Apparatus for connecting fan motor assembly to downrod and method of making same

FIELD OF THE INVENTION

[0001] The present invention relates to a device for connecting a ceiling fan motor assembly to a downrod.

BACKGROUND OF THE INVENTION

[0002] A downrod is generally used to hang a ceiling fan motor from a position overhead. In general, a first end of the downrod is mounted to a position on a ceiling, and the ceiling fan motor is attached to the second end of the downrod which hangs from the ceiling. Thus, the fan motor is suspended by the second end of the downrod.

[0003] Conventionally, the fan motor is attached to the downrod by a combination of screws and pins that lock the downrod into an insert assembly provided on a surface of the fan motor. More specifically, each of the downrod and the insert assembly on the fan motor in which the downrod will be inserted, are provided with corresponding holes which align when the second end of the downrod is positioned in the insert assembly in a predetermined manner. Accordingly, pins and screws can be inserted through the aligned holes of each of the downrod and the insert assembly in order to lock the fan motor onto the hanging downrod.

[0004] However, conventional devices for attaching a fan motor to a downrod present difficulty whenever it is necessary to install or remove the fan motor from the downrod. Because corresponding holes of the insert assembly on the fan motor and the downrod must be aligned in order for pins and screws to be inserted through each of the downrod and the insert assembly, the fan motor must be suspended and adjusted until the holes of the downrod and the holes of the insert assembly are aligned. Thus, great effort is required to suspend the fan motor assembly when aligning the insert assembly with the downrod before the fan motor can be secured to the downrod.

BRIEF SUMMARY OF THE INVENTION

[0005] Accordingly, the present invention provides a connection assembly for a fan that facilitates the connection of a downrod to a fan motor of a ceiling fan assembly.

[0006] In one aspect of the invention, a device for connecting a downrod to a fan motor assembly comprises a flange having an aperture defined therein, wherein the aperture in the flange is capable of receiving the downrod, and a sleeve assembly surrounding at least a portion of the flange, wherein a portion of the sleeve assembly projects into the aperture when the sleeve assembly is in a first position and retracts from the aperture when the sleeve assembly is in a second position.

[0007] In another aspect of the invention, a connection assembly for a fan comprises a downrod having a first end and a second end, a flange provided on a surface of a fan motor assembly, wherein the flange has an aperture defined therein that is capable of receiving the first end of the downrod, and a sleeve assembly surrounding at least a portion of the flange, wherein the first end of the downrod can be retained in the flange when the sleeve assembly is in a first position and the first end of the downrod can be released from said flange when the sleeve assembly is in a second position.

[0008] In yet another aspect of the present invention, a method of making a connection device for a fan comprises the steps of providing a flange having an aperture defined therein on a surface of a fan motor, wherein the aperture is capable of receiving a downrod, and positioning a sleeve assembly surrounding at least a portion of the flange, wherein a portion of the sleeve assembly projects into the aperture when the sleeve assembly is in a first position and retracts from the aperture when the sleeve assembly is in a second position.

[0009] In a further aspect of the present invention, a sleeve assembly comprises an actuator sleeve, a biasing member, and an adjusting sleeve, wherein the actuator sleeve and the biasing member each surround a portion of the flange, and the adjusting sleeve is provided between the flange and the actuator sleeve.

[0010] In yet another aspect of the invention, a projection is provided in a connector and a slot is provided in a downrod, wherein the slot is capable of receiving the tab. Accordingly, the downrod is restricted from rotation while inserted in the connector.

BRIEF DESCRIPTION OF THE DRAWINGS

[0011] Other advantages and features of the invention will become more apparent with reference to the following detailed description of the presently preferred embodiment thereof in connection with the accompanying drawings, wherein like reference numbers have been applied to like elements, in which:

[0012]FIG. 1 illustrates a fan assembly according to the one embodiment of the invention;

[0013]FIG. 2 illustrates a connection assembly according to the present embodiment of the invention;

[0014]FIG. 3 illustrates a cross-sectional view of the connection assembly according to the present embodiment of the invention;

[0015]FIG. 4 illustrates a cross-sectional view of the connection assembly according to the present embodiment of the invention; and

[0016]FIG. 5 illustrates a cross-sectional view of the connection assembly according to the present embodiment of the invention.

