U.S. patent application number 11/591902 was filed with the patent office on 2008-05-08 for fan blade connector component with skeleton and method of manufacturing such.
This patent application is currently assigned to Hunter Fan Company. Invention is credited to Brian Hunter Friedman.
Application Number | 20080107529 11/591902 |
Document ID | / |
Family ID | 39359889 |
Filed Date | 2008-05-08 |
United States Patent
Application |
20080107529 |
Kind Code |
A1 |
Friedman; Brian Hunter |
May 8, 2008 |
Fan blade connector component with skeleton and method of
manufacturing such
Abstract
A fan blade connector component having a moldable ornamental
housing that encloses a skeleton which includes links which span
between adjacent posts having a threaded bore therein. The links
include opposing side walls, a top wall, and a land therebetween. A
plurality of spaced-apart openings extend through the top wall for
securing the skeleton within the moldable ornamental housing.
Inventors: |
Friedman; Brian Hunter;
(Collierville, TN) |
Correspondence
Address: |
BAKER, DONELSON, BEARMAN, CALDWELL & BERKOWITZ
SIX CONCOURSE PARKWAY, SUITE 3100
ATLANTA
GA
30328
US
|
Assignee: |
Hunter Fan Company
|
Family ID: |
39359889 |
Appl. No.: |
11/591902 |
Filed: |
November 2, 2006 |
Current U.S.
Class: |
416/210R ;
29/889.21 |
Current CPC
Class: |
F04D 25/088 20130101;
F04D 29/34 20130101; Y10T 29/49321 20150115; F04D 29/005
20130101 |
Class at
Publication: |
416/210.R ;
29/889.21 |
International
Class: |
F01D 5/30 20060101
F01D005/30; B21K 25/00 20060101 B21K025/00 |
Claims
1. A skeleton for a cast fan blade connector component, comprising:
at least two posts having a threaded bore for receiving a fastener;
a link that interconnects adjacent said posts.
2. The skeleton as recited in claim 1, wherein said skeleton
includes three said posts interconnected by three said links.
3. The skeleton as recited in claim 2, wherein two said links are
of a first length and the third said links is of a second length
less than said first length.
4. The skeleton as recited in claim 1, wherein said link includes a
plurality of openings therein.
5. The skeleton as recited in claim 1, made of a cast metal.
6. The skeleton as recited in claim 1, wherein said link includes a
hub.
7. A skeleton for a cast fan blade iron component, comprising: a
hub; a plurality of elongated links extending radially from the
hub; and a plurality of posts, each post being positioned at a
distal end of a said link and having a threaded bore therein.
8. The skeleton of claim 7, wherein said links include a plurality
of spaced-apart openings therein.
9. A cast fan blade connector component for attaching a fan blade
to a fan motor, comprising: a skeleton having a plurality of
elongated links and a plurality of posts interconnected to each
other through said links, said posts having a threaded bore
therein; and an ornamental body mounted at least partially about
said skeleton with said post bores exposed outside said ornamental
body.
10. The fan blade connector component as recited in claim 9,
wherein said skeleton is made of a cast metal.
11. The fan blade connector component as recited in claim 9,
wherein the ornamental body is made of a resin.
12. The fan blade connector component of claim 9, wherein said fan
blade connector component is a fan blade connector.
13. The fan blade connector component of claim 9, wherein said fan
blade connector component is a fan blade connector medallion.
14. A method of manufacturing a fan blade connector component,
comprising the steps of: (a) providing a skeleton having at least
two posts having a threaded bore for receiving a fastener and a
link spanning the posts, and (b) forming an ornamental housing
about the skeleton so as to encase the link and at least a portion
of the posts yet allowing the bore of each post to remain exposed
from the housing.
15. The method as recited in claim 14, wherein the skeleton has
three posts interconnected by three links.
16. The method as recited in claim 14, wherein two of the links are
of a first length and a third one of the links is of a second
length less than the first length.
17. The method as recited in claim 14, the skeleton made of a cast
metal.
Description
TECHNICAL FIELD
[0001] The present invention relates to connectors components for
attaching fan blades to fan motors. More particularly, the present
invention relates to the interior structures for embedding in fan
blade connectors components and a method of manufacturing such.
