotational axis of the motor assembly; and housing surrounding the motor assembly, wherein the housing comprises: an annular and static upper housing portion correspondingly adjacent the radial flange and wherein the upper housing is detachable away from the peripheral flange in use, allowing for upper access to the affixation apertures. 10 5/11 LO) a) co. CN)

Description

5/11

LO) a)

co.

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A ceiling fan assembly Field of the Invention

[1] This invention relates generally to ceiling fan assemblies.

Background of the Invention

[2] Figure 1 shows a pendant-style ceiling fan assembly 44 in accordance with the prior art.

[3] The assembly 44 comprises a motor assembly suspended from a downrod 52. The motor assembly may be surrounded by housing which typically includes static upper housing 45 and static lower housing (not shown).

[4] The lower housing may take the form of a plate or disk which fastens to a static underplate 54 by way of a plurality of rotation-locking affixation apertures 49.

[5] Middle housing 53 locates between the upper housing 35 and the lower housing and rotates with the rotor of the motor assembly.

[6] Middle housing 53 may comprise a plurality of blade slots 51 through which a proximal ends of fan blades 46 are inserted during assembly and which are affixed to a radial flange of the rotor by way of fasteners 48 passing through fan blade fastening affixation apertures 47 from underneath.

[7] So as to allow access to the fastener apertures 47 of each blade, the static underplate 54 comprises a fastener access cutout 50. As such, for each blade, the rotor is rotated until such time that the affixation apertures 47 locate behind the fastener access cutout 50 so as to be accessible for fastening.

[8] This is the typical manner by which blades 46 are fastened to rotors in the industry.

[9] However, we have found that such installation method is time-consuming in that each blade 46 requires fastening one by one with rotation and alignment of the fastener access cutout 50 for each each blade installation.

[10] Furthermore, the access provided by the fastener access cutout 50 is limited making installation tricky especially when the rotor inadvertently rotates slightly during installation.

[11] Furthermore, whereas such installation is typically performed with the assembly 44 upside down, the fasteners 48 often times fall within the housing and become difficult to locate and dislodge.

[12] A need therefore exists for a fan assembly allowing for fan blade installation which ameliorates the disadvantages of the prior art, or at least provides an alternative thereto.

[13] The present invention seeks to provide a ceiling fan assembly, which will overcome or substantially ameliorate at least some of the deficiencies of the prior art, or to at least provide an alternative.

[14] 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

[15] There is provided herein a ceiling fan assembly characterised in comprising motor assembly

housing comprising an annular and static upper housing portion correspondingly adjacent to a radial

flange of the rotor of the motor assembly wherein fan blades may be fastened to the radial flange. The upper housing portion is detachable so as to facilitate ease of access to the rotor flange for

fastening of fan blades thereto.

[16] As such, with the foregoing in mind, in accordance with one aspect, there is provided a ceiling

fan assembly comprising: a motor assembly hung from a downrod, the motor assembly defining a

peripheral flange comprising a plurality of radial flange affixation apertures for the receipt of fan blade

fastening fasteners therethrough for the securement of fan blades thereto, the affixation apertures

each having a longitudinal axis perpendicular with a rotational axis of the motor assembly; and housing surrounding the motor assembly, wherein the housing comprises: an annular and static upper housing

portion correspondingly adjacent the radial flange and wherein the upper housing is detachable away

from the peripheral flange in use, allowing for upper access to the affixation apertures.

[17] The annular housing portion may encircle the downrod when detached from the peripheral

flange.

[18] The housing may comprise static lower housing and middle housing, the middle housing

located between the static upper and lower housing, the middle housing affixed to the motor

assembly so as to rotate therewith and wherein the middle housing may comprise a plurality of

elongate fan blade slots through which proximal ends of the fan blades are inserted, the proximal ends

of the fan blades each comprising fan blade affixation apertures corresponding to the radial flange

affixation apertures.

[19] The housing may comprise switchbox housing above the upper housing and wherein the

upper housing and the switchbox housing mechanically interlock in a selectively detachable manner.

[20] The upper housing may define at least one upper housing mechanical interlock portion and

wherein the switchbox housing may define at least one switchbox mechanical interlock portion for

interlocking with the upper housing mechanical interlock portion and wherein the switchbox

mechanical interlock portion may comprise a recess comprising a tangential tab extending across the

recess and wherein the upper housing mechanical interlock portion may comprise an upwardly facing

tangentially orientated ramp such that, for interlocking, the upper housing mechanical interlock portion may be inserted through the recess and subsequently rotated such that the tangential tab rides over the ramp for engagement.