DETAILED DESCRIPTION OF THE INVENTION

[0017] Turning to the drawings, a fan assembly <b>100</b> is illustrated in FIG. 1 according to one embodiment of the present invention. As shown, fan assembly <b>100</b> includes a connection assembly <b>101</b> provided on a motor assembly <b>102</b>. Fan assembly <b>100</b> further includes, a fan blade <b>103</b>, and a blade arm <b>104</b> for attaching fan blade <b>103</b> to motor assembly <b>102</b>.

[0018]FIG. 2 illustrates the portions of connection assembly <b>101</b> in detail. In particular, FIG. 2 illustrates a downrod <b>201</b> and a connector <b>202</b>, each of which will be described in detail hereinafter.

[0019] According to the present embodiment, connector <b>202</b> includes a flange <b>203</b>, which extends upwardly, away from motor assembly <b>102</b>. As shown, flange <b>203</b> defines the outer boundaries of an aperture <b>202</b><i>a</i>, which runs in a lengthwise direction from a surface <b>102</b><i>a </i>of motor assembly <b>102</b> upwardly through flange <b>203</b>.

[0020] Connector <b>202</b> also includes a sleeve assembly <b>204</b> which is formed by an actuator sleeve <b>204</b><i>a</i>, a biasing member <b>204</b><i>b</i>, and a plurality of spherical members <b>204</b><i>c</i>forming an adjusting sleeve. In accordance with the present embodiment, actuator sleeve <b>204</b><i>a </i>is a solid ring that is provided in engagement with biasing member <b>204</b><i>b</i>, which is in contact with surface <b>102</b><i>a </i>of motor assembly <b>102</b>. As shown in FIG. 2, actuator sleeve <b>204</b><i>a </i>is in an uppermost position when biasing member <b>204</b><i>b </i>is in a relaxed, or fully expanded state; however, actuator sleeve <b>204</b><i>a </i>is capable of traveling along flange <b>203</b> in a direction parallel to the length of flange <b>203</b> and aperture <b>202</b><i>a</i>. Accordingly, biasing member <b>204</b><i>b </i>can be compressed according to the amount of travel and the position of actuator sleeve <b>204</b><i>a. </i>

[0021] Although the present embodiment will be described with reference to an adjusting sleeve formed by a plurality of spherical members <b>204</b><i>c</i>, the adjusting sleeve can be of any known configuration, including a single ring, or a plurality of c-shaped rings. Similarly, although actuator sleeve <b>204</b><i>a </i>will be described with reference to a ring assembly which can be displaced by a sliding motion, actuator sleeve <b>204</b><i>a </i>can be of any configuration, including a threaded member. Likewise, biasing member <b>204</b><i>b </i>is not limited to the coil spring type illustrated, and any substitute, including an elastomeric sleeve, can be used without departing from the scope of the invention.

[0022] In the present embodiment, the plurality of spherical members <b>204</b><i>c </i>are positioned between actuator sleeve <b>204</b><i>a </i>and flange <b>203</b>. As shown, actuator sleeve <b>204</b><i>a</i>is in contact with each spherical member <b>204</b><i>c </i>such that each spherical member <b>204</b><i>c </i>is held against flange <b>203</b> and projects into aperture <b>202</b><i>a </i>through openings <b>203</b><i>a </i>defined in the wall of flange <b>203</b>. Further, when actuator sleeve <b>204</b><i>a </i>is in an uppermost position, as illustrated in FIG. 2, a chamber <b>205</b> is provided between actuator sleeve <b>204</b><i>a </i>and flange <b>203</b>, and above the plurality of spherical members <b>204</b><i>c. </i>

[0023]FIG. 2 also illustrates a projection <b>206</b>, provided in connector <b>202</b>, to project from flange <b>203</b> inwardly into aperture <b>202</b><i>a </i>and outwardly to a position between flange <b>203</b> and sleeve assembly <b>204</b>. Also, according to the present embodiment, actuator sleeve <b>204</b><i>a </i>is provided with a guide <b>206</b><i>a</i>, in which projection <b>206</b> projects. According to the present embodiment, guide <b>206</b><i>a </i>is an elongated aperture having a length in a direction that is generally perpendicular to a plane of surface <b>102</b><i>a </i>that is greater than a length in a direction that is generally parallel to the plane of surface <b>102</b><i>a</i>. As will be explained, the combination of projection <b>206</b> and guide <b>206</b><i>a </i>aid in controlling the amount of travel in actuator assembly <b>204</b>. The present description of projection <b>206</b> is merely exemplary, and it is understood that projection <b>206</b> can be formed by any configuration or shape, and similarly, guide <b>206</b><i>a </i>can be any shape that is capable of accommodating projection <b>206</b>.

