Ceiling fan assembly

Abstract

A blade for a ceiling fan can include a first half and a second half formed of a pulp material. The first half can be attached to the second half to form the blade. Additionally, the blade can include a skeleton having an overmold made of the pulp that forms the blade. Further, the blade base can be used to form the blade with a pulp top cap added to the blade to form an aerodynamic shape for the blade.

Description

Technical Field

[0001] This application relates to a ceiling fan assembly. Background Technology

[0002] Traditionally, ceiling fans consist of a set of blades rotatably coupled to a motor assembly to rotate the blades. The rotation of the blades drives a volume of fluid, typically ambient air in a room, space, or area.

[0003] Ceiling fan blades typically feature a flat bottom, offering consumers a classic ceiling fan style. However, flat blades are slightly less aerodynamically efficient compared to other aerodynamic blade shapes. Summary of the Invention

[0004] In one aspect, this disclosure relates to a ceiling fan comprising: a mounting member coupled to a structure; a lower rod suspending the ceiling fan from the mounting member; a motor suspended from the lower rod opposite the mounting member; and ceiling fan blades operatively coupled to the motor, wherein the ceiling fan blades are at least partially formed from molded pulp.

[0005] In another aspect, this disclosure relates to a ceiling fan component comprising: a mounting member coupled to a structure; a lower rod suspending the ceiling fan from the mounting member; a motor suspended from the lower rod opposite the mounting member; and a body at least partially made of molded pulp and coupled to at least one of the mounting member, the lower rod, or the motor. Attached Figure Description

[0006] In the attached diagram:

[0007] Figure 1 This is a partial schematic diagram of a ceiling fan with a set of blades suspended from the structure.

[0008] Figure 2 yes Figure 1 A view of a blade in the group of blades, the blade including an upper half separate from the lower half.

[0009] Figure 3 yes Figure 2 A view of an alternative arrangement of blades, wherein the upper and lower halves are connected by a hinge.

[0010] Figure 4 It is used for Figure 1 A view of another alternative arrangement of the blades in this set of blades, which includes a skeleton.

[0011] Figure 5 It is along Figure 4 The section VV cut Figure 4 A cross-sectional view of the skeleton, showing the ribs used in the skeleton.

[0012] Figure 6 It is set in Figure 4 A top view of the overmolded parts on the skeleton.

[0013] Figure 7 yes Figure 6 Cross-sectional views of the skeleton and the overmolded part.

[0014] Figure 8 yes Figure 1 An exploded view of another alternative arrangement of blades in this group of blades, the blade including a top cap coupled to the top surface of the blade base.

[0015] Figure 9 yes Figure 8 An assembly diagram of the blades.

[0016] Figure 10 yes Figure 9 A cross-sectional view of the blade shows the cable ring design for the top cover extending into the base of the blade.

[0017] Figure 11 It is used for Figure 1 A view of another alternative blade to the same set of blades, the alternative blade including a wireframe.

[0018] Figure 12 It is used for Figure 1 The view shows another alternative blade to the set of blades, which has a blade mount, a foam core, and a cover.

[0019] Figure 13 This is a flowchart illustrating a method for forming blades for a ceiling fan. Detailed Implementation

[0020] The disclosure herein relates to pulp ceiling fan blades and molded pulp ceiling fan blades. A pulp ceiling fan blade can be a ceiling fan blade made at least partially of pulp. A molded pulp ceiling fan blade can be any ceiling fan blade made of pulp, wherein pulp is formed and then molded into a desired ceiling fan blade shape or a portion thereof. Therefore, unlike cutting a product from a given volume of material formed of pulp, a molded pulp product must be formed by shaping or molding the pulp. More specifically, a molded pulp ceiling fan blade can be made from a slurry or unit of pulp, which is then compressed, stamped, molded, or otherwise shaped into a desired ceiling fan blade shape or a portion thereof. Thus, it should be understood that a molded pulp product or a molded pulp ceiling fan blade differs from a product formed from a combination of fibers and an adhesive to form a sheet or board, which is then cut to a desired size, shape, or dimensions.

[0021] The disclosure provided herein relates to blades, and more specifically, to blades for ceiling fans or other air-moving devices used to generate airflow, typically for localized cooling, heating, or air conditioning. The blades described herein relate to blades formed at least partially from a volume of pulp, such that at least a portion of the blade is made of pulp, thereby providing reduced cost, weight, and environmental impact, among other benefits. It should be understood that other ceiling fan elements, components, or parts are contemplated to be made of pulp, including but not limited to blades, blade irons, motor housings, switch housings, lighting kit fixtures or housings, motor adapters, lower rods, cover parts, or mounting parts. Although the description herein specifically pertains to ceiling fan blades, it should be understood that pulp ceiling fan elements can be applied to any suitable ceiling fan component.