[21] The tangential tab may comprise an engagement thereunderneath and wherein the ramp

leads to a seat such that the tangential tab rides up the ramp until the engagement locates within the

seat.

[22] The upper housing may be plastic.

[23] The upper housing may define an outer radial flange and wherein the upper housing portion

may define an inner radial flange and wherein, when engaged, the inner radial flange sits atop the

outer radial flange.

[24] The inner and outer radial flanges may comprise corresponding affixation apertures for the

receipt of fasteners therethrough.

[25] The affixation apertures comprise upper housing affixation apertures and wherein the upper

housing affixation apertures comprise a rotatably detachable affixation aperture comprising major

and minor apertures.

[26] The upper housing may be metallic.

[27] The upper housing portion may comprise a plurality of air vents.

[28] The assembly further may comprise an upper canopy at a top end of the downrod, the upper canopy having an outer diameter and wherein the upper housing may comprise an inner diameter

greater than the outer diameter.

[29] Other aspects of the invention are also disclosed.

Brief Description of the Drawings

[30] 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:

[31] Figure 1 shows a ceiling fan assembly in accordance with the prior art;

[32] Figure 2 shows a side elevation view of a ceiling fan assembly in accordance with a first

embodiment;

[33] Figure 3 shows a top perspective disassembled view of the ceiling fan in accordance with the

first embodiment;

[34] Figure 4 shows a further top perspective view of the ceiling fan in accordance with the first

embodiment;

[35] Figure 5 shows a top perspective disassembled view of the ceiling fan illustrating a mechanical

interlock between upper and switchbox housing in accordance with the first embodiment;

[36] Figure 6 shows a bottom perspective disassembled view of the ceiling fan illustrating the

mechanical interlock between upper and switchbox housing in accordance with the first embodiment;

[37] Figure 7 shows a side elevation view of a ceiling fan in accordance with a second embodiment;

[38] Figure 8 shows a top perspective disassembled view of the ceiling fan in accordance with the

second embodiment;

[39] Figure 9 shows a further top perspective disassembled view of the ceiling fan in accordance

with the second embodiment

[40] Figure 10 shows a side elevation view of a motor assembly in accordance with an

embodiment; and

[41] Figure 11 shows a top elevation view of the motor assembly in accordance with an

embodiment.

Description of Embodiments

[42] Figure 1 shows a fan assembly 1, which, in the embodiment shown, comprises an upper

canopy 7 from which a downrod 5 extends. A semi-spherical joint 6 may couple the downrod 5 and the upper canopy 7 so as to allow for downrod 5 angle tolerance.

[43] The lower end of the downrod 5 may be connected to a motor assembly 2 by way of connector

10.

[44] The motor assembly 2 is surrounded by housing. The housing may comprise static upper

housing 8 and static lower housing 9. In embodiments, the housing may further comprise switchbox

housing 11encasing various electrical componentry, such as switching 15, fuse componentry and the

like. Furthermore, the housing may comprise a lower canopy 42 above the switchbox housing 11.

[45] The housing may further comprise middle housing 3 located between the upper housing 8 and

the lower housing 9. The middle housing 3 rotates with the rotor of the motor assembly 2.

[46] Now, figure 3 shows the fan assembly 1 characterised in enhancing fan blade 4 assembly.

Specifically, figure 3 shows the middle housing 3 comprising a plurality of fan blade slots 14 through

which the proximal ends 17 of fan blades 4 are inserted for fastening. Furthermore, the proximal ends

17 of the fan blades 4 comprise fan blade affixation apertures 13 corresponding to radial flanges affixation apertures 55 for securement by fasteners 12.

[47] Now, as is shown in figure 3, the upper housing 8 may be detachable so as to facilitate

fastening of the fasteners 12.

[48] Figure 4 shows the assembly 1 from a further elevated perspective showing the radial flange

16 of the rotor, the radial flange 16 comprising the plurality of radial flanges affixation apertures 55 corresponding to the fan blade 4 affixation apertures 13 located on the proximal end 17 of the fan blade.

[49] As can be appreciated, the removal of the upper housing 8 allows simultaneous access to all

of the fasteners 12, thereby speeding the installation process, negating the need to align the apertures

30, 55 with fastener access cutouts 50 or the risk of fasteners falling through the fastener access

cutouts 50 as do prior art arrangements. Furthermore, the present configuration negates the need for

cumbersome inversion of the ceiling fan assembly 1for fan blade fastening.