[0024]FIG. 2 further illustrates downrod <b>201</b> which is generally a tubular member having a first end <b>207</b> and a second end <b>208</b> with an aperture <b>201</b><i>a </i>defined therein in a lengthwise direction of downrod <b>201</b>, i.e., from first end <b>207</b> to second end <b>208</b>, or vice versa. Downrod <b>201</b> is further characterized by an indentation <b>209</b>, which, according to the present embodiment, is an indented ring around the outside of downrod <b>201</b> in the vicinity of first end <b>207</b>. Downrod <b>201</b> also includes a slot <b>210</b>, which begins at a position that is below indentation <b>209</b> and extends to the edge of first end <b>207</b>. In one embodiment of the invention, aperture <b>201</b><i>a </i>in downrod <b>201</b> and aperture <b>202</b><i>a </i>in flange <b>203</b> are used to contain electrical wiring to fan motor assembly <b>102</b>. Although downrod <b>201</b> is illustrated and described herein according to a preferred embodiment, downrod <b>201</b> can be of any length, size, and shape, as would be appreciated by those skilled in the art.

[0025] According to the present embodiment, an inner diameter of flange <b>203</b> corresponds with an outer diameter of downrod <b>201</b>, such that downrod <b>201</b> can be inserted into flange <b>203</b>. The stages of this operation will be now explained with reference to FIGS. <b>3</b>-<b>5</b>.

[0026]FIG. 3 illustrates a cross-sectional view of connection assembly <b>101</b> with downrod <b>201</b> and connector <b>202</b> in a separated state, i.e., before downrod <b>201</b> is inserted into connector <b>202</b>. According to FIG. 3, biasing member <b>204</b><i>b </i>is in a relaxed, or expanded state, and accordingly, actuator sleeve <b>204</b><i>a </i>is in an uppermost position, with respect to surface <b>102</b><i>a</i>. As can be seen, actuator sleeve <b>204</b><i>a </i>is positioned to engage spherical members <b>204</b><i>c </i>whenever actuator sleeve <b>204</b><i>a </i>is in an upwardmost position with respect to surface <b>102</b><i>a. </i>

[0027] As shown, actuator sleeve <b>204</b><i>a </i>narrows at an upper edge thereof forming chamber <b>205</b> between flange <b>203</b> and actuator sleeve <b>204</b><i>a </i>when actuator sleeve <b>204</b><i>a </i>is in the upwardmost position. However, when in the upwardmost position, actuator sleeve <b>204</b><i>a </i>is formed such that a portion of actuator sleeve <b>204</b><i>a </i>engages spherical members <b>204</b><i>c</i>. Accordingly, when actuator sleeve <b>204</b><i>a </i>is in an upwardmost position with respect to surface <b>102</b><i>a</i>, each spherical member <b>204</b><i>c </i>is held fixedly in opening <b>203</b><i>a. </i>

[0028] According to the configuration previously described with respect to FIG. 3, the plurality of spherical members <b>204</b><i>c </i>project into aperture <b>202</b><i>a </i>in flange <b>203</b>. The plurality of spherical members <b>204</b><i>c </i>projecting into aperture <b>202</b><i>a </i>form a ring in flange <b>203</b> that has an effective diameter that is less than the outer diameter of downrod <b>201</b>. Thus, although downrod <b>201</b> may be inserted into a portion of connector <b>202</b> above the ring formed by the plurality of spherical members <b>204</b><i>c</i>, downrod <b>201</b> cannot be fully inserted into connector <b>202</b> because downrod <b>201</b> is unable to slide past the ring formed by the plurality of spherical members <b>204</b><i>c. </i>