[0022] As generally described herein, “pulp” can be defined as a material used to form, manufacture, or otherwise produce molded pulp products (MPPs). MPPs can include, but are not limited to, thermoformed molded pulp products, pulse-dried pulp products, and other types of forming or molding, such as pulp compression, are contemplated. Pulp may also include fibers typically formed by wetting or moistening, forming, and then shaping and drying to produce the final product. In non-limiting examples, such pulps or molded pulp products may, but do not need to, include wood fibers or other cellulose, other plant-based fibers, or paper. Additionally, it is contemplated that components such as chemical ingredients may be added to the pulp or pulp mixture to impart performance properties, such as improved efficiency. Such examples of MPPs can be found in U.S. Patent No. 9,856,608, which is incorporated herein by reference in its entirety. The most common known types of MPPs are water dispenser carriers, egg cartons, or other service trays or food containers, while there is an increase in industrial packaging or disposable items formed from molded pulps, particularly those involving the use of recycled paper products. Additionally, alternative materials for pulp or molded pulp products may include foam, such as polystyrene in one non-limiting example, which can replace pulp in forming products and fan blades as described herein, as well as other pulp alternatives, including foam, plastics or other suitable materials.

[0023] As used herein, the term "group" or a "group" of elements can be any number of elements, including only one.

[0024] All directional references (e.g., radial, axial, proximal, distal, up, down, upward, downward, left, right, lateral, front, rear, top, bottom, above, below, vertical, horizontal, clockwise, counterclockwise, upstream, downstream, forward, backward, etc.) are used for identification purposes only to aid the reader in understanding this disclosure and do not impose limitations, particularly on the location, orientation, or use of the aspects of this disclosure described herein. Unless otherwise indicated, connection references (e.g., attachment, coupling, connection, and engagement) are to be interpreted broadly and may include intermediate members between sets of elements and relative movement between elements. Thus, a connection reference does not necessarily imply that two elements are directly connected and fixed to each other. Exemplary figures are for illustrative purposes only, and the dimensions, positions, order, and relative sizes reflected in the accompanying figures may vary.

[0025] refer to Figure 1 An exemplary ceiling fan 10 is mounted to the ceiling 12 of structure 14, such as in a residence. Alternatively, in a non-limiting example, the ceiling fan 10 may be mounted or suspended in many environments, such as on a ceiling or wall, in a living space or residence, outdoors or indoors, in an industrial environment such as a manufacturing plant, or in an agricultural environment.

[0026] The ceiling fan 10 includes a mounting bracket 16 that suspends the ceiling fan 10 from and couples the ceiling fan 10 to the ceiling 12. A cover 18 covers the mounting bracket 16. A lower rod 20 is suspended from the mounting bracket 16 by a ball 22. A motor adapter 24 secures the lower rod 20 to the motor 26 via a motor shaft 28 extending from the motor 26. The motor 26 may include a stator 30 mounted to the motor shaft 28 and a rotor 32 rotatably driven about the stator 30. The motor adapter 24 may also be coupled to a motor housing 34 that at least partially surrounds the motor 26. A set of blades 36 couples a set of complementary blades 38 to the rotor 32 for rotating the blades 38 and driving a volume of fluid, such as air, around the structure 14 or a local space therein. A switch housing 48 may be mounted below the motor housing 34 and electrically coupled to the motor 26. A lighting kit 46 may be electrically and mechanically coupled to the switch housing 48.

[0027] It should be understood that, such as Figure 1 The ceiling fan 10 depicted is merely exemplary, and it should be understood that the ceiling fan 10 may include more or fewer components than those shown and described, and such variations among ceiling fan components are within the scope of this description.

[0028] The ceiling fan 10 may be coupled to a power source 40, such as a building power source. The power source 40 may be connected to one or more controllers 42 or switches 44. The controller 42 may be used to receive or transmit information relating to the control and operation of the ceiling fan 10, such as via wired or wireless signals. The switch 44 may be operated to control the ceiling fan 10, such as, for example, a wall-mounted switch. Although the controller 42 and switch 44 are schematically shown outside the ceiling 12, it should be understood that the controller 42 and switch 44 may be optional or may be located in other locations, such as on a wall or ceiling, or within a portion of the ceiling fan 10 itself.

[0029] Despite Figure 1 The ceiling fan shown and described herein is a "standard mount" which includes a mount 16 for suspending the lower rod 20 and from which the motor 26 is suspended; however, it should be understood that any suitable ceiling fan assembly is contemplated. For example, any suitable mount can be used, such as a conventional mount, a "ceiling-mount" mount flush against the ceiling, also known as a low-profile ceiling fan. Additionally, it is contemplated that the ceiling fan may or may not be used with the lower rod suspending the motor assembly. It should be understood that this disclosure is not necessarily limited to specific components of a particular ceiling fan assembly. Similarly, although... Figure 1 The illustration shows the use of blade iron 36, which extends from the rotor to the blades outside the motor housing; however, it should be understood that other blade mounting methods or styles are also contemplated. For example, in a non-limiting example, blades directly mounted to the rotor are contemplated, as well as various types of blade iron or different materials, including but not limited to aluminum, zinc, copper, cast iron, or plastic. Furthermore, the blade iron need not be a conventional blade iron mounted to the rotor and extending outside the motor housing, but can be any suitable component or system that effectively secures the blades to the motor for rotatable drive.

[0030] Go to Figure 2 The blade 50 can be Figure 1 The blade 38 may include a body 52 that can be divided into a first upper half 54 and a second lower half 56. It should be understood that the upper half is shown upside down so that the interior of the first half 54 of the blade 50 is visible, and the upper half 54 and the lower half 56 effectively form two separate halves of a clamshell, which can be substantially coupled together by pivoting the first half 54, as shown, to face the second half 56.

