Patent Application
20160319842
The conventional ceiling fan includes a mounting bracket or ceiling plate, which couples to an electric outlet box or the building structure. In a mounting system utilizing a ceiling fan-rated outlet box, machine screws couple the mounting bracket to the outlet box. Alternatively, in a standard electrical outlet box or building structure, wood screws couple the mounting bracket to a wood stud, supporting the ceiling fan. In either event, the screws are tightened until a structure mount is securely mounted to the building structure.
A typical ceiling fan assembly comprises, a motor, a motor housing, a plurality of fan blades, a canopy, and an optional light assembly, which secures to the ceiling plate or mounting bracket by a downrod or a hanger rod. The downrod passes through a central opening in the canopy. One end of the downrod couples to a downrod coupler for mounting to the mounting bracket while the opposite end of the downrod mounts to the ceiling fan assembly, utilizing a motor coupler. A ball attaches to the downrod coupler and is received in a seat formed in the mounting bracket, mounting the ceiling fan assembly to the mounting bracket, and thus the ceiling fan unit to the ceiling.
Traditionally, ceiling fans are sold with a single mounting style being either a low-profile mount, a traditional-profile mount, or a high or angled profile mount. A low-profile mount mounts the ceiling fan close to the ceiling, reducing the chance of collision with the fan blades during operation. When utilizing a low-profile mount, the canopy typically extends from the fan motor housing to the ceiling, completely covering the downrod. Conversely, in a traditional-profile or high profile mount, the downrod is visible, with a canopy that extends from the ceiling down to a portion of the downrod creating an aesthetic transition between the two. A traditional-profile mount or a high profile mount extend further from the ceiling, as compared to a low-profile mount, in order to optimize fan efficiency by increasing space above the fan promoting greater airflow.
Consumers purchase mounting styles based upon the consumer's ceiling in order to optimize fan efficiency, maintain safety, and promote aesthetic value. A consumer with a low height ceiling, generally less than 8 feet, will be limited to purchasing a low-profile mount ceiling fan to accommodate the low ceiling. A consumer with a normal height ceiling, generally 8 to 10 feet, will be limited to purchasing a traditional-profile ceiling fan to optimize fan efficiency. Finally, a consumer with a high, vaulted, or angled ceiling, extending higher than 10 feet, will purchase a ceiling fan specifically accommodating the specific ceiling style, such as a ceiling fan with high-profile mount utilizing an elongated downrod.
If a consumer wants to purchase a ceiling fan style specifically designed for a traditional-profile mount, but has a low-profile ceiling, the consumer will have to worry about the low hanging fan blades. Furthermore, if a consumer moves to another home with a different height ceiling or wants to move the ceiling fan to another room with a different height ceiling, the ceiling fan will have an incorrect mounting profile to accommodate new room. Transitioning ceiling fans between different heights or finding a ceiling fan style specific to a ceiling type often limits a consumer in purchasing and style options.
Additionally, installing the ceiling fan while making internal, electrical wiring connections is difficult. Holding the ceiling fan assembly while making connections is challenging. In a low-profile mount, the canopy extends from the fan assembly to the ceiling, creating a situation where the size of the canopy prevents an installer from making internal electrical connections. Installation requires an installer to hold the ceiling fan assembly while simultaneously making mounting or electrical connections, making the endeavor at least a two-person job and raising issues with safety.
A ceiling fan kit with a first downrod, a second downrod being longer than the first downrod, a structure mount configured to attach either downrod to a structure, an adjustable length canopy configured for use with the first downrod, and a non-adjustable length canopy configured for use with the second downrod. The adjustable length canopy is extendable and retractable and may provide a low-profile ceiling mount when used in conjunction with the first downrod. The non-adjustable canopy may provide a traditional-profile mount when used in conjunction with the second downrod. The extended length of the adjustable length canopy may be a greater length than the first downrod and the non-adjustable length canopy. The non-adjustable length canopy may be of a length less than the length of the second downrod. The structure mount may comprise a mounting bracket.
The kit may comprise additional elements such as fan motor assembly including at least one fan blade, and a downrod coupler for retaining either downrod. The downrod coupler may comprise a ball mount for coupling to either downrod, where the mounting bracket may retain the ball.