[0029]FIG. 4 illustrates connection assembly <b>101</b>, wherein downrod <b>201</b> is partially inserted in connector <b>202</b>. As shown, biasing member <b>204</b><i>b </i>is in a compressed state, and is displaced in a direction toward surface <b>102</b><i>a </i>of motor assembly <b>102</b>. Correspondingly, actuator sleeve <b>204</b><i>a </i>is also displaced to a downwardmost position, in a direction toward surface <b>102</b><i>a</i>. Thus, chamber <b>205</b>, which was formed between actuator sleeve <b>204</b><i>a </i>and flange <b>203</b>, is displaced downwardly in a direction toward surface <b>102</b><i>a</i>, such that the new position of chamber <b>205</b> corresponds with the position of the plurality of spherical members <b>204</b><i>c</i>. More specifically, spherical members <b>204</b><i>c </i>are released from their positions in openings <b>203</b><i>a </i>by the movement of actuator sleeve <b>204</b><i>a </i>in the direction toward surface <b>102</b><i>a</i>, and thus, each of the spherical members <b>204</b><i>c </i>retract into chamber <b>205</b>. As shown, in the present embodiment, chamber <b>205</b> provides sufficient spacing to accommodate the plurality of spherical members <b>204</b><i>c</i>, and therefore, spherical members <b>204</b><i>c </i>do not project into aperture <b>202</b><i>a</i>. Thus, the effective inner diameter of flange <b>203</b> becomes equal throughout the length of aperture <b>202</b><i>a</i>, and in particular, the effective inner diameter of flange <b>203</b> is now sufficient for downrod <b>201</b> to be inserted fully into flange <b>203</b>. Accordingly, downrod <b>201</b> can be inserted into connector <b>202</b> past the position of the ring previously formed by the plurality of spherical members <b>204</b><i>c</i>, as FIG. 4 shows.

[0030]FIG. 4 also illustrates one of the functions of projection <b>206</b>, according to one embodiment of the present invention. In particular, projection <b>206</b> is formed to mate with slot <b>210</b> provided in first end <b>207</b> of downrod <b>201</b>. Therefore, in order for first end <b>207</b> of downrod <b>201</b> to be fully inserted into connector <b>202</b>, projection <b>206</b> and slot <b>210</b> must be aligned, as shown in FIG. 4, when first end <b>207</b> of downrod <b>201</b> is being inserted into connector <b>201</b>. Thus, projection <b>206</b> and slot <b>210</b> provide a guide for installing downrod <b>201</b> into connector <b>202</b>.

[0031] Further, as can also be seen in FIG. 4, guide <b>206</b><i>a</i>, formed in actuator sleeve <b>204</b><i>a</i>also interacts with projection <b>206</b>. More specifically, projection <b>206</b> projects into guide <b>206</b><i>a </i>in actuator sleeve <b>204</b><i>a </i>such that the amount of travel of actuator sleeve <b>204</b><i>a </i>in a direction parallel to flange <b>203</b> is limited by the length of guide <b>206</b><i>a</i>. Accordingly, when actuator sleeve <b>204</b><i>a </i>is displaced in one direction, the movement of actuator sleeve <b>204</b><i>a </i>is halted when projection <b>206</b> encounters an uppermost wall of guide <b>206</b><i>a</i>. Similarly, when actuator sleeve <b>204</b><i>a </i>is displaced in a second direction, which is opposite to the first direction, the movement of actuator sleeve <b>204</b><i>a </i>is halted when projection <b>206</b> encounters a lowermost wall of guide <b>206</b><i>a</i>. Thus, projection <b>206</b> can be positioned in guide <b>206</b><i>a</i>when actuator sleeve <b>204</b><i>a </i>is displaced upwardly and downwardly with respect to surface <b>102</b><i>a</i>, and further, the combination of guide <b>206</b><i>a </i>and projection <b>206</b> can control the amount of upward and downward displacement of actuator sleeve <b>204</b><i>a. </i>

[0032]FIG. 5 illustrates connection assembly <b>101</b> with downrod <b>201</b> fully inserted in connector <b>202</b>. According to FIG. 5, biasing member <b>204</b><i>b </i>is returned to a relaxed, or expanded position, and correspondingly, actuator sleeve <b>204</b><i>a </i>is returned to an uppermost position, as in FIG. 3. Similarly, the plurality of spherical members <b>204</b><i>c </i>are re-positioned in openings <b>203</b><i>a </i>in flange <b>203</b> such that each spherical member <b>204</b> projects into aperture <b>202</b><i>a. </i>