[50] As can be appreciated from figure 3, the upper housing 8 detaches upwardly and encircles the

downrod 5 when upwardly detached.

[51] Furthermore, in embodiments, the inner diameter of the other housing 8 may be greater than

the outer diameter of the upper canopy 7 thereby allowing the entire removal of the upper housing 8

during assembly further eliminating hindrances.

[52] The upper housing 8 may comprise air vents 22 for heat dissipation purposes.

[53] Now, the fan assembly 1 shown in the embodiments illustrated in figure 2 - 6 are a first

embodiment wherein the ceiling fan 1 housing may be manufactured from plastic. Conversely, the

ceiling fan embodiment 25 as is illustrated in figure 7 - 9, and as will be described in further detail

below, may comprise metallic housing, such as diecast aluminium housing.

[54] Turning now to figure 5, there is illustrated the detachability of the upper housing 8 in further

detail. In this embodiment, the upper housing 8 is rotationally detachable from the fan assembly 1

allowing detachment by hand negating the need for tools.

[55] In embodiments, the upper housing 8 may mechanically interlock with the switchbox housing

11.

[56] In accordance with one embodiments, such a mechanical interlock may comprise an upper

housing mechanical interlock portion 18 which mechanically interlocks with a switchbox housing

mechanical interlock portion 21 as is substantially shown in figure 6.

[57] The upper housing mechanical interlock portion 18 may comprise an upper facing tangentially

orientated ramp 2 leading to a seat 9. Correspondingly, the switchbox housing mechanical interlock

portion 21may comprise a recess having a tangentially orientated tab 23 extending across the recess

which rides over the ramp 20 when rotated until such time that a semicylindrical (or the like)

engagement 24 thereunderneath locates within the seat 19.

[58] As such, attachment of the upper housing 8 may comprise the counterclockwise rotation of

the upper housing 8 given the orientation in figure 5 until such time that the upper housing mechanical

interlock portion 18 slides from underneath the tab 23 of the switchbox housing mechanical interlock

portion 21 whereafter the upper housing mechanical interlock portion 18 may be lifted upwardly.

Fasting of the upper housing 8 may be performed in the opposite manner in a clockwise manner given

the orientation of figure 5.

[59] As alluded to above, figure 7 - 9 shows a further embodiment of the fan assembly 25 wherein

the housing (or at least portions of the housing) comprises metal, such as by being manufactured from

diecast aluminium.

[60] In this embodiment, given the rigidity of the metal, and therefore the insuitability of the

slightly flexible plastic mechanical interlock arrangement described above, the mechanical interlock

utilises a differing mechanical interlock arrangement comprising fasteners 26. Furthermore, the

utilisation of fasteners 26 securely holds the upper housing 9 against the switchbox housing 11 thereby

reducing creaking noises is may be typical of abutting metallic componentry.

[61] As is better illustrated in figure 8, the switchbox housing 11 may define an outer radial flange

58 having switchbox housing affixation apertures therein for the fasteners 26. In embodiments, the

outer radial flange 58 may comprise projecting tabs 56 at the location of the switchbox housing

affixation apertures.

[62] Similarly, the upper housing 8 may comprise an inner radial flange 57 which sits on the outer

radial flange 58 when fastened together.

[63] Furthermore, the inner radial flange 57 may comprise upper housing affixation apertures 28 through which the fasteners 27 are inserted as a substantially illustrated in figure 9.

[64] In an embodiment, the upper housing affixation apertures 28 may be rotationally

disengageable affixation apertures comprising major and minor aperture portions which, for

engagement, the upper housing 8 is lowered over the fasteners 27 such that the fastener heads pass

through the major apertures whereafter the upper housing 8 is rotated slightly such that the fastener

stems move into the minor apertures thereby engaging underneath the fastener heads. As such, the

rotationally disengageable affixation apertures 28 allow the removal of the upper housing 8 without

complete unscrewing of the fasteners 27.

[65] Turning now to figures 10 - 11, there is shown the motor assembly in further detail in

accordance with an embodiment. The motor assembly 2 has a low profile and is therefore suited for

many different types of fan styles.

[66] As is shown in figure 10, the motor assembly 2 comprises a rotor 34 and a static stator 32. The

stator 32 may comprise copper windings 33. The copper windings 33 may be electrically connected to an electrical wire 30 and a fuse 31.

