ceiling fan

Abstract

18. The fan assembly of claim 17, wherein the motor is mounted on a cam and has a plurality of blades mounted thereto. The motor is mounted on a cam and has a plurality of cams configured to extend along the length of the cam face. The motor is mounted on a cam face and has a plurality of cams configured to extend along the length of the cam face. The motor is mounted on a cam face and has a plurality of cams configured to extend along the length of the cam face.

Description

[0001] This application is a divisional application of the Chinese patent invention application "Ceiling Fan" with an application date of December 14, 2016 and application number 202110271672.6.

[0002] Citation of Related Applications

[0003] This application claims priority to U.S. Provisional Patent Application No. 62 / 267,033, filed December 14, 2015, U.S. Provisional Patent Application No. 62 / 281,860, filed January 22, 2016, U.S. Provisional Patent Application No. 62 / 281,866, filed January 22, 2016, and U.S. Provisional Patent Application No. 62 / 350,799, filed June 16, 2016, all of which are incorporated herein by reference in their entirety. Technical Field

[0004] The present application relates to a ceiling fan. Background Art

[0005] Ceiling fans are used to create airflow within a space or area, often for cooling or temperature regulation. Ceiling fans can be used in industrial, commercial, or agricultural settings to circulate air to maintain proper temperature regulation. This is typically achieved by using a high-capacity, low-speed fan. Summary of the Invention

[0006] In one aspect, the present disclosure relates to a ceiling fan comprising: a motor assembly having a rotating blade hub and a hanger mount; a plurality of blades mounted to the rotating blade hub; a hanger having an upper end configured to be mounted to a building and having a lower end including a motor mount; a plurality of studs disposed in one of the hanger mount and the motor mount, and corresponding openings disposed in the other of the hanger mount and the motor mount, the studs being received in the openings to help secure the hanger to the motor assembly; and a motor assembly plate coupled to the motor assembly and a hanger plate coupled to the lower end of the hanger, wherein the studs are disposed on one of the motor assembly plate and the hanger plate, and the openings are disposed in the other of the motor assembly plate and the hanger plate; the motor assembly includes a non-rotating motor shaft, the rotating blade hub rotates about the non-rotating motor shaft, and the non-rotating motor shaft has a coupling forming the motor assembly plate. BRIEF DESCRIPTION OF THE DRAWINGS

[0007] In the attached figure:

[0008] Figure 1A is a top perspective view of a ceiling fan incorporating several embodiments of the present invention.

[0009] Figure 1B yes Figure 1AAn enlarged top perspective view of a ceiling fan showing the motor housing, blade mountings, and hanger rod assembly with guy wire fitting.

[0010] Figure 1C yes Figure 1A An enlarged bottom perspective view of a ceiling fan, showing the motor housing and retention system.

[0011] Figure 1D It shows Figure 1B An exploded view of the internal components of a ceiling fan.

[0012] Figure 2A yes Figures 1A to 1D A top perspective view of a ceiling fan's suspension rod assembly.

[0013] Figure 2B Includes turnbuckle Figure 2A Exploded view of the hanger.

[0014] Figure 2C It is used to install to the Figure 2A Exploded view of the suspension arm's motor shaft.

[0015] Figure 3A yes Figures 1A to 1D top view of fan blades of a ceiling fan.

[0016] Figure 3B yes Figure 3A Cross-sectional view of a blade.

[0017] Figure 3C It shows Figure 3A A close up view of a two-part embodiment of a blade.

[0018] Figure 4A yes Figures 1A to 1D A perspective view of a ceiling fan's blade bracket.

[0019] Figure 4B yes Figure 4A Exploded view of the blade bracket with the push-lock assembly removed.

[0020] Figure 4C yes Figure 4B Exploded view of the push-latch assembly.

[0021] Figure 5A is a top perspective view of the upper portion of the motor housing, with a close-up of the blade bracket.

[0022] Figure 5B is an exploded view showing the upper portion of the motor housing, the blade bracket, and the combination of the blades.

[0023] Figure 6 yes Figures 1A to 1DAn exploded view of a portion of the motor housing assembly.

[0024] Figure 7A is a top perspective view of an alternative motor housing assembly.

[0025] Figure 7B yes Figure 7A Exploded view of the motor housing assembly.