A method of installing a ceiling fan comprising the steps of: (A) selecting a downrod from at least a first downrod and a second downrod, where the second downrod is longer than the first downrod; (B) selecting a canopy from either an adjustable length or a non-adjustable length canopy based on the selected downrod; (C) mounting the selected downrod to a downrod coupler; (D) positioning the selected canopy about the selected downrod; (E) mounting the downrod to a fan assembly; and (F) mounting the downrod coupler to a structure mount. The method may further comprise securing the downrod coupler to the structure mount.
When the adjustable length canopy is selected, the method may further comprise extending the length of the adjustable length canopy after securing the downrod coupler to the structure mount and securing the adjustable length canopy to the structure mount after extending the length. Securing the downrod coupler to the structure mount may include placing a ball on the downrod coupler within a complementary seat on the structure mount. The adjustable length canopy may include telescoping segments.
When selecting the non-adjustable length canopy, the method may further comprise sliding the non-adjustable length canopy along the selected downrod until a portion of the non-adjustable length canopy is adjacent to the structure mount or securing the portion of the non-adjustable length canopy to the structure mount.
The method may further comprise selecting the adjustable length canopy when the selected downrod is the first downrod or selecting a non-adjustable length canopy when the selected downrod is the second downrod.
Turning now to the drawings and to
The ceiling fan kit 10 shown comprises a modular fan assembly 60, wiring harness 50, downrod set 40, mounting assembly 30, and canopy set 20. The modular fan assembly 60 comprises a motor 70, including motor wires 68, blade mounting ring 66, which mounts a plurality of fan blades 72. The upper motor housing 62, with a canopy rest 92 situated on an outer surface, and lower motor housing 74 enclose the motor 70 while leaving an annular opening through which the fan blades 72 extend. A motor coupler 64 mounts to an upper end of the motor 70, and a motor coupler brace 76 mounts to a lower end of the motor 70. A light globe or shade 78 mounts to the lower end of the lower motor housing 74.
The downrod set 40 comprises a short downrod 42 and a long downrod 44. The long downrod 44 can be a downrod of any length being greater than the length of the short downrod 42. The short downrod 42 is suitable for a low profile mounting of the motor 70 to the ceiling, whereas the long downrod 44 may be suitable for a traditional-profile mounting, high-profile mounting, or mounting the motor 70 to an angled or vaulted ceiling. While two downrods are shown, more than two downrods having differing lengths may be included in the downrod set 40.
The wiring harness 50 includes wiring 54, which can terminate on one or more ends with a connector 52. The connector 52 can be preassembled to the wiring 54 or can be ready for assembly by the installer. In either case, the connector 52 may be a push connector having multiple slots or openings in which the leads of the wiring 54 may be pushed in to establish an electrical connection between the wiring 54 and the connector 52. Further, the ceiling fan kit 10 may comprise a set of harnesses, complementary to each downrod in the downrod set 40. Harnesses may be pre-installed within each downrod or may require installation. Still further, the ceiling fan kit 10 may have no wiring harness 50 or may include a length of wire that can be stripped and cut to electrically couple the motor 70 to the structure power supply.
The mounting assembly 30 comprises a structure mount 34, downrod coupler 36, and a ball 32. The structure mount 34 can be mounted to the ceiling or other structure to which the motor 70 is to be mounted. A portion of the structure mount 34 forms a seat adapted to receive the ball 32. The ball 32 couples to the downrod coupler 36, which couples to the selected downrod 42, 44. The ball 32, upon resting in the seat, can provide for pivoting movement of the downrod 42, 44 relative to the structure mount 34. The ball 32 can have a tri-lobe configuration to improve the seating and pivoting movement relative to the structure mount 34.
The canopy set 20 can comprise a non-adjustable length canopy 22, best suited for a traditional mounting, and an adjustable length canopy 24, best suited for a low profile mounting. While two canopies are shown in the canopy set 20, more than two canopies may be included in the canopy set 20.
The elements of the ceiling fan kit 10 are interconnectably combinable, as shown in
Turning now to
The mounting assembly 30 has been combined. The downrod coupler 36 couples the end of the long downrod 44, opposite of the modular fan assembly 60, to the ball 32. The ball 32 is seated in the structure mount 34, mounting the modular fan assembly 60 to the ceiling. The non-adjustable length canopy 22 positions around and attaches to the structure mount 34, resting flush against the ceiling.