[0031] The blade 50 is shown as having separate halves 54, 56, thus showing the inner surfaces of the two halves 54, 56. The two halves 54, 56 of the blade 50 include a root 58 and a top 60 defining a spanwise direction therebetween, and a first edge 62 and a second edge 64 defining a chordwise direction therebetween. In one example, the first edge 62 may be a leading edge and the second edge 64 may be a trailing edge, while the direction of rotation of the ceiling fan to which the blade 50 is attached may define the leading and trailing edges. Additionally, the blade 50 and its halves 54, 56 may include tapered edges 66 at the junctions between the root 58 and edges 62, 64, and between the top 60 and edges 62, 64. However, it should be understood that any planar shape (top-down shape) of the blade 50 is contemplated, and the shape with tapered edges 66 shown is merely exemplary.

[0032] The first half 54 includes a set of rib receivers 70 and a set of stops 72. The rib receivers 70 are formed as a pair of spaced-apart extensions that can be arranged in a specific pattern along the inner surface 76 of the first half 54. The rib receivers 70 near the root 58 can have a shorter length compared to those further from the root 58. Additionally, the rib receivers 70 near the root 58 can be curved or arcuate and can be angled away from the mounting hole 82. It is evident that some of the rib receivers 70 at the mounting hole 82 extend radially from the mounting hole 82. Further moving from the root 58, some of the rib receivers 70 can be arranged parallel to the leading edge 62 or the trailing edge 64, while others are arranged perpendicular to the leading edge 62 or the trailing edge 64. Furthermore, it should be noted that the specific arrangement, such as curved, parallel, or perpendicular, can vary or be slightly offset; however, any suitable arrangement is conceivable. Similarly, the set of stops 72 can be arranged in a predetermined pattern along the inner surface 76. The stop 72 can be formed as a cylindrical extension extending from the inner surface 76, however, alternative shapes are conceivable.

[0033] The second half 56 includes a set of structural ribs 78 and a stop receiving portion 80. The structural ribs 78 may form an interconnected lattice structure; however, each structural rib 78 is conceivable to be discrete and separate from the other ribs 78. The ribs 78 near the root 58 may be curved or arcuate, complementing the rib receiving portions 70 of the first half 54. The ribs 78 closer to the root 58 may have a greater curvature than those further away from the root 58, and some of the ribs 78 may be arranged parallel or perpendicular to the edges 62, 64, similar to the rib receiving portions. Additionally, some of the ribs 78 may extend radially from one or more of the mounting receiving portions 84.

[0034] The structural ribs 78 can be sized to complement the spacing between each pair of rib receivers 70 and can be arranged to complement the pattern of the set of rib receivers 70. This allows attaching the first half 54 to the second half 56, aligning the first half 54 with the second half 56 and securing the first half 54 to the second half 56. In one example, the first half 54 may include an adhesive, such as glue or epoxy resin, disposed between the rib receivers 70 such that when the structural ribs 78 of the second half 56 are inserted between the rib receivers 70 of the first half 54, the adhesive secures the first half 54 to the second half 56. Additionally, it is contemplated that adhesive may be applied to the edges of the two halves 54, 56 of the blade 50 to prevent separation of the halves 54, 56 during fan operation. Alternative attachment methods are contemplated, such as compression or interference fits between the ribs 78 and the rib receivers 70; however, any suitable attachment means or method is contemplated. It is understood that the ends of the structural rib 78 may taper to facilitate varying thicknesses of the blade 50 extending between the first edge 62 and the second edge 64. This taper of the structural rib 78 can, for example, provide an airfoil for the blade 50.

[0035] The dimensions and arrangement of the stop receiver 80 can be designed to complement the stop 72, such that the stop 72 abuts the stop receiver 80 when the first half 54 is connected to the second half 56. This allows the stop 72 to maintain an appropriate spacing and blade thickness between the first half 54 and the second half 56. In one example, the stop receiver 80 can be formed as a raised annular ridge on its inner surface 76, which receives the end of the stop 72, but prevents or inhibits movement of the stop 72 from the stop receiver 80 when the first half 54 is connected to the second half 56.

[0036] Additionally, the first half 54 includes a set of mounting holes 82, and the second half 56 includes a set of complementary mounting receivers 84. The mounting holes 82 can be configured to receive fasteners that pass through the holes 82 and extend into the mounting receivers 84. When the blades 50 are coupled to a ceiling fan motor, the blade iron, such as... Figure 1 The blade iron 36 can be used to couple the blade 50 to the motor for rotating the blade via the mounting hole 82 and the mounting receiver 84. By being completely contained within the blade 50, the mounting receiver 84 can be designed to have a height similar to the thickness of the blade 50 in order to maintain a uniform thickness of the blade 50 and to create an aesthetically pleasing appearance without any aerodynamic disadvantages.

[0037] The blade 50, as described herein, can be made of pulp, or at least partially of pulp. Forming the blade 50 from pulp provides reduced manufacturing costs that can be passed on to consumers. Additionally, pulp can provide blades with reduced weight, which can reduce the energy requirements for operating the fan, thereby lowering operating costs and improving operational efficiency. Furthermore, the pulp can be made from recyclable or biodegradable materials, reducing the environmental impact from the fan, or minimizing the environmental impact of the blade itself. The features described herein provide blades formed partially or entirely of pulp. More specifically, this feature provides structurally sound blades capable of withstanding operating stresses and bending moments. Rib receivers 70, stops 72, structural ribs 78, and stop receivers 80, for example, serve to maintain the shape and structural integrity of the blade 50 during operation. Forming the blade from pulp can make the blade 50 more susceptible to deformation or bending. As described herein, the use of stops and ribs provides blades formed from pulp material while still maintaining the structural integrity required during operation.