[0026] Figure 7C yes Figure 7A A top view of a motor housing assembly with the blade support exploded from the motor housing assembly.

[0027] Figure 8A yes Figure 2C A perspective view of the motor shaft.

[0028] Figure 8B Including bearings Figure 8A Cross-sectional view of the motor shaft.

[0029] Figure 8C yes Figures 1A to 1D Cross-sectional view of the motor housing assembly.

[0030] Figure 9A yes Figures 1A to 1D A perspective view of a ceiling fan's retainer system.

[0031] Figure 9B yes Figure 9A Exploded view of the retainer system.

[0032] Figure 10A yes Figures 1A to 1D A top perspective view of a ceiling fan's wiring harness.

[0033] Figure 10B yes Figure 10A An exploded view of the wiring harness, showing the Figure 2A The connection between the stator and the motor shaft.

[0034] Figure 11A It is installed inside the motor shaft Figure 9A The retainer system and Figure 10A Cross-sectional view of the wiring harness.

[0035] Figure 11B is included Figures 1A to 1D An exploded view of all the components of a ceiling fan's motor assembly.

[0036] Figure 12 is a perspective view of an alternative ceiling fan according to aspects described herein.

[0037] Figure 13 yes Figure 12A magnified view of the motor housing of a replacement ceiling fan.

[0038] Figure 14 It is along Figure 13 Cross-section of the motor housing taken along line XIV-XIV.

[0039] Figure 15 yes Figure 14 Exploded view of the motor housing.

[0040] Figure 16 Is used to install Figure 13 A perspective view of the motor housing's mounting struts.

[0041] Figure 17 is a perspective view of the blade bracket with the push lock assembly exploded therefrom.

[0042] Figure 18 yes Figure 17 A perspective view of a push-lock assembly is shown with the end cap shown in phantom. DETAILED DESCRIPTION

[0043] The described embodiments of the present invention relate to systems, methods, and other apparatus related to ceiling fans.

[0044] Figure 1A A top perspective view of a ceiling fan 10 is shown. The ceiling fan 10 includes a ceiling mounting structure 12 for mounting to a ceiling (not shown) or a building, having a hanger assembly 14 extending therefrom. The hanger assembly 14 is coupled to a motor assembly 16. A plurality of blade brackets 18 couple blades 20 to the motor assembly 16. Although five blades 20 and five blade brackets 18 are shown, any number of blades 20 and blade brackets 18 are contemplated. Optionally, a plurality of guy wires 22 may be used to mount the hanger assembly 14 to the ceiling independently of the ceiling mounting structure 12. As used herein, a ceiling or building may be any structure from which a ceiling fan may be hung or mounted. For example, the ceiling may be the ceiling of a building, a factory, or a farm building.

[0045] Figure 1Bis a close-up view of the hanger assembly 14 and motor assembly 16. The ceiling mounting structure 12 includes a mounting plate 13 having two upper plates 15 for securing the ceiling mounting structure 12 to the building using a bolt assembly. A support cable 302 and a conduit 342 extend from the hanger assembly 14 below the mounting plate 13 for connecting the ceiling fan 10 to the building and a power source, respectively. The conduit 342 terminates at an electrical connector 343. The hanger plate 50 mounts the hanger assembly 14 to the motor assembly 16. The hanger assembly 14 further includes a guy wire fitting 58 for connecting the guy wire 22 to the hanger assembly 14 using a set of turnbuckles 80. The motor housing 198 includes a plurality of mounting members 204 for connecting the blades 20 to the motor assembly 16 using the blade bracket 18. Figure 1C A portion of the retention system 300 is shown, with the remainder inside the motor assembly 16. The retention system 300 includes a retention plate 310 disposed along the bottom of the motor housing 198, providing redundant suspension for suspending the ceiling fan 10 from a ceiling or building. Additionally, the bottom of the mounting plate 13 includes two integral tabs 24 for attaching the plate to fasteners 19. The fasteners 19 couple the mounting plate 13 to the hanger assembly 14 at swivels 36. Forming the tabs 24 in the mounting plate 13 during manufacturing, rather than welding them in, reduces costs while improving the reliability of the tabs 24 during fan operation.