BACKGROUND OF THE INVENTION
[0002] Electrically powered ceiling fans typically have a motor
mounted within a stationary housing that is suspended from a
ceiling. In operation, the motor rotates an annular array of
connectors coupled to blades. The blade connectors of ceiling fans
are typically mounted to the blade through a series of mounting
bolts or screws that pass through holes in the fan blade and thread
within threaded mounting holes in the blade connector.
Alternatively, the blade connector includes a medallion which is
positioned against the blade opposite the blade mounting portion of
the blade connector, thereby sandwiching the blade
therebetween.
[0003] Blade connectors are typically made of die cast metal. These
materials allow for limited aesthetic flexibility and provide the
rigidity and support needed to support a fan blade that is spinning
upwards of 200 rpm. The use of these materials however is costly
due to the tooling process needed to manufacture the blade
connector and because of the costs of the raw material.
[0004] Accordingly, there is a need in the art for an improved
blade connector component, such as a blade connector or blade
connector medallion, that readily provides aesthetic flexibility
yet is strong enough to support the fan blades of fans. It is to
such that the present invention is directed.
SUMMARY OF THE INVENTION
[0005] A skeleton for a cast fan blade connector component
comprises at least two posts having a threaded bore for receiving a
fastener, and a link that interconnects adjacent posts.
[0006] A method of manufacturing a fan blade connector component
comprises the steps of providing a skeleton having at least two
posts having a threaded bore for receiving a fastener and a link
spanning the posts, and forming an ornamental housing about the
skeleton so as to encase the link and at least a portion of the
posts yet allowing the bore of each post to remain exposed from the
housing.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] FIG. 1 illustrates in perspective partially cut-away view a
skeleton for a fan blade connector component embodying principles
of the invention in a preferred form.
[0008] FIG. 2 illustrates in perspective view of a skeleton for a
fan blade connector component in another preferred form of the
invention.
[0009] FIG. 3 illustrates a perspective view of a skeleton shown
partially encased within a blade connector medallion.
[0010] FIG. 4 illustrates in perspective exploded view the skeleton
shown partially encased in a fan blade connector for attaching a
fan blade to a fan motor.
DETAILED DESCRIPTION
[0011] With reference to the drawings in which like parts have like
reference numerals, FIG. 1 illustrates in perspective partially
cut-away view of a skeleton 10 for a fan blade connector component
12, which may be utilized to form a blade connector or a blade
connector medallion. The skeleton shown in FIG. 1 is preferably
designed to be utilized specifically with a blade connector
medallion. The skeleton 10 includes a hub 14 from which a plurality
of elongated links 16 extend radially. In the illustrated
embodiment, the skeleton 10 is made of a cast metal, such as zinc,
but may also be made of a stamped sheet metal or other similarly
formed metal. The skeleton 10 may be made of any substantially
rigid material capable of supporting a fan blade and withstanding
the force exerted upon the blade connector during the revolution of
the fan blade. The skeleton 10 is of sufficient overall dimension
to support fan blades of varying length and weight.
[0012] The links 16 may be spaced-apart equidistantly or may be
oriented at varying angles. In the illustrated embodiment the
skeleton has three links wherein two pairs of the links 16 are
approximately 130 degrees apart as indicated at 18 and one pair is
approximately 100 degrees apart as indicated at 20. It is
understood, however, that there may be varying numbers of links at
various lengths. Each link 16 terminates at a post 22 having a
threaded bore 24 therein and a closed bottom 26.
[0013] Each links 16 has opposing side walls 28 and a land 30
spanning therebetween. The land 30 and the side walls 28
cooperatively define a first valley 32 and an opposing second
valley 34. A top wall 35 extends between the tops of the side walls
28. The top wall 35 has a plurality of spaced apart openings 36
extending therethrough. In the present embodiment, the openings 36
on each link 16 provide cavities or spaces through which resin,
upon hardening during fabrication, may embed. This, in turn, helps
secure the skeleton 10 within the blade connector 12.
