Patent Application
20110305571
The present invention relates to ceiling fans in general and specifically to a method and an article to protect not only the fan blades but also the entire fan assembly, including the motor and, if any, a lighting fixture.
Although ceiling fans (sometimes-referred to as overhead fans) have been known since the late 1800s, see U.S. Pat. No. 564,455, they have only recently become popular for outside use. Many problems exist for outside versus inside use. The main problem concerns the effect that the elements, e.g. moisture, rain, snow, wind, dust and the like have on the components of the fan. The elements can cause damage to the electrical and mechanical components of the fan including, most importantly, the motor. In addition, it is not only extreme natural conditions such as rain and windstorms but also the mere presence of moisture, lighter winds and dust can cause damage to the internal and external parts of the fan.
These damaging conditions can be especially troublesome when outdoor use is suspended because of seasonal use restrictions such as the closing of outdoor eating areas during cold Michigan, USA winters. Severe damage can be caused by snow, ice, wind, rain and the like. Damage is also caused by severe storms, such as hurricanes in the southern United States and dust storms such as found in Egypt and in the southern United States. Excessive free spinning of the fan blades can damage the stator, rotor, and bearings of the fan motor. This free spinning can also potentially compromise the installation and cause the fan to break away from its mount.
Attempts to resolve some these problems have focused primarily on building motors that are more rugged and sealing the motors from the elements such as moisture, using rubber sealants, o-rings, compression fittings and film wrappings. U.S. Pat. No. 5,507,619 illustrates attempts to provide water resistance for motors. It has even been suggested to manufacture outdoor overhead fans from materials like, stainless steel, titanium, and aluminum. These attempts have been somewhat successful but at the expense of driving up the cost of outdoor overheads fans. In fact, some fans are even water rated. These efforts however do not address all of the problems with using overhead fans outdoors.
The invention taught herein is directed to a simple, inexpensive method and article that address all of the problems associated with the use of outdoor overhead fans without having to change the basic design of the fan. The invention is also useful for protecting ceiling fans located indoors for example when painting, sanding and washing walls and ceilings.
The invention is an article that can be easily used to cover and protect overhead fans, including the motor, blades, and a lighting fixture, if present on the fan. The cover can be comprised of a flexible sheet like material that is easily placed on and removed from the fan and thus can be used even for short periods such as overnight or when a sudden storm comes up. When the cover is formed of a flexible material it can be easily folded or rolled up for storage. Alternative designs such as clamshell designs will permit the use of stronger less flexible materials such as molded plastics and the like. With slight variations in its design and size, such as diameter and the like, the invention is usable on all standard ceiling fans. Most overhead fans have blade lengths ranging from about thirty-six to fifty-two inches.
The diameter of the arc inscribed when the fan is rotating can vary depending on the size of the motor, the length of the blades and the manner of attaching the blades to the rotor. They usually have three, four, or five blades but may contain more. The blades also vary in width depending on the particular manufacturer. The invention can be adapted to work with all standard ceiling fans.
Embodiments or variations are now described by way of example with reference to the accompanying drawings. Objects, features, and advantages of inventive matter disclosed herein may be better understood by referring to the following description in conjunction with the drawings, in which the numerals indicate like structural elements and features in the various figures. The drawings are not meant to limit the scope of the invention. For clarity, not every element may be labeled in every figure. The drawings are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the invention.