[0046] Figure 1D 1 is an exploded view showing the combination of components comprising the boom assembly 14 and the motor assembly 16. The boom assembly 14 includes a hollow rod 30 having a swivel seat 36 for coupling the boom assembly 14 to the ceiling mounting structure 12.

[0047] Guy wire fitting 58 is mounted around hollow rod 30. Hanger plate 50 is mounted to hanger assembly 14 opposite swivel base 36. Hanger plate 50 is coupled to coupling 52 for coupling hanger assembly 14 to motor assembly 16. Motor assembly 16 includes motor housing 198, which is divided into upper housing portion 200 and lower housing portion 230. A non-rotating motor shaft 90 is disposed within motor housing 198 to support a stator 232, an upper bearing 272, and a lower bearing 274. A locknut 92 can be used to secure motor shaft 90 to hanger assembly 14 at coupling 52. A spring member 282 can be disposed between lower bearing 274 and lower motor housing portion 230. A rotor 234 is mounted to upper and lower motor housing portions 200, 230, allowing motor housing 198 to rotate about non-rotating motor shaft 90. Retention system 300 further includes support cables 302 and a retention rod 304 for suspending retention plate 310 from a building. A retention plate 310 may be mounted to the non-rotating motor shaft 90 and positioned beneath the lower housing portion 230 to provide redundant support for both the non-rotating and rotating components of the motor assembly 16. A wiring harness 340 may extend through the motor shaft 90 and out the center of the motor shaft 90 to provide current to the stator 232.

[0048] Watch Now Figure 2A The hanger assembly 14 includes a hollow rod 30 having a configuration for Figure 1A The ceiling mounting structure 12 is mounted to the ceiling at an upper end 32. A lower end 34 is disposed relative to the upper end 32, mounting the hanger assembly 14 to the motor assembly 16. The upper end 32 includes a swivel 36 mounted to the hollow rod 30. The swivel 36 may include two extensions 40 defining a connecting fork, each extension 40 having a mounting aperture 42. The mounting apertures 42 may be aligned to receive a fastener, such as a pin, for pivotally coupling the upper end 32 to the ceiling mounting structure 12.

[0049] The lower end 34 may include a hanger plate 50 and a coupling 52. The hanger plate 50 may be mounted to the hollow rod 30, such as by welding, or may be integral with the hollow rod 30. The coupling 52 may be coupled to the hanger plate 50 using a plurality of fasteners 54, such as screws or bolts. The guy wire fitting 58 may be a disc 60 that may be secured around the hollow rod 30 between the upper end 32 and the lower end 34 and may have one or more openings 62 for mounting. Figure 1A The traction rope 22.

[0050] Watch Now Figure 2B, an exploded view shows the separate parts of the hanger assembly 14. The guy wire fitting 58 can be welded to the hollow rod 30 or can be machined as part of the hollow rod 30. The guy wire fitting 58 can alternatively include an inner ring 70 and an outer ring 72 with an opening 62 disposed between the rings 70, 72. A turnbuckle 80 has a hook 82 that can extend through the outer ring 72 through the opening 62 and be coupled to the outer ring 72. The turnbuckle 80 can couple the hanger assembly 14 to the ceiling via the guy wire 22 to provide additional support for the ceiling fan 10 and reduce vibration or rotational movement of the ceiling fan 10 during operation.

[0051] The hanger plate 50 and the coupling 52 may include a plurality of fastener openings 74 adapted to receive insertion of fasteners 54 for coupling the hanger plate 50 and the coupling 52. The fasteners 54 may be threaded into one or more of the hanger plate 50 and the coupling 52, or a secondary fastener such as a nut may be utilized to secure the hanger plate 50 and the coupling 52 together. The coupling 52 may take the form of a collar 76 having a central opening 78. Figure 2C , the collar 76 can be threaded into place to couple to the threaded upper end of the motor shaft 90, thereby mounting the hanger assembly 14 to the motor assembly 16. Additionally, the collar 76 or coupling 52 can be indexed relative to the motor shaft 90, such as being keyed to receive a keyway 88 on the motor shaft 90.

