Patent Grant
8210824
This invention relates to fans, in particular to devices, apparatus, and methods of providing, modular drum fan that can be separately shipped and easily assembled and dissembled by a distributor and/or by an end user.
Drum fans have become popular in recent years for a wide variety of usages. Typically, drum fans that are manufactured overseas are currently shipped in either a fully assembled or partially assembled configuration. With drum fans ranging from approximately twenty four (24″) to approximately (60″) inches in diameter, the large assembled or partially assembled units require large containers such as rectangular boxes for each of the drum fans.
The large rectangular boxes often have empty space that can take up to approximately 50 to approximately 75 percent of the box. Also, the empty space often needs to have additional packing materials such as but not limited to foam, bubble wrap, and the like. The large amounts of packing space results in fewer units per container and higher shipping cost per unit. This has made manufacturing drum fans overseas at a disadvantage when competing with local competitors.
The problem of requiring extra large packaging containers discussed above occurs again when drum fans needs to be reboxed, stored and/or moved to other locations. Just storing the large oblong drum fans is difficult if a large storage box is not found. Storing the drum fans without a storage container is also not desirable since the unprotected drum fan can become damaged and destroyed if not properly reboxed. Furthermore, the large containers used to hold the drum fans take up extra valuable space for storage as well as take up the valuable space that is needed when the repackaged drum fans are being moved to other locations.
Thus, the need exists for solutions to the above problems.
A primary objective of the present invention is to provide devices, apparatus, and methods of assembling, dissembling and re-assembling modular components into a drum fan by a retailers and/or distributors and/or and end users.
A secondary objective of the present invention is to provide devices, apparatus, and methods of packaging and shipping modular components of a drum fan in packaging containers that can significantly reduce packaging sizes from about 50% to about 75% less than current shipping containers.
A third objective of the present invention is to provide devices, apparatus, and methods of providing modular components that can be easy to be assembled for any size drum fan ranging from about 24″ in diameter to approximately 60″ in diameter or more.
A preferred embodiment of the knock-down drum fan, can include a cylindrical shroud housing having a plurality of identical curved members that attach to one another end to end to form the cylindrical shroud, a front grill having a plurality of identical generally triangular shaped members that together form the front grill, fan blades having a plurality of identical blade members that together form the fan blades, a rear grill having a plurality of identical generally triangular shaped members that together form the rear grill, a hub for supporting fan blades within the cylindrical shroud housing between the front grill and the rear grill, a motor inside of the cylindrical shroud housing for rotating the blades, a front cap for covering a central opening in the front grill, and wheels attached beneath the cylindrical shroud for allowing the drum fan to be mobile, wherein the drum fan is assembled from shroud housing, the front cap, the front grill, the rear grill, the hub, the fan blades, the motor, the back grill and the wheels.
The shroud housing can consist essentially of four identical shroud members that assembled together form the cylindrical shroud housing. Both the front grill and the rear grill can each consist essentially of four equal shaped grill members, the members being generally triangular and pie shaped.
The shroud housing can also consist essentially of six identical shroud members that assembled together form the cylindrical shroud housing. Both the front grill and the rear grill can each consist essentially of six equal shaped grill members.
Each of the identical generally triangular shaped members of the front grill and the rear grill attach can be attached to the cylindrical shroud housing with interconnecting members that allow the front grill and the rear grill to snap into place within the identical shroud members.
Additionally, each of the identical generally triangular shaped members of the front grill and the rear grill attach can be attached to the cylindrical shroud housing with overlapping curved connecting members that allow the front grill and the rear grill to be held into place within the identical shroud members.
Additionally, each of the identical generally triangular shaped members of the front grill and the rear grill attach can be attached to the cylindrical shroud housing with connecting members that connect together with threaded fasteners to allow the front grill and the rear grill to be held into place within the identical shroud members.
The knock-down drum fan can also include a plurality of handles attached to upper portions of the identical shroud members. The knock-down drum fan can also include a plurality of front external brace members adjacent to sides of each of the identical grill members, for holding the front grill together, the plurality of front external brace members being identical in number to the plurality of the front grill members, and a plurality of rear external brace members adjacent to sides of each of the identical grill members, for holding the rear grill together, the plurality of rear external brace numbers being identical in number to the plurality of rear grill members.
The blades can include identical blade members, where the blades can also nest with one another when not being used.
