CA3020741A1 - A quick fit fan blade interface - Google Patents

Abstract

There is provided herein a quick fit fan blade interface for a ceiling fan. The interface comprises a plurality of fan blades which quickly and easily slot into corresponding slots of a motor assembly and which are locked therein. The motor assembly has a motor assembly female slot portion into which corresponding fan blade male slot portions of corresponding fan blades insert. The motor assembly female slot portion comprises at least one locking tab engagements, typically by way of apertures through an upper portion thereof. The fan blade male slot portion similarly comprises deflectable locking tabs, typically being integrally formed and biased upwardly by way of a leading live hinge. When the fan blade male slot portion is inserted, the slot deflects the applicable locking tabs until fully inserted wherein the at least one deflectable locking tabs moves up into the corresponding locking tab engagement.

Description

A quick fit fan blade interface Field of the Invention [1] This invention relates generally to ceiling fan assemblies. More particularly, this invention relates to a quick fit fan blade interface for a ceiling fan to simplify and/or quicken the assembly of a ceiling fan.
Background of the Invention

[2] Conventional assembly of ceiling fans typically entails inserting proximal ends of fan blades via fan blade slots of a motor assembly housing and securing the proximal ends of the fan blades to a peripheral flange of a motor assembly therein with screws. The flange is typically accessed by removing a bottom cover plate and, in embodiments, rotating the motor assembly housing to align a fastener access cutout therein with each blade.

[3] However, such a process is difficult and time-consuming.

[4] The present invention seeks to provide a way to overcome or substantially ameliorate at least some of the deficiencies of the prior art, or to at least provide an alternative.

[5] 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

[6] There is provided herein a quick fit fan blade interface for connecting fan blades to a motor assembly of ceiling fan.

[7] Specifically, the motor assembly comprises a motor assembly female slot portion into which a corresponding fan blade male slot portion of a corresponding fan blade inserts. The motor assembly female slot portion may comprise a pair of locking tab engagements, typically by way of apertures open through an upper portion thereof. The fan blade male slot portion may similarly comprise a pair deflectable locking tabs, each typically being integrally formed and biased upwardly by way of a proximal live hinge from which the tab ramps up to a distal raised orthogonal deflectable edge.

[8] When the fan blade male slot portion is inserted into a slot of the motor assembly female slot portion, the slot deflects the applicable locking tabs until fully inserted wherein the deflectable locking tabs spring up into the corresponding locking tab engagement apertures. The engagement apertures may be rectangular, thereby defining a corresponding edge which catches the distal raised orthogonal deflectable edge of the respective locking tab.

[9] In this way, the fan blades may be quickly attached to the motor assembly simply by pushing the proximal end thereof into the corresponding slots of the motor assembly.

[10] Furthermore, the locking tabs and locking tab engagements are aesthetically hidden from view underneath.

[11] Furthermore, the locking tab engagement apertures may be open via the upper portion of the motor assembly female slot portion such that releasing the fan blades may comprises easily inserting fingers via the open engagement apertures to push the locking tabs down to disengage the raised orthogonal deflectable edge of the locking tabs.

[12] In embodiments, the fan blade male slot portion is keyed with orientation controlling insertion guide ridges/channels which correspond to corresponding insertion guide ridges/channels of the motor assembly female slot portion only when the fan blade male slot portion is inserted in the correct orientation, thereby preventing the inadvertent insertion of the fan blades upside down.

[13] In one embodiment the interface is wide, narrow and horizontally orientated such as by having a width to height ratio of 10:1 or more. Furthermore, the locking tabs may be spaced apart, such as by approximately 4 cm or more from inner edges thereof which may strengthen the engagement from lateral forces on the blades, such as from air resistance or when under start-up acceleration

[14] In embodiments, the interface may be secured by way of a metallic radial reinforcement arm which may extend from the motor assembly and which may be secured at a proximal end thereof to a flange of a motor housing within the motor assembly. The radial reinforcement arm may extend above the motor assembly female slot portion and comprise a distal fastener aperture which corresponds with a corresponding fan blade male slot portion fastener aperture when the fan blade male slot portion is inserted fully within the motor assembly female slot portion for the receipt of a securing fastener therethrough. In embodiments the fan blade male slot portion may comprise a metallic reinforcement substrate having the fan blade male slot portion fastener aperture therein.