[0038] Additionally, blade 50 and any other blades described herein may include an external coating 86. The external coating 86 may be a waterproof material, for example, to prevent water damage to the pulp blade. Furthermore, the external coating 86 may be a material with a reduced coefficient of friction, at least compared to the coefficient of friction of the pulp material of blade 50, thereby improving aerodynamic efficiency compared to blade 50 without the external coating 86. Moreover, the external coating 86 may also be used for coloring or other design aesthetics of blade 50. Furthermore, there may be multiple external coatings, such as one coating for waterproofing the pulp material while another coating is used to color the blade or reduce aerodynamic drag. Therefore, it should be understood that the use of multiple coatings with blades as described herein is contemplated.

[0039] Figure 3 Another blade 150 for use in ceiling fans is depicted. Blade 150 can be used with... Figure 2 The leaves are basically similar to those of type 50, except that... Figure 3 The blade includes a hinge 152 that couples a first half 154 to a second half 156. In one example, the hinge 152 may be a movable hinge such that the first half 154 and the second half 156 are integral, and the first half 154 can be secured to the second half 156 by bending the blade 150 along the movable hinge and attaching the halves 154, 156 to each other. Therefore, it should be understood that the halves 154, 156 as discussed herein can be mounted to each other in various ways, including at a movable hinge where the two halves 154, 156 are integrally or collectively formed and assembled by folding along the movable hinge 152.

[0040] Now for reference Figure 4The blade frame 200 for the ceiling fan blades extends between a root end 202 and a top end 204, and between a first edge 206 and a second edge 208. In a non-limiting example, the frame 200 may be made of stamped metal or molded plastic; however, any suitable material or manufacturing method is contemplated. The frame 200 includes a series of perforations 210 extending along the length of the blade frame 200. The perforations 210 are arranged in three rows 212, each row 212 being separated by ribs 214 extending between the root end 202 and the top end 204. Additional mounting holes 216 may be provided at the root end 202 for securing blade iron to the frame 200, or for securing the frame 200 to a motor for driving the fan blades. It should be understood that the arrangement with ribs 214 and perforations 210 shown is exemplary and may have any suitable configuration, as well as more or fewer elements, including but not limited to ribs, perforations, bulges, extensions, openings, holes, grooves, channels, valleys or any other suitable structure or lack thereof.

[0041] Figure 5 It shows along Figure 4 The cross-sectional view of the blade frame 200 taken by section VV better depicts the shape of the rib 214. The rib 214 may include two circular portions of the frame 200 having a generally circular convex shape extending away from the rest of the frame 200.

[0042] Figure 6 The device includes a blade frame 200 having an overmolded component 220 forming the ceiling fan blades 222. The overmolded component 220 can be made of pulp, as discussed herein; however, it is also conceivable that the overmolded component 220 is another material, such as foam or high-density foam in a non-limiting example. The overmolded component 220 can be shaped into any top-to-bottom form, such as the shape shown, or any conventional ceiling fan blade shape. Additionally, a brief observation is shown... Figure 6 cross-sectional view Figure 7 The overmolded part 220 can be formed in any suitable geometry or 3D (three-dimensional) manner, such as performance edge profiles including curved or otherwise shaped edges, or other profiles such as airfoils. Figure 7 The profile shown offers improved blade performance due to its rounded edge profile, while maintaining the traditional aesthetic of upward-looking ceiling fan blades with flat bottoms.

[0043] The blade 222 provides a structurally robust blade with a frame 200, and is easy and inexpensive to manufacture. For example, the frame 200 can be easily stamped or molded. The overmolded part 220 can then be molded onto the frame 200 to form the final blade 222. The perforations 210 in the frame 200, together with the ribs 214, provide improved adhesion of the overmolded part 220 to the frame 200. In addition, the ribs 214 provide improved attachment of the overmolded part 220 to the frame 200 over time, as the ribs 214 help to support and drive the overmolded part 220 during operation of the ceiling fan.

[0044] refer to Figure 8 An exploded view of another exemplary blade 300 includes a blade base 302 and a top cap 304. The blade base 302 can be a standard ceiling fan blade, such as those conventionally manufactured with a flat top and / or flat bottom. Alternatively, the blade base 302 can be any suitable blade structure to which the top cap 304 can be mounted or coupled. As described herein, the top cap 304 can be made of pulp; however, additional materials such as foam or high-density foam are also contemplated. Any suitable material can be used, although it is preferably lightweight while having high tensile strength to improve overall operating efficiency. The top cap 304 can be coupled to the top surface 306 of the blade base 302. The top cap 304 can be included or shaped to form an aerodynamic profile for the blade when attached to the blade base 302, thereby improving blade efficiency, such as having an airfoil or rounded leading or trailing edge, at least compared to the blade alone as the blade base 302. Additionally, it is envisioned that the top cover 304 may include a blade skeleton (such as in relation to...) Figure 4 The blade skeleton shown in the description) or wireframe (such as the one described below) Figure 11 (The wireframe shown and described).