[67] The rotor 34 may be encased within a covering, which covering may comprise an upper motor

cover 37 and a lower motor cover 36.

[68] Bearings 38 may rotatably couple the rotor 34 to a central spindle 41 via the covering which

may be fastened to the rotor 34 utilising fastener screws 35.

[69] The upper and/or lower covers 37, 36 may comprise directed air vents 40 to scoop warm air

from the interior of the motor assembly 2.

[70] As can be appreciated, the engagement of the casing 37, 36 to the rotor 34 in the manner

shown, allows for a low profile motor assembly 2 and wherein the casing 37, 36 may be shaped and/or

configured so as to suit differing fan styles.

[71] In embodiments in figure 10, the casing 37, 36 is shaped in accordance with a particular fan

style wherein, as can be seen, the upper casing 37 is peripherally flared to define a radial flange profile

60. As a substantial shown in figure 11, the radial flange profile may comprise a plurality of affixation

apertures 39 therein for fastening of fan blades 4 thereto.

[72] 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

Claims 1. A ceiling fan assembly comprising: a motor assembly rotatably hung from adownrod, the motor assembly comprising: a plurality of affixation apertures for securement of fan blades to the motor assembly; and housing comprising an annular upper housing portion which is removeable to allow upper access to the affixation apertures when securing the fan blades to the motor assembly, wherein the upper housing portion defines at least one mechanical interlock portion so that the upper housing portion is rotatably detachable.
2. A ceiling fan assembly as claimed in claim 1, wherein the motor assembly has a peripheral flange having the affixation apertures.
3. A ceiling fan assembly as claimed in claim 1, wherein the affixation apertures each have a longitudinal axis parallel with a rotational axis of the motor assembly.
4. A ceiling fan assembly as claimed in claim 1, wherein the upper housing portion encircles the downrod when removed.
5. A ceiling fan assembly as claimed in claim 1, wherein the housing comprises a middle housing portion affixed to the motor assembly so as to rotate with the motor housing.
6. A ceiling fan assembly as claimed in claim 5, wherein the middle housing portion comprises a plurality of elongate fan blade slots through which proximal ends of the fan blades can be inserted.
7. A ceiling fan assembly as claimed in claim 6, wherein the proximal ends of the fan blades each comprise fan blade affixation apertures corresponding to the affixation apertures.
8. A ceiling fan assembly as claimed in claim 1, wherein the housing comprises switchbox housing and wherein the upper housing portion and the switchbox housing mechanically interlock in a selectively detachable manner when the upper housing portion is rotated with respect to the switchbox housing.
9. A ceiling fan assembly as claimed in claim 8, wherein the switchbox housing defines at least one corresponding mechanical interlock portion and wherein the mechanical interlock portion of the switchbox housing comprises a recess comprising a tangential tab extending across the recess and wherein the mechanical interlock portion of the upper housing portion comprises an upwardly facing tangentially orientated ramp such that, for interlocking, the mechanical interlock portion of the upper housing portion may be inserted through the recess and subsequently rotated such that the tangential tab goes over the ramp for engagement.
10. A ceiling fan assembly as claimed in claim 9, wherein the tangential tab comprises an

engagement thereunderneath and wherein the ramp leads to a seat such that the tangential tab

rides up the ramp until the engagement locates within the seat.
11. A ceiling fan assembly as claimed in claim 9, wherein the upper housing portion is plastic.
12. A ceiling fan assembly as claimed in claim 1, wherein the housing comprises switchbox

housing defining an outer radial flange and the upper housing portion defines an inner flange which

sits atop the outer radial flange.
13. A ceiling fan assembly as claimed in claim 12, wherein the inner and outer radial flanges

comprise corresponding affixation apertures for the receipt of fasteners therethrough.
14. A ceiling fan assembly as claimed in claim 13, wherein the affixation apertures comprise

upper housing portion affixation apertures comprising a rotatably detachable affixation aperture

comprising major and minor apertures.
15. A ceiling fan assembly as claimed in claim 12, wherein the upper housing portion is metallic.
16. A ceiling fan assembly as claimed in claim 1, wherein the upper housing portion comprises a

plurality of air vents.
17. A ceiling fan assembly as claimed in claim 1, wherein the assembly further comprises an

upper canopy at a top end of thedownrod, the upper canopy having an outer diameter and wherein the upper housing portion comprises an inner diameter greater than the outer diameter.