A method of knocking down a drum fan into a compact disassembled drum, can include the steps of nesting identical curved housing shroud members of the disassembled drum fan together in a stacked arrangement, nesting together identical drum fan blades together, separating a front grill into plural identical parts, separating a rear grill into plural identical parts, separating a motor and a hub, compacting the stacked curved housing shroud members with the nested identical drum fan blades and the separated front and rear grill parts and separated motor and hub into a space that is approximately 50 to approximately 75 percent smaller than space needed for an assembled drum fan.
The identical curved housing shroud members, the plural identical front grill parts and the plural identical rear grill parts, can each include four identical curved shroud members, four identical pie shaped front grill members, and four identical pie shaped rear grill members.
The identical curved housing shroud members, the plural identical front grill parts and the plural identical rear grill parts, can each include six identical curved shroud members, six identical pie shaped front grill members, six identical pie shaped rear grill members.
As an additional safety measure, pliable and bendable fasteners, such as plastic tie wraps, and/or other, bendable and pliable wires, strings, and other materials can be used to further attach each of the front grill members/components to each other and/or to other parts of the drum fan, such as the shroud cover, braces, and other structural supports.
The method can include assembling the identical curved housing shroud members into a cylinder shaped outer housing. Methods of assembling the modular components can be easily accomplished by distributors, retailers, and/or end users.
Further objects and advantages of this invention will be apparent from the following detailed description of the presently preferred embodiments which are illustrated schematically in the accompanying drawings.
Before explaining the disclosed embodiments of the present invention in detail it is to be understood that the invention is not limited in its applications to the details of the particular arrangements shown since the invention is capable of other embodiments. Also, the terminology used herein is for the purpose of description and not of limitation.
A listing description of the components will now be described.
Referring to
The front grill 30 can be assembled from four identically shaped grill members 30A, 30B, 30C and 30D, (two are shown in
A center cap 20 having an outer side 22 (that functions as a front grill cap cover) holds the grill 30 together in the center by snapping into place using a backplate 28. The cap 20 surrounds the center ring of the grill and goes through the first two rings then snapping into the back plate 28.
To be assembled, each of the four equal pie shaped grill members 30A-30D with one male and one female connector snap each other into place, forming a disc shape. The Grill 30 can then fold slightly connecting into the outer ring portions 12 of each of the four separate shroud members 10A-10D, and can be held in place by braces 40.
Referring to
Two handles 50A, 50B held into place with fasteners 60 such as screws, which attach through the top of the shroud 10. The screw holes 13 are in the same location as the leg 140 and the Wheel Brace 110.
Other fasteners 60 such as bolts, screws, nuts, and the like, can be used to hold the braces 40 to the shroud 10, as well as assemble other components to one another.
The fan blades 70 can include four equal blades 70A, 70B, 70C and 70D that each can fold into each other with an offset. Blades have the ability to nest together with a moveable hub 80C, 80B for packaging. The blades 70A, 70B, 70C and 70D can also be taken off for packaging if necessary.
A hub 80 can be used to hold the blades 70 with three bolts. The Hub 80M has a moveable feature on offset arms 80C that nest beneath the other two arms. The drum fan 1 can include a motor 90 such as approximately ½ for smaller fans up to approximately 1 horsepower motor for larger fans.
The back grill 100 can be formed from four equal pie shaped members 100A, 100B, 100C and 100D that each have male and female holes and inserts that hold the grill together similar to the front grill components 30. The back grill 100 can be then held into place by fasteners 60, such as screws that enter through the holes and into the back of the shroud 10. The back grill 100 can have inserts on the back to hold the motor 90. The motor 90 will help to hold the structure of the Grill together.
The wheel brace 110 can be attached to the shroud 10 with bolt holes in the same location as the handle 50A, 50B and the Front Leg 140. Wheel brace 110 has a center hole that holds the shaft for the wheels. The wheels 120 can include a pair of wheels 120A, 120B connected by a shaft 122 with center ball bearing to a mount 126. Each of the wheels can include solid rubber tires for an extended life.
A motor shaft 130 connects the motor 90 to the shroud 10, and the shaft 130 can be placed in the motor 90 for shipping. The motor shaft 130 has a connector that houses the Hub 80 for break down capability.
The front leg 140 mimics the shape of the shroud 10 held into place with the same holes as the handle 50A, 50B and the Wheel Brace 110. The front leg 140 is used to hold the assembled fan 1 in place on a floor surface and to balance the assembled Fan.
As an additional safety measure a plurality of additional flexible and pliable fasteners such as plastic tie wraps 700(
Referring to
The novel modular configuration of the knock down drum fan can significantly reduce packaging size from to approximately 50 to approximately 75% less than current drum fan products. The modular constructed knock down drum fan is easy to re-assemble, because of its' modular components. The knock down drum fan modular components can be applied to any size drum fan from less than approximately 24″ to approximately 60″ and larger in diameter.