The coupling of the long downrod 44 between the structure mount 34 and the modular fan assembly 60 is best shown with respect to
Opposite of the motor coupler 64, the long downrod 44 mounts to the downrod coupler 36 with a pin 84. The ball 32 is adapted to receive and support the downrod coupler 36 such that the downrod coupler 36 rests on a ledge extending into an internal recess within the ball 32. The structure mount 34 has a seat 86 adapted to receive the ball 32. Upon attaching the structure mount 34 to the ceiling and positioning the ball 32 within the seat 86, the structure mount 34 couples the other combined elements comprising the ceiling fan kit 10 to the ceiling.
Turning now to
The adjustable length canopy 24 extends between the upper motor housing 62 and the structure mount 34, while enveloping the structure mount 34 and short downrod 42, to effectively fill in any gap between the upper motor housing 62 and the structure to which the upper motor housing 62 is mounted. In this manner, the adjustable length canopy 24 provides a cover for the short downrod 42, unlike the non-adjustable length canopy 22 in the traditional-profile mounting.
The adjustable length canopy 24 is comprised of two separate elements including an upper member 24a and a lower member 24b, which may be moved relative to each other between an extended position (
The structure of the adjustable length canopy 24 is best seen with reference to
Still referring to
Unlike the traditional-profile assembly 80, in the low-profile assembly 90, the lower member 24b of the adjustable length canopy 24 rests on the canopy rest 92. The canopy rest 92 has a groove 96 with pad 94 situated in the bottom of the groove 96. The groove 96 runs circumferentially around canopy rest 92 having a diameter adapted to receive the bottom edge of the lower member 24b. The pad 94 can be an absorption member used to attenuate the transfer of vibrational forces between the modular fan assembly 60 and the adjustable length canopy 24.
When in the extended position, the upper member 24a of the adjustable length canopy 24 can be coupled to the structure mount 34 by screws 82. In the extended position, the adjustable length canopy 24 surrounds the structure mount 34, the ball 32, the downrod coupler 36, and a portion of the short downrod 42. In the extended position, the bottom edge of the reduced portion 28 of the upper member 24a is situated within the internal recess of the lower member 24b.
Turning now to
The method of mounting the ceiling fan kit 10 of
The modular fan assembly 60 is combined such that the motor wires 68 extend out of the motor coupler 64. Opposite of the downrod coupler 36, one connector 52 of the wiring harness 50, extending from inside the selected downrod 42, 44, couples to the motor wires 68 and the selected downrod 42, 44 couples to the motor coupler 64. The other connector 52 of the wiring harness 50 extends through and out of the ball 32.
The selected canopy 22, 24 is positioned about the selected downrod 42, 44. If the selected canopy 22, 24 is the non-adjustable length canopy 22, it may be slid down the selected downrod 42, 44 until abutting the modular fan assembly 60. If the selected canopy is the adjustable length canopy 24, the lower member 24b rests on the canopy rest 92 within the groove 96, while the reduced portion 28 of the upper member 24a is telescopically slid within the lower member 24b. In either case, after positioning the selected canopy 22, 24, the ball 32 is positioned within the seat 86 of the structure mount 34, mounting the downrod coupler 36 to the structure mount 34. The connector 52 extending through the ball 32 couples the wiring 54 to an electrical supply, providing electrical connectivity to the motor 70.
If the selected canopy 22, 24 is the non-adjustable length canopy 22, it is slid up the selected downrod 42, 44 and coupled to the structure mount 34, covering the structure mount 34 and resting flush against the ceiling. If the selected canopy 22, 24 is the adjustable length canopy 24, most of the upper member 24a is telescopically slid out of the lower member 24b, while remaining only partially within the lower member 24b, and couples to the structure mount 34, covering the structured mount 34 and resting flush against the ceiling.
Turning now to
At 114, the installer mounts the selected downrod to a downrod coupler, and, at 116, the installer positions the selected canopy about the selected downrod. At 118, the installer mounts the selected downrod to a fan assembly and at 120, the installer mounts the downrod coupler to a structure mount. In additional methods for mounting the ceiling fan kit, 116 and 118 may be completed in any order as a particular fan assembly may require. The fan assembly of 118 can be the combined modular fan assembly 60 of
The method 108 of mounting the kit, may comprise selecting the first downrod at 110 and selecting the adjustable length canopy at 112, wherein mounting the first downrod and adjustable length canopy in 114 through 120 comprises a low-profile mount. The method 108 may also comprise selecting the second downrod at 110 and selecting the non-adjustable length canopy at 112, wherein mounting the second downrod and the non-adjustable length canopy in 114 through 120 comprises a traditional-profile mount.