[15] According to one aspect, there is provided a quick fit fan blade interface for connecting a fan blade to a motor assembly of a ceiling fan, the motor assembly comprising a motor assembly female slot portion and the fan blade comprising a proximal fan blade male slot portion insertable within the motor assembly female slot portion, wherein the fan blade male slot portion comprises a pair of adjacent, upwardly extending and deflectable locking tabs each having a distal raised orthogonal deflectable edge and wherein the motor assembly female slot portion comprises a pair of engagement apertures sized and located to catch respective orthogonal deflectable edges of the locking tabs when the fan blade male slot portion is fully inserted within the motor assembly female slot portion and wherein the engagement apertures are open via an upper portion of the motor assembly female slot portion to allow for pressing down of the deflectable locking tabs therethrough for disengagement of orthogonal deflectable edges from the engagement apertures.

[16] Inner edges of the flexible locking tabs may be spaced apart by more than 30 mm.

[17] Each deflectable tab may ramp up from a proximal live hinge to the distal raised orthogonal deflectable edge.

[18] The deflectable locking tabs each may be substantially rectangular and wherein the engagement apertures may be each substantially rectangular and sized according to each respective deflectable locking tab.

[19] The fan blade male slot portion and the motor assembly female slot portion may comprise corresponding longitudinal ridges and channels for controlling the insertion orientation of the fan blade male slot portion into the motor assembly female slot portion.

[20] Each of the fan blade male slot portion and the motor assembly female slot portion may comprise upper and lower surfaces, each surface comprising corresponding longitudinal ridges and channels and wherein upper surface corresponding longitudinal ridges and channels may be spaced apart differently from lower surface corresponding longitudinal ridges and channels.

[21] The fan blade may comprise a fan blade undersurface distally adjacent the fan blade male slot portion and wherein the motor assembly female slot portion may comprise a female slot portion undersurface and wherein, when the fan blade male slot portion may be inserted within the motor assembly female slot portion, the fan blade undersurface and the female slot portion undersurface align.

[22] The fan blade undersurface may be substantially planar and female slot portion undersurface may be substantially planar and wherein, when the fan blade slot portion may be inserted within the motor assembly female slot portion, the fan blade undersurface and the female slot portion may be substantially coplanar.

[23] The fan blade may comprise a proximal orthogonal upward projection which abuts against a facing edge of the motor assembly female slot portion and wherein the proximal orthogonal upward projection may have a height corresponding substantially to that of the motor assembly female slot portion.

[24] The fan blade further may comprise bracing between the proximal orthogonal upward projection and a distally adjacent upper surface of the fan blade.

[25] The motor assembly further may comprise a radial reinforcement arm extending above the motor assembly female slot portion and comprising a radial reinforcement arm fastener aperture at a distal end thereof and wherein the fan blade male slot portion further may comprise a corresponding fan blade male slot portion aperture which collocates with the radial reinforcement arm fastener aperture when the fan blade male slot portion may be fully inserted within the motor assembly female slot portion for the insertion of a fastener therethrough.

[26] The motor assembly may comprise an upper covering and wherein the upper covering may comprise a slot for accommodating the radial reinforcement arm therethrough.

[27] The radial reinforcement arm may be connected to a motor housing within the motor assembly.

[28] The radial reinforcement arm may be connected to a peripheral flange of the motor housing.

[29] The fan blade male slot portion further may comprise a metallic reinforcement plate having the fan blade male slot portion fastener aperture therein.

[30] The radial reinforcement arm further may comprise a further fastener aperture located in from the radial reinforcement arm fastener aperture for a further fastener.

[31] The radial reinforcement arm may be metallic.

[32] The motor assembly female slot portion may comprise an inner gap having a width of greater than 10 cm.

[33] The inner gap may have a height of less than 1 cm.

[34] The fan blade male slot portion may comprise a length of greater than 3 cm.