Referring to
Hub 280 can have a motor 290 built inside (not shown), and have a main hub with non-rotatable portion 280M with outer circumferential grooves 285, a rotatable hub portion 280R with protruding rotatable axle pin 280P, and hub cap 280C. The internal hub braces 260(260A, 260B, 260C, 260D) support and attach the four outer shroud members 210(210A, 210B, 210C, 210D) to the internal hub 280. Each of the internal hub braces 260(260A, 260B, 260C, 260D), can include an outer end with raised ridge member 262 that can snap in or slide within a pair of internal facing raised flanges 215 on each of the shroud members 210A-210D. The raised ridge members 262 can have enlarged heads that can also be gripped by sliding through ends of internal facing parallel flanges 215 that have gripping edges that wrap about the enlarged heads of the raised ridge members 262, or alternatively, snap into the flanges 215.
Each of the internal hub braces 260(260A, 260B, 260C, 260D), can include an inner arc portion 265 that can fit within and wrap about the outer circumferential grooves 285 of the hub 280. Each of the inner arc portions 265 of the four internal hub braces 260(260A, 260B, 260C, 260D), can attach to one another by having male protruding end(s) 266 that fit within, and/or snap into female receptacle end(s) 267, such as the way protruding tips 262 attach into flanges 215. Similarly, each of the connection points 262, 268 can be further locked together by extra fasteners, such as screws, bolts, and the like.
The invention can have blades 270 that includes a first blade arm 270A with blade ends 272, 278, and a second blade arm 270B with blade ends 272, 278. Each of the blade arms 270A, 270B, and have an central portion plate portion 274 with through-hole 275 that allows the blade arms to be tightly sandwiched together at the central plate portion, where the through-hole 275 fits over the pin axle 280P of the hub 280. The cap 280C can lock the blades 270A, 270B to the hub 280. When assembled, the blade ends 272, 278 on each of the blade arms 270A, 270B form four blades 272, 278 on each blade arm 270A, 270B equi-distant from one another.
The front grill 230 can be formed from four identical arc shaped grill members 230A, 230B, 230C, 230D, each having side ends perpendicular to one another, so that the ends of each arc grill member to hook one another to form a disc shape. Each of the side ends can have rounded (curved edges) that allow the grill members to overlap and hook to one another. Alternatively, the arc shaped grill members can attach to one another by the interconnecting male and female connector ends, and other types of connections similar to that described in the previous embodiment. Front grill braces 240(240A, 240B, 240C, 240D) can be located outside and over the connection points of grill members 230(230A, 230B, 230C, 230D) to cover the hook connection points on the grill members. Each of the grill braces 240(240A, 240B, 240C, 240D) can have an inner facing end with male protruding tip 242 that fits within a circumferential groove 225 about front grill cap 220, and an outer bent hook end 248 that wraps about side raised edges 213 of the shroud members 210.
The back/rear grill 300 can be formed from four identical arc shaped grill members 300A, 300B, 300C, 300D, each having side ends with exteriors generally perpendicular to one another, so that the ends of each arc grill member hook one another to form a disc shape. Each of the side ends can have rounded (curved edges) that allow the grill members to overlap and hook to one another. Alternatively, the arc shaped grill members can attach to one another by the interconnecting male and female connector ends, and other types of connections similar to that described in the previous embodiment. Rear/back grill braces 340(340A, 340B, 340C, 340D) can be located outside and over the connection points of grill members 300(300A, 300B, 300C, 300D) to cover the hook connection points on the grill members. Each of the grill braces 340(340A, 340B, 340C, 340D) can have an inner facing end with male protruding tip 342 that fits within a circumferential groove 229 about rear/back grill ring 228, and an outer bent hook end 348 that wraps about side raised edges 217 of the shroud members 210.
The invention can have two handles 250(250A, 250B) that can be pre-attached by fasteners (such as but not limited to screws, bolts, and the like) to the outside of shroud members 210A, 210B.
Wheels 320 can be attached to the lower rear shroud member 210C by wheel braces 310. Two wheels 320A, 320B can be attached by axle fasteners (not shown) to outer flange ends of U-shaped braces 310A, 310B. Each of the braces 310A, 310B can be attached to an exterior lower portion of shroud member 210C by fasteners, such as but not limited to screws, bolts, and the like. The two wheels 320A, 320B can be spaced apart to add stability to the assembled drum fan 1. A single front leg 350 having a generally U shape can have bent ends 352 attached to a lower exterior portion of shroud member 210D by fasteners, such as but not limited to screws, bolts, and the like. A lower end portion 355 can have a flat end with or without a rubber/elastomer tip 357.
