U.S. patent application number 14/568996 was filed with the patent office on 2016-06-16 for method for manufacturing ceiling fan blade and ceiling fan blade.
The applicant listed for this patent is CHUN-WEI CHIANG. Invention is credited to CHUN-WEI CHIANG, MING-TSUNG GAU.
Application Number | 20160169244 14/568996 |
Document ID | / |
Family ID | 56110725 |
Filed Date | 2016-06-16 |
United States Patent
Application |
20160169244 |
Kind Code |
A1 |
CHIANG; CHUN-WEI ; et
al. |
June 16, 2016 |
METHOD FOR MANUFACTURING CEILING FAN BLADE AND CEILING FAN
BLADE
Abstract
A ceiling fan blade includes a foamed layer, two paper layers,
and two cover layers. The foamed layer is formed by foaming a
polyvinyl chloride material. The paper layers are positioned on two
opposite faces of the foamed layer respectively The cover layers
are positioned on the paper layers respectively so that each paper
layer is sandwiched between the foamed layer and one of the cover
layers. Thereby, the ceiling fan blade is light-weight, low-cost,
and easy to manufacture. In addition, energy to rotate the ceiling
fan is reduced.
Inventors: |
CHIANG; CHUN-WEI; (Taichung
City, TW) ; GAU; MING-TSUNG; (Taichung City,
TW) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
CHIANG; CHUN-WEI |
Taichung City |
|
TW |
|
|
Family ID: |
56110725 |
Appl. No.: |
14/568996 |
Filed: |
December 12, 2014 |
Current U.S.
Class: |
416/229R ;
29/889.71 |
Current CPC
Class: |
F04D 25/088 20130101;
F05D 2300/612 20130101; F04D 29/388 20130101; F05D 2300/43
20130101 |
International
Class: |
F04D 29/38 20060101
F04D029/38; F04D 25/08 20060101 F04D025/08 |
Claims
1. A method for manufacturing ceiling fan blade, including steps
of: (a) preparing a foamed layer: preparing polyvinyl chloride
material and foaming the polyvinyl chloride material to form a
foamed layer; (b) adding paper layers: positioning a paper sheet on
each of two opposite faces of the foamed layer to form a paper
layer; (c) adding cover layers: positioning a cover layer on a face
of each paper layer opposite to the foamed layer to form a ceiling
fan blade wherein two cover layers define upside and downside of
the ceiling fan blade.
2. The method for manufacturing ceiling fan blade of claim 1,
wherein in the step of (c), each paper layer is positioned with one
of the cover layer to form a raw product, and the raw product is
further cut to form the ceiling fan blade.
3. The method for manufacturing ceiling fan blade of claim 1,
wherein in the step of (c), a part of the foamed layer which is not
covered by the paper layers and the cover layers is colored after
the cover layers have been positioned on the paper layers.
4. The method for manufacturing ceiling fan blade of claim 1,
wherein a step that positioning a metal sheet on the face of each
paper layer opposite to the foamed layer to form a metal layer is
processed between the steps of (b) and (c).
5. The method for manufacturing ceiling fan blade of claim 1,
wherein each cover layer is a wood grain sheet or a metallic
sheet.
6. The method for manufacturing ceiling fan blade of claim 1,
wherein the polyvinyl chloride material is colored before being
foamed.
7. A ceiling fan blade, including: a foamed layer, prepared by
foaming a polyvinyl chloride material; two paper layers, positioned
on two opposite faces of the foamed layer respectively; two cover
layers, positioned on the two paper layers respectively so that
each paper layer is sandwiched between the foamed layer and one of
the cover layers.
8. The ceiling fan blade of claim 7, wherein a part of the foamed
layer which is not covered by the paper layers and the cover layers
is colored.
9. The ceiling fan blade of claim 7, wherein a metal layer is
sandwiched between each paper layer and its adjacent cover
layer.
10. The ceiling fan blade of claim 7, wherein the polyvinyl
chloride material of the foamed layer is colored before being
foamed.
Description
BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a method for manufacturing
a ceiling fan blade and to a ceiling fan blade.
[0003] 2. Description of the Prior Art
[0004] A conventional ceiling fan blade is usually made by wooden
veneer or wooden fiberboard. A fan blade made by wooden veneer is
weighted approximately 300-350 g, and a fan blade made by wooden
fiberboard is weighted approximately 350-400 g. Thus, a
conventional ceiling fan including five fan blades may be weighted
approximately 1500-2000g. As a result, a conventional ceiling fan
is difficult to install, and the loading of motor to rotate the
ceiling fan is quite high.
[0005] In addition, when an earthquake or other accident occurs,
the heavy wooden fan blade may fall to hurt people.
[0006] Besides, the wooden fan blade may accelerate
deforestation.
[0007] Thus, foam material is introduced to manufacture improved
fan blades, as disclosed in patents TW 224062 and TW 229720. In the
disclosures, a steel bar or other rigid objects is placed into a
mold, and a foam material is injected into the mold. The foam
material is foamed and expanded to wrap the steel bar to give a
ceiling fan blade which is lighter.
[0008] However, the process to manufacture is complicated and
time-consuming, and the weight is not really reduced due to the
steel bar. On the other hand, gravity center of the fan blade may
be alternated by position of the steel bar in the fan blade. Thus,
error of the position of the steel bar may result that the ceiling
fan blade lose its balance, and calibration may be necessary during
installation.
SUMMARY OF THE INVENTION
[0009] The main object of the present invention is to provide a
ceiling fan blade which is easy to manufacture, low-cost, and
light-weight.