[35] Other aspects of the invention are also disclosed.
Brief Description of the Drawings

[36] 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:

[37] Figure 1 shows an underside perspective view of a ceiling fan in accordance with an embodiment;

[38] Figure 2 shows an upper perspective view of the ceiling fan;

[39] Figure 3 shows a side elevation view illustrating the insertion and interlock of fan blades and a motor assembly of the ceiling fan in accordance with an embodiment;

[40] Figure 4 shows a top perspective view of the motor assembly of the ceiling fan in accordance with an embodiment;

[41] Figure 5 shows a top perspective view of the motor assembly of the ceiling fan having a plurality of fan blades inserted therein in accordance with an embodiment;

[42] Figure 6 shows a preferred embodiment of a quick fit fan blade interface in accordance with an embodiment; and half

[43] Figure 7 shows an underside perspective view of the quick fit fan blade interface of Figure 6 in accordance with an embodiment.

Description of Embodiments

[44] Figure 1 shows a ceiling fan 100 comprising a motor assembly 101 suspended from a ceiling by a down rod and canopy assembly 102. A plurality of fan blades 103 interlock with the motor assembly 101. In embodiment shown, three fan blades 103 are shown. However, it should be appreciated that various numbers of fan blades 103 may be provided.

[45] Orientational referencing will be described with proximal being generally towards the centre of the motor assembly 101 and distal being generally towards the tips of the fan blades 103.

[46] Figure 2 shows a top perspective view of the ceiling fan 100. The down rod and canopy assembly 102 is shown as having a down rod pulley 104 and bifurcated canopy portions 105 which screw together around the down rod and pulley 104. The motor assembly 101 may comprise an upper cover plate 106 and heat vents 107 therethrough. Each fan blade 103 interfaces with the motor assembly 100 by way of a quick fit fan blade interface 108 and, in embodiments, locking screws 109.

[47] Figure 3 shows a side elevation view of the ceiling fan 100 showing the quick fit fan blade interface 108 comprising the motor assembly 101 having a motor assembly female slot portion 110 into which a fan blade female slot portion 111 inserts in the direction indicated.

[48] Figure 4 shows the motor assembly 101 in further detail. The upper cover plate 106 may be removed from a lower portion 112 of the motor assembly 101 and held in place by fasteners through fastener apertures 113. There is shown the down rod 114 secured to a motor housing 115 by way of transverse bolts 116. The down rod 114 comprises the pulley 104 at the upper end thereof for suspension of the assembly 101 from a ceiling hook/pulley by way of a pulley cable. Electrical cabling 117 and a safety cable 118 may be provided.

[49] Figure 4 further shows the motor assembly female slot portion 110 for receiving the fan blade male slot portion 111 therein. The motor assembly female slot portion 110 defines a slot 119 which is preferably wide, narrow and horizontally orientated.

[50] The motor assembly female slot portion 110 comprises at least one locking tab engagement 120. The fan blade male slot portion 111 comprises at least one corresponding deflectable locking tab which locks within the at least one locking tab engagement 120 when the fan blade male slot portion 111 is inserted through the slot 119. In the embodiment shown, the locking tab engagement 120 comprises rectangular apertures which extend through an upper portion of the motor assembly female slot portion 110.

[51] A locking screw aperture 121 may also be provided in the upper portion of the motor assembly female slot portion 110 for the receipt of the locking screw 109 therethrough and into the fan blade male slot portion 111 to lock the fan blade male slot portion 111 within the motor assembly female slot portion 110.

[52] Insertion guides channels 124 may be provided within the slot 119 which may key with corresponding insertion guide ridges of the fan blade male slot portion 111 to control the correct orientation so as to prevent the fan blade 103 from being inserted upside down.

[53] Figure 5 shows the ceiling fan 100 having three fan blades 103 slotted into the motor assembly 101. Balancing plate weights 122 or slidable edge engaging balancing clip weights 123 may be located along the fan blade 103 for balancing.

[54] Figure 6 shows an embodiment of the fan blade interface 108 in accordance with a preferred embodiment. There is shown the fan blade 103 comprising a proximal orthogonal upward projection 125 which abuts against the facing edge 126 of the motor assembly female slot portion 110. Bracing 128 may brace the upward projection 125. The proximal upward projection 125 may lead to lateral orthogonal upward projections 127.