[0045] Figure 9 It shows Figure 8The complete form of the blade 300 is achieved by attaching a top cap 304 to the blade base 302 to form the complete blade 300. Although the blade is shown as having a diverging-then-converging shape in a chordal direction extending from the root to the top, it should be understood that any blade shape is contemplated, and it may or may not include a blade iron mounting extending from the root of the blade base 302. Additionally, it is contemplated that the top cap 304 may also cover the iron portion of the blade base 302. Although the top cap 304 is described herein as a "top cap," it should be understood that it is not necessarily limited to a top cap in the conventional sense attached to the top of the blade base 302. It should be understood that the top cap 304 can be any suitable pulp element attached to any part of the blade base 302 to give the blade 300 an aerodynamic profile. The aerodynamic profile can be any suitable shape that improves the aerodynamic performance of the blade 300 when added to the top cap 304. Thus, in a non-limiting example, a "top cap" as described herein can be added to the bottom of the blade to improve aerodynamic efficiency.

[0046] refer to Figure 10 A first system for mounting and securing the top cover 404 to the blade base 402 to form a ceiling fan blade 400 may include forming a loop portion 410 integral with the top cover 404 and sized to receive a fastener 406, such as a screw. Although the fastener 406 is shown extending beyond the blade 400 at the bottom, it should be understood that the fastener 406 may be used, for example, to mount the blade 400 to the rest of the ceiling fan via the blade iron to apply rotational movement to the blade 400. The loop portion 410 extends from the rest of the top cover 404 and may be shaped to insert into a hole formed in the blade base 402, such as, for example Figure 2 Mounting hole 82. The integral cable ring design reduces the number of integral parts, thus eliminating the need for additional cable rings. Furthermore, the top cover 404, together with the cable ring portion 410, helps to mitigate any vibrations generated by the blade 400 between the blade base 402 and the top cover 404. In this way, vibrations or blade balance problems that could negatively impact performance can be reduced, minimized, or otherwise mitigated.

[0047] Additionally, the blade base 402 may be shaped to be wider, longer, or both relative to the top cap 404, thereby defining an edge or boundary 412 that completely or partially defines the blade 400. Similarly, the top cap 404 may be shaped to be thinner and shorter than the blade base 402, which can be used to attach the top cap 404 to an existing blade serving as the blade base 402 without extending along the edge of the blade base 402. The boundary 412 provides space for attaching the top cap 404 to the blade base 402. The aerodynamic benefits of the top cap are visible with the boundary 412, while reducing the chance of the top cap 404 extending beyond the blade base 402, thereby reducing the possibility of detachment of the top cap or aerodynamic inefficiency after installation. Furthermore, the boundary 412 serves to prevent the top cap 404 from creating sharp areas on the blade edge.

[0048] refer to Figure 11 Another exemplary blade 500 includes an internal wireframe 502 coupled to a plate 504 (wireframe 502 and plate 504 are shown in dashed lines). In one example, plate 504 may be welded to wireframe 502; however, any suitable attachment method is contemplated. In an additional example, wireframe 502 and plate 504 may be integral or formed as a single structure, such as by casting.

[0049] The exterior of the blade 500 may include a pulp cover 506, with a wire frame 502 and a plate 504 serving as a framework supporting the pulp cover 506. Alternatively, the pulp cover 506 may be foam or other material that covers, encloses, or otherwise attaches to and encapsulates the framework or wire frame 502. A set of mounting holes 508 may be provided in the plate 504 for attaching a blade iron (not shown) to the blade 500 at the plate 504. For example, the plate 504 provides for mounting blade iron (such as...) Figure 1 The blade (iron 36) has a durable attachment point. The wire frame 502 extends along the periphery of the blade 500, where the blade 500 experiences greater forces during the rotational movement of the blade and operation of the ceiling fan.

[0050] A pulp cover 506 formed on the skeleton of wire frame 502 and plate 504 provides a structurally supported blade 500. In a non-limiting example, the blade is lightweight and can be formed with aerodynamic features, such as an airfoil. Lightweight blades with aerodynamic features can provide improved efficiency and reduced operating costs. Furthermore, the pulp cover provides a blade 500 that is, at least compared to ceiling fan blades formed without a pulp cover, largely recyclable or with reduced or minimal environmental impact.

[0051] refer to Figure 12Another blade 600 includes a blade mounting structure 602, such as a skeleton as described herein. The blade mounting structure 602 can be a robust internal structure capable of supporting the blade 600 during rotational operation. In a non-limiting example, the blade mounting structure 602 can be made of stamped metal or molded plastic. Additionally, the blade mounting structure 602 may include a mounting extension 604 comprising a set of mounting holes 606 for attaching the blade 600 to a blade iron or rotor (not shown).

[0052] A core 608 is disposed around the blade mounting structure 602. Compared to a flat blade, the core 608 can be formed with a three-dimensional blade shape, such as having an airfoil suitable for improving blade efficiency and airflow. In one example, the core 608 can be made of foam or other similar lightweight materials, such as open-cell or closed-cell foam.