[0010] To achieve the above and other objects, a method for
manufacturing ceiling fan blade of the present invention includes
the steps of:
[0011] Preparing a foamed layer: preparing a polyvinyl chloride
material and foaming the polyvinyl chloride material to form a
foamed layer; adding paper layers: positioning a paper sheet on
each of two opposite faces of the foamed layer to form a paper
layer; adding cover layers: positioning a cover layer on a face of
each paper layer opposite to the foamed layer to form a ceiling fan
blade wherein two cover layers define upside and downside of the
ceiling fan blade.
[0012] A ceiling fan blade is also provided in the present
invention. The ceiling fan blade includes a foamed layer, two paper
layers, and two cover layers.
[0013] The foamed layer is prepared by foaming a polyvinyl chloride
material. The paper layers are positioned on two opposite faces of
the foamed layer respectively. The cover layers are positioned on
the two paper layers respectively so that each paper layer is
sandwiched between the foamed layer and one of the cover
layers.
[0014] Thereby, the polyvinyl chloride foamed material helps reduce
weight of the ceiling fan blade, and the loading of motor is
reduced too. In addition, the ceiling fan blade of the present
invention looks similar to conventional one, but less wood is
used.
[0015] The present invention will become more obvious from the
following description when taken in connection with the
accompanying drawings, which show, for purpose of illustrations
only, the preferred embodiment(s) in accordance with the present
invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0016] FIG. 1 is a flow chart of the present invention;
[0017] FIG. 2 is an illustration of the present invention;
[0018] FIG. 3 is a breakdown drawing of the present invention;
[0019] FIG. 3A is a stereogram of the present invention;
[0020] FIG. 4 is a profile of the present invention;
[0021] FIG. 5 is a profile showing a second embodiment of the
present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0022] Please refer to FIG. 1 to FIG. 5 and FIG. 3A, the method for
manufacturing ceiling fan blade is provided in the present
embodiment. The ceiling fan blade 10, 10' is adapted for being
disposed on a ceiling fan base 20. The method for manufacturing the
ceiling fan blade 10, 10' includes the following steps.
[0023] (a) Prepare a foamed layer S1: prepare a polyvinyl chloride
material and foam the polyvinyl chloride material to form a foamed
layer 11 which has a predetermined thickness. The foaming
magnification of the foamed layer is not larger than 20 to maintain
sufficient structure strength.
[0024] (b) Add paper layers S2: Position a paper sheet on each of
two opposite faces of the foamed layer 11 to form a paper layer 12.
More specifically, two paper sheets are adhered onto two opposite
faces of the foamed layer 11 from two ends of the thickness
direction of the foamed layer by glue or adhesive. The paper layers
12 improve the structure strength by aggregating the foam material
to be a single piece so that the foamed layer is prevented from
rupture.
[0025] (b-1) Add metal layers S3: position a metal sheet on a face
of each paper layer 12 opposite to the foamed layer 11 to form a
metal layer 14 wherein the metal sheet is preferably aluminum. The
metal layers 14 further improve structure strength of the ceiling
fan blade 10'. However, the metal layers are selectively
introduced. In the embodiment shown in FIGS. 3 and 4, the metal
layers are omitted.
[0026] (c) Add cover layers S4: position a cover layer 13 on each
paper layer 12 (or each metal layer 14) to form a ceiling fan blade
10, 10'. The two cover layers 13 define upside and downside of the
ceiling fan blade 10, 10'. Preferably, each cover layer 13 is a
wood grain sheet, a metallic sheet, or other decorative
material.
[0027] (d) Cutting S5: cut the aggregated foamed layer 11, the
paper layers 12, the metal layers 14, and the cover layers 13 into
a predetermined size to give a final product.
[0028] (e) Coloring S6: a part of the foamed layer 11 which is not
covered by the paper layers 12 and the cover layers 13 is colored.
More specifically, the exposed part of the foamed layer 11 is
colored into a color similar to the cover layers. Alternatively,
this step can be replaced by a step that coloring the polyvinyl
chloride material before foaming the polyvinyl chloride material.
For example, the polyvinyl chloride can be blended with dye.
Thereby, the foamed layer is able to show a color similar to the
cover layers.
[0029] The present invention also provides a ceiling fan blade
including a foamed layer 11, two paper layers 12, two metal layers
14, and two cover layers 13, as shown in FIGS. 2 to 5. The foamed
layer 11 is prepared by foaming a polyvinyl chloride material and
has a predetermined thickness. The two paper layers 12 are
positioned on two opposite faces of the foamed layer 11
respectively by glue or adhesive so that the foamed layer 11 is
sandwiched by the two paper layers 12. The two metal layers 14 are
adhered onto the two paper layers 12 for improving structure
strength. However, the metal layers are selectively introduced and
is able to be omitted. The two cover layers 13 are positioned on
the two paper layers 12 (or the two metal layers 14) respectively
so that each paper layer is sandwiched between the foamed layer 11
and one of the cover layers 13. Each cover layer 13 is a wood grain
sheet, a metallic sheet, or other decorative material.
[0030] In addition, a part of the foamed layer 11 which is not
covered (the lateral periphery) is colored into a color similar to
the cover layers 13. Alternatively, the polyvinyl chloride material
can be colored before being foamed, so the foamed layer shows a
color similar to the cover layers.
[0031] In conclusion, the ceiling fan blade of the present
invention is much easier to manufacture, so manufacturing process
is simplified and speeded. Also, the cost is reduced. Besides, the
present invention is made of foam material and paper instead of
steel bars, so the ceiling fan blade is light-weighted (about 40-50
g). As a result, the loading of the motor to drive the ceiling fan
is reduced to save energy. On the other hand, when earthquake or
other accident occurs, the falling ceiling fan blade may not hurt
people too much. Besides, less wood is used to manufacture the
ceiling fan blade of the present invention.
* * * * *