In the aforementioned, ceiling fan elements or combinations thereof are accommodating of either downrod 42, 44, and either canopy 22, 24 in any combination utilizing at least one downrod 42, 44 and at least one canopy 22, 24. The elements of the downrod set 40 and the canopy set 20 are modularly interchangeable with other elements of the ceiling fan kit 10.
The ceiling fan kit as previously described may come in different configurations. For example, one configuration that is suitable when the fan assembly is not needed, may have a first downrod and second downrod longer than the first, adjustable and non-adjustable length canopies, and a structure mount. In another configuration, the ceiling fan kit can include just an adjustable length canopy, which is extendable between a retracted and an extended length, and the shorter downrod, which kit would be suitable for a low-profile mount. In such a configuration, the adjustable length canopy may comprise telescoping segments. The adjustable length canopy may have an extended length that is greater than the length of the shorter downrod.
Any of the kit configurations may further include a downrod coupler to retain a first end of either downrod to the structure mount. The downrod coupler may comprise a ball, mounting a first end of either downrod. The structure mount may be configured to mount to a structure and further comprise a mounting bracket to retain the ball.
Any of the kit configurations may further comprise a fan motor assembly to securely mount to a second end of the either downrod, opposite of the first end. The fan motor assembly may comprise at least one fan blade configured to mount to the fan motor.
The method of mounting the ceiling fan kit, consists of steps comprising selecting a downrod from at least a first downrod and a second downrod being longer than the first, selecting either an adjustable length canopy or nonadjustable length canopy based upon selection of the downrod, mounting the selected downrod to a downrod coupler, positioning the selected canopy about the selected downrod, and mounting the downrod to a fan assembly. The aforementioned method is but one method for mounting the ceiling fan kit, and has natural variations comprising steps in varying orders or combinations, or including additional steps.
In one variation, the method may comprise selecting the adjustable length canopy when the selected downrod is the first downrod. In another, the method may comprise selecting the non-adjustable length canopy when the selected downrod is the second downrod.
In a further variation, the method may comprise securing the downrod coupler to a structure mount. Securing the downrod to a structure mount may comprise placing a ball on the downrod coupler and within a complementary seat in the structure mount. The method may further comprise securing the selected canopy to the structure mount.
In another variation where the selected canopy is the adjustable length canopy, the method may further comprise extending the length of the canopy after securing the downrod coupler to the structure mount. Extending the length of the canopy may comprise extending telescoping segments of the adjustable length canopy. The adjustable length canopy can be secured to the structure mount after extending the length.
In yet another separate variation, where the non-adjustable length canopy is selected, the non-adjustable length canopy can be slid along the selected downrod until a portion of the non-adjustable length canopy is adjacent to the structure mount. Further, the non-adjustable length canopy can be secured to the structure mount.
As may be appreciated, this ceiling fan kit and method of mounting thereof solves problems associated with installing a ceiling fan designed for a specific ceiling height on another ceiling height. Additionally, an installer wishing to move a ceiling fan from one ceiling to another will be able to do so quickly and efficiently, regardless of differences among ceiling heights or designs. Having multiple selectable downrods as well as complementary canopies gives the installer options for different ceiling types rather than a single ceiling type.
Additionally, problems associated with using a non-adjustable canopy in a low profile environment are solved utilizing an adjustable length canopy, enabling easy internal electrical or mechanical connections to be made without interference from the canopy. The adjustable length canopy enables an installer to extend or retract the canopy for installation purposes, such as mechanical or electrical connections, while maintaining an aesthetically pleasing cover over the structure mount, ceiling hole, and electrical box after installation.
It should be understood that as used herein the term “ceiling” of a structure is intended to include not only the conventional ceiling of a building or house, but also any other structure, which can support a ceiling fan such as an exposed beam, post, or the like.
While the invention has been described in connection with certain specific embodiments thereof, it is to be understood that this is by way of illustration and not of limitation. Reasonable variation and modification are possible within the scope of the forgoing disclosure and drawings without departing from the spirit of the invention, which is defined in the appended claims.