[0053] Pulp covering 610 may be formed around and cover core 608. Pulp covering 610 can be used to form a blade shape based on core 608, and then the pulp covering core 608 can be used to provide a structurally stable blade. Alternatively, it is contemplated that the pulp covering 610 may be coated with blade coating 612 or colored to decorate the blade, or to improve structural integrity or aerodynamic efficiency using a low-friction surface. In a non-limiting example, blade coating 612 may also be multiple coatings, such as a waterproof coating, a colored coating, or another coating to reduce aerodynamic drag. Therefore, it should be understood that it is contemplated to use numerous coatings for blades as described herein.

[0054] As discussed in this article, the blades offer reduced manufacturing costs, which translates to lower costs for consumers. Additionally, the blades provide improved aerodynamic efficiency, resulting in enhanced operational efficiency and reduced operating costs. Furthermore, the pulp used to form the blades can be made from biodegradable materials, which provides a reduced environmental impact and meets the growing demand in consumer markets that prioritize environmental impact and sustainability.

[0055] refer to Figure 13 The method 700 for forming a leaf may include forming at least a portion of the leaf using pulp at 702. At 704, the method may further include a forming step comprising forming two halves of the leaf from pulp. One or two halves may be formed from pulp. The method may further include attaching the two halves to each other. The two halves may be, for example, formed by... Figure 2Ribs 78 and rib receiving portions 70 are attached. Additionally, it is envisioned that the halves are connected by an integral hinge (such as a movable hinge), which may also be made of pulp material. Furthermore, it is envisioned that method 700 may include discretely forming each half of the blade from pulp, such as using pulp material, such as fibrous pulp, and mixing the pulp with a binder. After mixing, the pulp material with the binder can be compressed, such as within a mold, to form a blade or portion thereof as described herein. In one example, the blade may be heated to cure the binder. It is also envisioned that the formation of the molded blade may be cured by pressure curing or may be dried after manufacturing.

[0056] At 706, method 700 may further include a forming step comprising forming the pulp into a pulp cover disposed on a wire frame, such as Figure 11 The pulp cover 506 is on the wire frame 502. Additionally, plates can be attached to the wire frame to provide further stability for the blades and to provide portions for mounting blade irons to the blades or mounting the blades to the rotor.

[0057] At 708, method 700 may further include forming the blade by using pulp to form an overmolded part disposed on a skeleton to form the blade. For example, the overmolded part may be disposed on a skeleton. Figures 4 to 7 The overmolded part 220 is attached to the skeleton 200. Alternatively, the skeleton can be... Figure 11 The wireframe 502, wherein the overmolded part is formed as a pulp cover 506.

[0058] At point 710, the method may further include the forming steps comprising forming a core on the blade mounting structure and forming a pulp cover on the blade mounting structure. For example, the blade mounting structure may be... Figure 12 The blade mounting structure 602. The core can be... Figure 12 The core is 608, and can be made of foam or another strong but lightweight material. Additionally, Figure 12 The pulp cover 610 can be made of pulp and cover the core 608. Furthermore, it is envisioned that a coating can be applied to the pulp cover for sealing the blades, or for coloring or otherwise decorating the fan.

[0059] At 712, method 700 may further include attaching a top cap formed as pulp to the base of a blade to form a blade. For example, the base blade can be any blade, such as an existing blade having a flat top surface or a flat bottom surface, or both. The top cap can be, for example... Figures 8 to 10The top cover 404, and the blade base may be a blade base 402. Additionally, method 700 may include a top cover forming an aerodynamic shape for the blade that is more efficient than an aerodynamic shape formed only at the blade base. Method 700 may also include a top cover including a loop portion that can be inserted into a mounting hole in the base blade, which helps dampen vibrations between the blade base and the top cover.

[0060] The methods described herein should be considered non-limiting in the order or arrangement described. It should be understood that aspects of the method may be mixed, recombined, reordered, or parts of one method may be combined with other parts of the method.

[0061] The following clauses provide further aspects of the invention:

[0062] A ceiling fan includes: a motor including a rotor; blades coupled to the rotor and rotatably driven by the motor, the blades including: a first portion defining a first inner surface of the blade; and a second portion fixed to the first portion to form a complete body of the blade, wherein the second portion defines a second inner surface of the blade; wherein the blades are at least partially formed of pulp.

[0063] The ceiling fan as described in any of the foregoing clauses, wherein both the first and second portions are formed entirely of paper pulp.

[0064] The ceiling fan according to any of the foregoing terms, wherein the first portion includes a set of ribs extending from the first inner surface.

[0065] According to any of the foregoing provisions, the second part includes a set of rib receivers configured to receive the set of ribs to secure the first part to the second part.

[0066] The ceiling fan as described in any of the foregoing clauses, wherein the first part also includes a set of stops.

[0067] According to any of the foregoing provisions, the second part further includes a set of stop receiving portions configured to receive the set of stops to define the thickness of the blades via the set of stops.

[0068] The ceiling fan according to any of the foregoing clauses, wherein the first part and the second part are connected by a hinge.

[0069] The ceiling fan as described in any of the foregoing clauses, wherein the hinge is a movable hinge formed of pulp.

[0070] The ceiling fan as described in any of the foregoing clauses, wherein the first part includes a set of mounting holes.

[0071] According to any of the foregoing provisions, the second portion includes a set of mounting receivers that are arranged to complement the set of mounting holes when the first portion is engaged with the second portion.

[0072] A blade for a ceiling fan, the blade comprising: a frame; an overmolded part formed around the frame; wherein the overmolded part is formed of pulp.