[0014] FIG. 2 illustrates in perspective exploded view the skeleton
10 shown encased in a fan blade connector component in the form of
a blade connector medallion. The fan blade connector medallion
includes an exterior ornamental shape or housing 37. FIG. 4
illustrates in perspective view of the skeleton 10 shown encased in
a fan blade connector 41. It should be understood that the skeleton
may be used with a fan blade connector or a fan blade connector
medallion as shown in U.S. Pat. No. 5,304,037, which is
specifically incorporated herein. The blade connector is coupled to
a fan motor 42 through additional links which extend to the motor,
shown in phantom lines. In the illustrated embodiment, the blade
connector 12 has a motor mounting flange or portion 44 and a blade
mounting portion 46. The motor mounting flange 44 connects the
blade connector 12 to the motor 42 by unshown mounting bolts. The
blade mounting portion 46 encases the skeleton 10 and secures the
blade connector 12 to the fan blade 40.
[0015] During fabrication, the cast metal skeleton 10 is placed in
a mold and over-molded with a resin or other suitable moldable
material in a desired ornamental shape. This may be done to form
the blade mounting portion 46 of the blade connector 41, as shown
in FIG. 4, or to form the blade connector medallion, as shown in
FIG. 3. It is understood, however, that the skeleton may be encased
in any polymerized synthetic or chemically modified natural resin
including thermoplastic materials such as polyvinyl, polystyrene,
and polyethylene or thermosetting materials such as polyesters,
epoxies, and silicones. Resin has the advantage of providing
aesthetic flexibility and cost efficiency in comparison to metals
such as zinc or brass or other metal alloy.
[0016] Each blade connector medallion or blade connector attaches
one ceiling fan blade 40 to the motor. Each ceiling fan blade 40
has a plurality of mounting holes 43 that correspond to the posts
22 on the skeleton 10. In the illustrated embodiment, three
mounting holes 43 are aligned with the three posts 22 of the
skeleton 10. A mounting screw 48 inserts through a respective one
of the mounting holes 43 and into the threaded bore 24 of each post
22 to secure the blade connector medallion to a blade connector.
Each post of the skeleton 10 has a short enough height to allow the
skeleton 10 to be completely molded with resin with the exception
of the post ends, yet sufficient height to allow mounting screws 48
to engage the threaded bore 24 of each post 22.
[0017] FIG. 3 illustrates in perspective view an alternate
embodiment of the skeleton 10a for the fan blade connector
medallion 12. The skeleton 10a includes at least two posts 22 each
having the threaded bore 24 for receiving a fastener such as a
screw. Each of the posts 22 includes the closed bottom 26.
[0018] In the illustrated embodiment, the links 16 form a
triangular-like structure. The skeleton 10a includes three posts 22
interconnected by three links 16. The link 16 interconnects
adjacent posts 22. The skeleton 10a includes two links 16 of a
first length and a third link of a second length less than the
first length. The links 16 may have varying lengths in comparison
to each other and may include varying numbers of links 16 and posts
22 so as to form a variety of polygon-type structures. Each link 16
includes openings 36 therein.
[0019] The skeleton 10a illustrated in FIG. 3 is similarly encased
in the moldable fan blade connector or blade connector medallion 12
for attaching the fan blade 40. During fabrication, the metal cast
skeleton 10a is over molded with a resin and encased therein. It is
understood, however, that the skeleton may be encased in any
polymerized synthetic or chemically modified natural resin
including thermoplastic materials such as polyvinyl, polystyrene,
and polyethylene or thermosetting materials such as polyesters,
epoxies, and silicones.
[0020] Each blade connector or medallion 12 attaches to one of the
ceiling fan blades 40. The mounting holes 43 in the fan blade 40
align with the posts 22 of skeleton 10a. The mounting screws 48
insert through the respective mounting holes 43 and into the
threaded bores 24 of the posts 22. Each post of the skeleton 10 has
a short enough height to allow the skeleton 10a to be completely
molded with resin and encased within the fan blade connector 12,
yet sufficient height to allow mounting screws 48 to engage the
threaded bore 24 of each post 22.
[0021] It thus is seen that a skeleton and the encompassing blade
connector or medallion is now provided which is not only cost
efficient but esthetically alterable thus overcoming the
shortcomings of the existing art. It should be understood that many
modifications, additions and deletions, in addition to those
expressly recited, may be made thereto without departure from the
spirit and scope of the invention as set forth in the following
claims.
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