[55] Figure 7 shows an underside view of the interface 108 in accordance with the preferred embodiment wherein, as can be seen, the configuration of the projections 125, 127 and bracing 128 provides a smooth aesthetic undersurface 129 of the fan blade. Furthermore, the interface 108 may be configured such that the undersurface 129 of the fan blade 103 abuts flush against a corresponding undersurface 130 of the motor assembly 101.

[56] The fan blade male slot portion 111 comprises the guide channel ridges 131 which corresponded to the corresponding insertion guide channels 124 in the correct insertion orientation of the fan blade 103.

[57] The fan blade male slot portion 111 may further comprise a pair of deflectable locking tabs 132 which ramp upwardly and distally away from the proximal edge of the fan blade male slot portion 111 to an orthogonal deflectable edge 141. The deflectable locking tabs 132 may be integrally formed with the fan blade male slot portion 111 and interface by way of leading-edge live hinges 133. When the fan blade male slot portion 111 is inserted into the slot 119, the edge 126 thereof pushes the deflectable locking tabs 132 downwardly. When the fan blade male slot portion 111 is fully inserted within the motor assembly female slot portion 110, the deflectable locking tabs 132 spring upwardly into the locking tab engagement apertures 120, locking the fan blade 103 to the motor assembly 101.
Removal of the fan blade 103 may comprise pushing the locking tabs 132 down through the locking tab engagement apertures 120 and pulling the fan blade 103 from the motor assembly 101.

[58] As can be seen from Figure 7, the deflectable locking tabs 132 and locking tab engagement apertures 120 are concealed from view underneath.

[59] The fan blade male slot portion 111 may comprise a metallic plate reinforcement substrate sandwiched between upper and lower layers of plastic.

[60] The interface 108 may further comprise a radial metallic reinforcement arm 134 protruding from an upper entrance 135 of the upper covering 106. The metallic reinforcement arm 134 may connect to the metallic motor housing within the motor assembly 101 such as to a peripheral flange of the metallic motor housing. The metallic reinforcement arm 134 may be secured to the motor assembly female slot portion by way of permanent securement fastener 136 and may be seated on prow 137 to jut horizontally despite the fall of the upper surface of the motor assembly female slot portion 110.

[61] The fan blade male slot portion 111 may comprise an avoidance channel 138 which avoids the permanent securement fastener 136 during insertion. Furthermore, the metallic reinforcement arm 134 may comprise a distal additional locking fastener aperture 139 at a distal end thereof and the fan blade male slot portion 111 may comprise a corresponding threaded locking fastener aperture 140. In this way, an additional fastener (not shown) may insert through the additional locking fastener aperture 139 of the metallic reinforcement arm 134 so as to engage within the locking fastener aperture 140 of the fan blade male slot portion 111.

[62] As alluded to above, the fan blade male slot portion 111 may comprise a metallic plate substrate and, in this regard, the fastener aperture 140 may be formed within the metallic substrate.

[63] In embodiments, the female slot may comprise an inner width of approximately 122 mm and a width of approximately 5 mm. The fan blade male slot portion 110 may be similarly sized so as to slide therein.

[64] The deflectable tabs may be spaced apart at respective inner edges thereof by approximately 40 mm. Each tab may be approximately 30 mm wide and approximately 20 mm long.
The live hinge may be located approximately 10 mm from the proximal end of the fan blade male slot portion.

[65] The avoidance channel may be approximately 20 mm long. Furthermore, the additional insertion aperture may be located approximately 27 mm from the proximal edge of the fan blade male slot portion.