[0073] The blade according to any of the foregoing clauses, wherein the skeleton includes a set of perforations that facilitate the adhesion of the overmolded part to the skeleton.

[0074] The blade, as described in any of the foregoing clauses, also includes a set of ribs extending along the skeleton.

[0075] The blade according to any of the foregoing provisions, wherein the rib extends along the skeleton from the first end to the second end.

[0076] The blade according to any of the foregoing clauses, wherein the overmolded part surrounds the entire skeleton except for a portion of the root of the skeleton, wherein the portion of the root of the skeleton includes a set of mounting holes.

[0077] The blade according to any of the foregoing provisions, wherein the skeleton comprises a wireframe extending around at least a portion of the periphery of the blade.

[0078] The blade according to any of the foregoing clauses, wherein the skeleton also includes a plate attached to the wireframe.

[0079] The blade according to any of the foregoing provisions also includes a foam core disposed on the skeleton, wherein the overmolded part is disposed on the foam core.

[0080] A blade for a ceiling fan includes: a blade base having an upper surface and a lower surface and extending longitudinally between a root and a top, and extending tangentially between a first edge and a second edge; and a top cover attached to the blade base to form the blade, wherein the top cover is at least partially formed of pulp.

[0081] The blade as described in any of the foregoing clauses, wherein the top cover also includes a cable ring portion.

[0082] The blade according to any of the foregoing provisions, wherein the blade base further includes a mounting hole, and the grommets are inserted into the mounting hole.

[0083] The blade according to any of the foregoing provisions, wherein the chordal width of the top cover is less than the chordal width of the blade base between the first edge and the second edge, such that a peripheral edge is defined along the upper surface of the blade base not covered by the top cover.

[0084] A blade for a ceiling fan includes: a blade mounting structure; a core surrounding and attached to the blade mounting structure; and a pulp cover disposed on the core.

[0085] The blades described in any of the foregoing clauses also include a coating disposed on the pulp cover.

[0086] The blades, as described in any of the foregoing clauses, have a core made of open cell foam.

[0087] The blade according to any of the foregoing provisions, wherein a portion of the blade mounting structure extends from the core and includes a set of mounting holes.

[0088] A method for forming blades for a ceiling fan, the method comprising: forming at least a portion of the blades using pulp.

[0089] The method according to any of the foregoing provisions, wherein the forming step further includes forming two halves of the blade from the pulp.

[0090] The method described under any of the foregoing provisions also includes attaching the two halves to form the blade.

[0091] According to any of the foregoing provisions, the two halves are integral and attached by a common hinge.

[0092] The method according to any of the foregoing provisions, wherein the forming step further includes using the pulp to form an overmolded part on the skeleton to form the blade.

[0093] The method according to any of the foregoing provisions, wherein the forming step further includes attaching a top cover formed from the pulp to the base blade.

[0094] The method according to any of the foregoing provisions, wherein attaching the top cover forms an aerodynamic shape for the blade that is more efficient than the aerodynamic shape of the base blade without the top cover.

[0095] The method described under any of the foregoing clauses also includes using a loop portion integral with the top cover to dampen vibrations.

[0096] The method according to any of the foregoing provisions, wherein the forming step further includes forming the pulp into a pulp cover disposed on a wire frame.

[0097] The method according to any of the foregoing provisions further includes using a plate coupled to the wireframe inside the pulp cover to stabilize the pulp cover on the wireframe.

[0098] The method according to any of the foregoing provisions, wherein the forming step further includes forming a pulp cover around the core, the core being formed around the blade mounting structure.

[0099] Within the scope not described, different features and structures of each aspect may be used in combination or interchangeably as desired.

[0100] The fact that a feature is not shown in all examples is not to imply that it cannot be shown in this way, but rather for the sake of brevity. Therefore, regardless of whether a new aspect is explicitly described, various features of different aspects can be mixed and matched as desired to form a new aspect. All combinations or substitutions of the features described herein are covered by this disclosure. Therefore, it should be understood that features of one embodiment are contemplated to be applicable to another embodiment and can be interchanged, added, or removed to form other embodiments not explicitly shown but still within the scope of this disclosure.

[0101] Although embodiments of the invention have been shown and described, those skilled in the art will understand that changes can be made to these embodiments without departing from the principles and spirit of the invention. While specific terms are used herein, they are used in a general and descriptive sense only and not for limiting purposes.

Claims

1. A ceiling fan assembly comprising: a motor having a rotor with a blade mount; a mount for coupling to a structure and for suspending the motor; and a ceiling fan blade comprising a molded pulp blade body formed from a molded and compressed pulp slurry, the pulp slurry including at least one of paper fibers, plant fibers, and wood fibers; wherein the blade body includes a first portion and a second portion, wherein each of the first portion and the second portion includes an inner surface that collectively defines an interior of the ceiling fan blade, and wherein both the first portion and the second portion are entirely formed from molded pulp.

2. The ceiling fan assembly of claim 1, wherein one of the first portion and the second portion further includes a set of stops.

3. The ceiling fan assembly of claim 2, wherein the other of the first portion and the second portion that does not include the set of stops includes a set of stop receivers, wherein the set of stop receivers are adapted to receive the set of stops.

4. The ceiling fan assembly of claim 1, wherein the first portion and the second portion are connected by a living hinge.

5. The ceiling fan assembly of claim 1, wherein the ceiling fan blade further includes a skeleton, and the molded pulp is formed around at least a portion of the skeleton.