In one embodiment the cover 20 is constructed of a material that is sufficiently flexible that it can be easily fit on an overhead fan and can be removed and rolled or folded for storing. Cotton and synthetic cloth, woven or unwoven, are suitable. Preferably, the material is water-resistant or water proof. If the material of construction of the cover 20 is essentially waterproof it is preferred that the cover 20 contain air vents such as shown in the figures as component number 24. The vent can be composed of a material that permits moisture that should happen to gather inside the cover to escape. The vents can be located on the top or bottom portion of the cover depending on the material used in the vent. If the vents are composed of a material that is water resistant, but also breathable, they can be placed on the top and or bottom portion of the cover. It is preferred to manufacture the cover or at least portions thereof (such as the vents) from a material that is water resistance but also breathable. Fabrics sold under the trade names Rhino-weave, Tron-weve and Raintite are examples of suitable fabrics. Plastic coated cotton and canvas are suitable. Polyvinyl chloride coated fabrics are further examples of suitable materials. Flexible plastic sheets such as polyvinyl chloride, polyethylene, and polycarbonate are also useful. When plastics are used it is preferred that they be laminated to a soft inner fabric such as fleece or cotton so as not to scratch the surface of the parts of the ceiling fan. Polypropylene fabrics such as described in U.S. Pat. No. 6,342,456 are especially useful. Fiberglass cloth is also useful. If a clamshell construction is used as shown in
The cover 20 is made employing any suitable process. If made from a fabric, panels of fabric can be cut to form a generally circular form and sewed together around the perimeter to form the disc shape cover 20. The two sections are then cut so that the top portion has an opening that equals the length of the radius of the circle and the bottom side is cut sufficiently across to permit the cover to be pulled over the fan. If desired, the bottom can be cut completely across, as shown in the FIGs. The two cuts match one another so that a closing means 22, such as a zipper can be installed to close the cover over a ceiling fan. The joined sections are then turned inside out so that the top and bottom outsides are now inside. This method places the seam around the perimeter on the inside. This improves the appearance and the water resistance of the cover. Preferably, the seams are waterproofed. Another process for manufacturing the cover is taught in the EXAMPLE. If the cover is constructed from a plastic, the seams can be glued or heat welded using techniques known in the art. The diameter of the cover 20 can be varied to match closely the diameter of the arc inscribed by the fan blades when in motion. The diameter of the cover is preferably just slightly larger than the inscribed arc. If the cover is much larger than the arc inscribed by the blades, the cover will tend to flap in heavy winds and may have a damaging effect on the ceiling fan. It will be readily apparent that other means of constructing the cover can be employed as well as other shapes. For example, the top and bottom portions may each be cut into two semi-circles and then the top and bottom portions are joined together at the perimeter except at one of the points where the closing means is to be placed. The two semicircles forming the bottom are left unattached. Only one half of the top two semicircles are attached together such as by sewing thus providing the required opening to attach the closing means 22. In another embodiment, a clamshell construction can be used. In the embodiment shown in
The closing means 22 can be made from any of a variety of systems. For example, zippers, simple ties, button and eye or button and loop, hoop and loop strips such as made under the trade name Velcro, or snaps can be employed. For covers constructed of flexible materials the closing means preferably comprises a one or two-way zipper mechanism. “Two-way” means that there are two zipper pulls and thus the cover can be closed by zippering from the top to bottom or from the bottom to top or a combination thereof. Preferably, the cover also contains as an option a storm flap 30 as shown in
The cover 20 can be further modified to make it even more stable in windy conditions.
To provide further protection against the elements the cover can be provided with a storm flap that covers the closing mean 22, such a zipper. This embodiment is shown in
As previously discussed
A fan cover was made having a diameter of approximately 56 inches. It was made from breathable, waterproof fabric made by Kimberly Clark. Four semicircles, having the same dimensions, of material were prepared. Two of the semicircles were cut from the fabric and two were made from sections cut from the fabric and sewn on a commercial Mitsubishi sewing machine using number 92 nylon threads to make the other two semicircles. Thus, a potion of the cover contained seams resulting from piecing sections of the cloth together to form the semicircle. Two of the semicircles of the fabric were then sewn around their perimeter and likewise with the other two half circles to form portions of the top and bottom of the cover. An 84-inch plastic one-way zipper was then sewn onto the straight edges of each semicircle with the zipper closing at the length of the radius (26 inches) of the top half of the cover. Finally, the open radius length (26 inches) of the two semicircles not containing the zipper were sewn together and the assembled piece was turned inside out so that the seams did not show. An 18 by 1 inch hook and loop strip (hooks on one side and loops on the other) was then sewn to the top of the cover at the end of the seam on the top side where the zipper ended. One elastic gathering band was also sewn to opposite sides of the inside of the cover using the top seam and one side of the seam on the bottom potion formed when placing the zipper, as attachment points. The cover was easily placed over a 52-inch blade Hunter brand ceiling fan and zippered closed. The hoop and loop strap was wound around the suspending rod of the fan to provide a tight fit. The cover could also be easily removed.
Other modifications can be made to the embodiments described herein without departing from the principles of the invention.
This application claims the benefits of the filing date of U.S. Provisional Application No. 61/269, filed Jul. 1, 2009, the provisional being incorporated herein by reference.