[66] 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 (20)

Claims

1. A quick fit fan blade interface for connecting a fan blade to a motor assembly of a ceiling fan, the motor assembly comprising a motor assembly female slot portion and the fan blade comprising a proximal fan blade male slot portion insertable within the motor assembly female slot portion, wherein the fan blade male slot portion comprises a pair of adjacent, upwardly extending and deflectable locking tabs each having a distal raised orthogonal deflectable edge and wherein the motor assembly female slot portion comprises a pair of engagement apertures sized and located to catch respective orthogonal deflectable edges of the locking tabs when the fan blade male slot portion is fully inserted within the motor assembly female slot portion and wherein the engagement apertures are open via an upper portion of the motor assembly female slot portion to allow for pressing down of the deflectable locking tabs therethrough for disengagement of orthogonal deflectable edges from the engagement apertures.

2. The interface as claimed in claim 1, wherein inner edges of the flexible locking tabs are spaced apart by more than 30 mm.

3. The interface as claimed in claim 1, wherein each deflectable tab ramps up from a proximal live hinge to the distal raised orthogonal deflectable edge.

4. The interface as claimed in claim 1, wherein the deflectable locking tabs each are substantially rectangular and wherein the engagement apertures are each substantially rectangular and sized according to each respective deflectable locking tab.

5. The interface as claimed in claim 1, wherein the fan blade male slot portion and the motor assembly female slot portion comprise corresponding longitudinal ridges and channels for controlling the insertion orientation of the fan blade male slot portion into the motor assembly female slot portion.

6. The interface as claimed in claim 5, wherein each of the fan blade male slot portion and the motor assembly female slot portion comprises upper and lower surfaces, each surface comprising corresponding longitudinal ridges and channels and wherein upper surface corresponding longitudinal ridges and channels are spaced apart differently from lower surface corresponding longitudinal ridges and channels.

7. The interface as claimed in claim 1, wherein the fan blade comprises a fan blade undersurface distally adjacent the fan blade male slot portion and wherein the motor assembly female slot portion comprises a female slot portion undersurface and wherein, when the fan blade male slot portion is inserted within the motor assembly female slot portion, the fan blade undersurface and the female slot portion undersurface align.

8. The interface as claimed in claim 7, wherein the fan blade undersurface is substantially planar and female slot portion undersurface is substantially planar and wherein, when the fan blade slot portion is inserted within the motor assembly female slot portion, the fan blade undersurface and the female slot portion are substantially coplanar.

9. The interface as claimed in claim 1, wherein the fan blade comprises a proximal orthogonal upward projection which abuts against a facing edge of the motor assembly female slot portion and wherein the proximal orthogonal upward projection has a height corresponding substantially to that of the motor assembly female slot portion.

10. The interface as claimed in claim 9, wherein the fan blade further comprises bracing between the proximal orthogonal upward projection and a distally adjacent upper surface of the fan blade.

11. The interface as claimed in claim 1, wherein the motor assembly further comprises a radial reinforcement arm extending above the motor assembly female slot portion and comprising a radial reinforcement arm fastener aperture at a distal end thereof and wherein the fan blade male slot portion further comprises a corresponding fan blade male slot portion aperture which collocates with the radial reinforcement arm fastener aperture when the fan blade male slot portion is fully inserted within the motor assembly female slot portion for the insertion of a fastener therethrough.

12. The interface as claimed in claim 11, wherein the motor assembly comprises an upper covering and wherein the upper covering comprises a slot for accommodating the radial reinforcement arm therethrough.

13. The interface as claimed in claim 11, wherein the radial reinforcement arm is connected to a motor housing within the motor assembly.

14. The interface as claimed in claim 13, wherein the radial reinforcement arm is connected to a peripheral flange of the motor housing.

15. The interface as claimed in claim 11, wherein the fan blade male slot portion further comprises a metallic reinforcement plate having the fan blade male slot portion fastener aperture therein.

16. The interface as claimed in claim 15, wherein the radial reinforcement arm further comprises a further fastener aperture located in from the radial reinforcement arm fastener aperture for a further fastener.

17. The interface as claimed in claim 11, wherein the radial reinforcement arm is metallic.

18. The interface as claimed in claim 1, wherein the motor assembly female slot portion comprises an inner gap having a width of greater than 10 cm.

19. The interface as claimed in claim 18, wherein the inner gap has a height of less than 1 cm.

20. The interface as claimed in claim 1, wherein the fan blade male slot portion comprises a length of greater than 3 cm.