6. The ceiling fan assembly of claim 5, wherein the skeleton includes a set of perforations to facilitate adhesion of the molded pulp to the skeleton.

7. The ceiling fan assembly of claim 6, wherein the skeleton includes a wire frame extending around a periphery of at least a portion of the ceiling fan blade.

8. The ceiling fan assembly of claim 5, further comprising a core coupled to the skeleton, and wherein the molded pulp is formed on the core.

9. The ceiling fan assembly of claim 8, wherein the core is made of foam.

10. The ceiling fan assembly of claim 1, wherein the ceiling fan blade further includes a ceiling fan blade base and a top cover attached to the ceiling fan blade base, wherein the top cover is at least partially formed from the molded pulp.

11. The ceiling fan assembly of claim 10, wherein the top cover further includes a grommet portion that extends into a mounting hole of the ceiling fan blade base.

12. The ceiling fan assembly of claim 10, wherein the top cover is smaller than the ceiling fan blade base, the ceiling fan blade base defining a peripheral edge along at least a portion of the ceiling fan blade base not occupied by the top cover.

13. The ceiling fan assembly of claim 1, further comprising a coating disposed on at least a portion of the molded pulp of the blade body.

14. The ceiling fan assembly of claim 1, wherein the molded pulp is made from one of a recyclable material and a biodegradable material. forming a molded pulp blade body from a molded and compressed pulp slurry including at least one of paper fibers, plant fibers, and wood fibers; wherein the forming further includes forming two halves of the blade body entirely from molded pulp.

15. A method of forming a blade for a ceiling fan, the method comprising: ​ 16. The method of claim 15, further comprising attaching the two halves to form the blade body.

17. The method of claim 15, wherein, The forming includes shaping but not cutting.

18. A ceiling fan assembly comprising: a motor; a mount for coupling to a structure and for suspending the motor; and a ceiling fan blade comprising only a molded pulp blade body for coupling to the motor, wherein the blade body is formed from a molded and compressed pulp slurry comprising at least one of paper fibers, plant fibers, and wood fibers, and the ceiling fan blade comprises a wire frame skeleton and the blade body is formed around at least a portion of the wire frame skeleton, wherein the blade body comprises a first portion and a second portion, wherein each of the first portion and the second portion comprises an inner surface that collectively defines an interior of the ceiling fan blade, and wherein both the first portion and the second portion are entirely formed from molded pulp.

19. A ceiling fan assembly comprising: a motor; a mount for coupling to a structure and for suspending the motor; and a ceiling fan blade comprising only a molded pulp blade body for coupling to the motor, wherein the blade body is formed from a molded and compressed pulp slurry comprising at least one of paper fibers, plant fibers, and wood fibers, and the ceiling fan blade comprises a foam core and the blade body is formed around at least a portion of the foam core; wherein the blade body comprises a first portion and a second portion, wherein each of the first portion and the second portion comprises an inner surface that collectively defines an interior of the ceiling fan blade, and wherein both the first portion and the second portion are entirely formed from molded pulp.

20. A ceiling fan assembly comprising: a motor; a mount for coupling to a structure and for suspending the motor; and a ceiling fan blade for coupling to the motor, wherein the ceiling fan blade is entirely formed from molded pulp comprising at least one of paper fibers, plant fibers, and wood fibers; wherein the ceiling fan blade is formed from a first portion and a second portion, wherein each of the first portion and the second portion comprises an inner surface that collectively defines an interior of the ceiling fan blade, wherein both the first portion and the second portion are entirely formed from molded pulp, and wherein the first portion comprises a set of ribs extending from its inner surface, and the second portion comprises a set of rib receivers extending from its inner surface, wherein the set of rib receivers are adapted to receive the set of ribs from the first portion when the first portion is coupled to the second portion.

21. The ceiling fan assembly of claim 20, wherein the first portion and the second portion are connected by a living hinge.

22. The ceiling fan assembly of claim 20, wherein the molded pulp is made from one of a recyclable material and a biodegradable material.

23. The ceiling fan assembly of claim 20, wherein one of the first portion and the second portion further comprises a set of detents. ​ ​ ​ 24. The ceiling fan assembly of claim 23, wherein the other of the first portion and the second portion that does not include the set of detents includes a set of detent receivers, wherein the set of detent receivers are adapted to receive the set of detents.

25. A ceiling fan component for use with a ceiling fan assembly comprising a mount, a lower rod, and a motor, the ceiling fan component comprising: a body defining a blade made entirely of molded pulp containing at least one of paper fibers, plant fibers, and wood fibers, and the body is coupled to at least one of the mount, the lower rod, and the motor; wherein the blade is formed from a first portion and a second portion, wherein each of the first portion and the second portion includes an inner surface that collectively defines an interior of the blade, wherein both the first portion and the second portion are formed entirely of molded pulp; and wherein the first portion includes a set of ribs extending from its inner surface, and the second portion includes a set of rib receivers extending from its inner surface, wherein the set of rib receivers are adapted to receive the set of ribs from the first portion when the first portion is coupled to the second portion.

26. The ceiling fan component of claim 25, further comprising a coating disposed on at least a portion of the molded pulp of the body.

27. The ceiling fan component of claim 25, wherein, the body is formed by shaping but not cutting.

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