[0033] Further, the projected portions of each spherical member <b>204</b><i>c </i>is now at least partially housed in indentation <b>209</b> of downrod <b>201</b>. More specifically, according to the present embodiment, indentation <b>209</b> has a predetermined shape which corresponds with a shape of the ring formed by spherical members <b>204</b><i>c</i>. In other words, in the present embodiment, indentation <b>209</b> has a contour of a curve in order to receive each spherical member <b>204</b><i>c </i>that projects through opening <b>203</b><i>a </i>of flange <b>203</b>. Thus, when downrod <b>201</b> is fully inserted into connector <b>201</b>, and actuator sleeve <b>204</b><i>a </i>and biasing member <b>204</b><i>b </i>are released to return to a relaxed and upperwardmost position, each spherical member <b>204</b><i>c </i>is re-positioned in opening <b>203</b><i>a </i>in flange <b>203</b>, and correspondingly, each spherical member <b>204</b><i>c </i>engages indentation <b>209</b> in downrod <b>201</b> in order to retain, or lock, downrod <b>201</b> in flange <b>203</b> such that downrod <b>201</b> is substantially restrained from movement in a direction parallel to a length of flange <b>203</b> . Thus, when downrod <b>201</b> is inserted into connector <b>202</b>, the engagement of the plurality of spherical members <b>204</b><i>c </i>with indentation <b>209</b> in downrod <b>201</b>, aid in locking downrod <b>201</b> into connector <b>202</b>. Further, the force of actuator sleeve <b>204</b><i>a </i>against the adjusting sleeve formed by the plurality of spherical members <b>204</b><i>c </i>also prevents the adjusting sleeve from releasing downrod <b>201</b>.

[0034] Additionally, as shown in FIG. 5, projection <b>206</b> is inserted into slot <b>210</b> of downrod <b>201</b>. Thus, projection <b>206</b> also aids in locking downrod <b>201</b> into connector <b>202</b>, and in particular, aids in preventing downrod <b>201</b> from rotating while positioned in connector <b>202</b>.

[0035] In order to release downrod <b>201</b> from the position illustrated in FIG. 5, it is only necessary to move sleeve assembly <b>204</b> to the position shown in FIG. 4, wherein the plurality of spherical members <b>204</b><i>c </i>do not project into aperture <b>202</b><i>a</i>, and more specifically, do not interfere with the movement of downrod <b>201</b>. Thus, downrod <b>201</b> can be removed from flange <b>203</b> of connector <b>202</b> because downrod <b>201</b> is free to move in a direction parallel to the length of flange <b>203</b>.

[0036] In a construction of the presently preferred embodiment of connection assembly <b>101</b>, flange <b>203</b> can be formed with aperture <b>202</b><i>a </i>having a predetermined diameter corresponding to a diameter of downrod <b>201</b>, which is also formed to mate with flange <b>203</b>. Flange <b>203</b> can be provided on surface <b>102</b><i>a </i>of motor assembly <b>102</b> by any suitable manner including, welding, or a one-piece construction with motor assembly <b>102</b>. In a similar manner, projection <b>206</b> can be provided in flange <b>203</b>. Thereafter, sleeve assembly <b>204</b> can be positioned to surround flange <b>203</b> as previously described. Alternatively, flange <b>203</b> and sleeve assembly <b>204</b> can be formed integrally, then positioned on surface <b>102</b><i>a. </i>

[0037] Although the present invention has been described with reference to a presently preferred embodiment, it will be appreciated by those skilled in the art that various modifications, alternatives, variations, and substitution of parts and elements, may be made without departing from the spirit of the invention. For example, indentation <b>209</b> provided in downrod <b>201</b> is not limited to a curved contour as described, but rather, can be of any shape capable of mating with the sleeve assembly <b>204</b>. Similarly, projection <b>206</b>, downrod slot <b>210</b>, and guide <b>206</b><i>a </i>can be of any configuration which are capable of mating with each other. Furthermore, connection connector <b>202</b> can be constructed with actuator sleeve <b>204</b><i>a </i>against surface <b>102</b><i>a </i>and biasing member <b>204</b><i>b </i>provided thereon, such that the operation described above, in the present embodiment is reversed. Thus, the present application is intended to cover such modifications, alternatives, variations and elements as fall within the scope of the appended claims.