As an additional safety measure, a plurality of additional flexible and pliable fasteners such as plastic tie wraps 700(
Referring to
The front grill 430 can include six identical arc shaped grill members 430A, 430B, 430C, 430D, 430E and 430F each having side ends perpendicular to one another, so that the ends of each arc grill member abut to one another. The grill members 430(430A-430F) each having inner arc ends 432 and outer flat arc ends 438 with a series of holes 439 therethrough. Each of the grill members 430(430A-430F) can be held in place by being fastened to front side bent edges 413 on each of the respective shroud members 410A-410F by fasteners, such as but not limited to screws, bolts, and the like. The inner ends 432 of each of the grill members 430(430A-430F) can be held in place by similarly being fastened to a flat shaped ring (not shown) with holes by similar types of fasteners.
Alternatively, each of the side ends can have rounded (curved edges) that allow the grill members to overlap and hook to one another such as those described in the previous embodiments. Alternatively, the arc shaped grill members can attach to one another by the interconnecting male and female connector ends, and other types of connections similar to that described in the previous embodiment.
The back/rear grill 500 can be formed from six identical arc shaped grill members 500A, 500B, 500C, 500D, 500E and 500F each having side ends perpendicular to one another, so that the ends of each arc grill member abut to one another. The grill members 500(500A-500F) each having inner arc ends 532 and outer flat arc ends 538 with a series of holes 509 therethrough. Each of the grill members 500(500A-500F) can be held in place by being fastened to rear side bent edges 417 on each of the respective shroud members 410A-410F by fasteners, such as but not limited to screws, bolts, and the like. The inner ends 502 of each of the grill members 500(500A-500F) can be held in place by similarly being fastened to a flat shaped ring (not shown) with holes by similar types of fasteners.
As an additional safety measure, a plurality of additional flexible and pliable fasteners such as plastic tie wraps 700(
Alternatively, each of the side ends can have rounded (curved edges) that allow the grill members to overlap and hook to one another such as those described in the previous embodiments. Alternatively, the arc shaped grill members can attach to one another by the interconnecting male and female connector ends, and other types of connections similar to that described in the previous embodiment.
The invention can have two handles 550(550A, 550B) that can be pre-attached by fasteners (such as but not limited to screws, bolts, and the like) to the outside of shroud members 410B, 410C.
As previously described, the main components (front grill, rear grill, hub housing) can each be broken down into separate modular components that can be assembled by the distributor and/or the end user.
Although, the additional flexible and pliable fasteners described in each of the above embodiments references plastic tie wraps as a preferred fastener, other types of pliable, flexible and bendable fasteners, may be used. For example, bendable and pliable wires, strings, and other materials can be used to further attach each of the front grill and rear grill members/components to each other and/or to other parts of the drum fan.
The various embodiments of the knock down drum fan can be used to form drum fans having fan diameters of any size drum fan from approximately 24″, 36″, and 42″ up to approximately 60″ in diameter. The novel modular components can allow for easy break down and followup assembly by any user.
While the invention has been described, disclosed, illustrated and shown in various terms of certain embodiments or modifications which it has presumed in practice, the scope of the invention is not intended to be, nor should it be deemed to be, limited thereby and such other modifications or embodiments as may be suggested by the teachings herein are particularly reserved especially as they fall within the breadth and scope of the claims here appended.
This invention claims the benefit of priority to U.S. Provisional Patent Application Ser. No. 60/954,664 filed Aug. 8, 2007.
| Number | Name | Date | Kind |
|---|---|---|---|
| 2794509 | Mix | Jun 1957 | A |
| 3284021 | Ryll et al. | Nov 1966 | A |
| 5441391 | Frost et al. | Aug 1995 | A |
| 5944488 | Matson | Aug 1999 | A |
| 6213716 | Bucher et al. | Apr 2001 | B1 |
| D480466 | Bucher et al. | Oct 2003 | S |
| D482770 | Bucher et al. | Nov 2003 | S |
| D529165 | Bucher et al. | Sep 2006 | S |
| D531718 | Bucher et al. | Nov 2006 | S |
| 20050271516 | Chang et al. | Dec 2005 | A1 |
| Number | Date | Country | |
|---|---|---|---|
| 60954664 | Aug 2007 | US |
