Patent Application
20080107529
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.
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.
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.
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.
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.
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.
With reference to the drawings in which like parts have like reference numerals,
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.
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.
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
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.
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.
The skeleton 10a illustrated in
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.
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.