[0052] Alternatively, as Figure 2C As can be seen in the figure, a threaded retainer 92 can be used to secure the coupling 52 to the motor shaft 90. In an alternative embodiment, by utilizing the threaded retainer 92, the collar 76 can be slid onto the motor shaft 90, allowing the retainer 92 to be screwed onto the threaded portion of the motor shaft 90 to secure the coupling 52 to the motor shaft 90. The diameter of the retainer 92 can be sized to fit within the upper opening 96 of the coupling 52. An upper collar 95, which is complementary to the retainer 92, can be used to secure the motor shaft 90 to the locknut 92 as a threaded redundancy. Additionally, a spring ring 93 can be inserted between the locknut 92 and the coupling 52 to provide a biasing force therebetween. The biasing force of the spring ring 93 secures the locknut 92 to the motor shaft 90, preventing unwanted rotation of the two, which could otherwise cause them to loosen. In another alternative example, both the coupling 52 and the retainer 92 may be threaded to couple to the motor shaft 90 to provide additional support for mounting the boom assembly 14 to the motor assembly 16 .

[0053] As an alternative to threaded fasteners 54, the hanger plate 50 or coupling 52 may include tapped studs 94 or press bolts, with the remainder of the hanger plate 50 or motor coupler 52 having openings 74 adapted to receive the studs 94. Nuts or other fasteners may be threaded or engaged onto the studs 94 to secure the hanger plate 50 and motor coupler 52 together.

[0054] It should be appreciated that the hanger assembly 14 facilitates suspending the motor assembly 16 from the ceiling, allowing for the use of a non-rotating hanger assembly 14 and a non-rotating motor shaft 90. The hanger plate 50, in combination with the coupling 52, facilitates coupling the hanger assembly 14 to the motor assembly 16. Additionally, the guy wire fitting 58 facilitates connecting additional suspension elements to the hanger assembly 14, such as the guy wire 22, thereby reducing vibration or movement associated with the operation of the ceiling fan 10. Additionally, the guy wire provides an additional redundant suspension system in the event of a failure of the ceiling mounting structure 12.

[0055] It should also be appreciated that the studs 94 or press bolts facilitate alignment and installation of the hanger plate 50 and the coupling 52. Additionally, the use of the locknut 92 facilitates sliding insertion of the motor shaft 90 into the coupling 52 and can provide a redundant connection for attaching the motor shaft 90.

[0056] Now turn Figure 3A , the top view of the blade 20 shows three mounting holes 100 on the first end 102 and a second end 104 opposite the first end 102. The mounting holes 100 can mount the blade to the motor assembly 16. The blade 20 can further include a blade span 106, such as the distance between the first end 102 and the outermost end of the second end 104. The blade 20 can have an airfoil 110 cross-section, such as Figure 3B As shown in FIG, the leading edge 112 and the trailing edge 114 define a chord 116, which is the straight-line distance between the leading edge 112 and the trailing edge 114. In one example, the blade chord 116 can be approximately seven inches (in.), and can be between six and eight inches. The airfoil 110 can be asymmetrical and can have an internal cavity 117.

[0057] The blade 20 may further include a pressure side 118 and a suction side 120, such that the pressure side 118 faces the ground below the ceiling fan 10 and the suction side 120 faces the ceiling from which the ceiling fan 10 is mounted. The blade thickness 122 may be the maximum distance between the pressure side 118 and the suction side 120. Figure 3C As can be seen in FIG, the blade 20 may also be in two parts, being a combination of a leading edge member 130 and a trailing edge member 132 coupled together.

[0058] Blade thickness 122 can be adjusted so that the thickness-to-chord ratio can be less than 0.14 and greater than 0.13. For example, blade chord 116 can be 7.01 inches and thickness 122 can be 0.97 inches, resulting in a thickness-to-chord ratio of 13.8% or 0.138. Blade chord 116 and thickness 122 can be varied relative to each other to maintain a thickness-to-chord ratio of approximately 13.8%. Furthermore, blade 20 can be adapted to rotate at a speed defined by revolutions per minute (rpm). The speed of blade 20 can depend on blade span 106 or the total fan width. The total fan width can be the diameter of the circle defined by the outermost rotations of blades 20. In one example, fan 10 can have an overall width of approximately 24 feet, with a blade span 106 of approximately 12 feet, a chord 116 of 7.01 feet, and a thickness 122 of 0.97 feet. The exemplary fan 10 can be adapted to rotate at a specific speed to generate a specific volumetric flow rate or air velocity.

[0059] It should be understood that the size of the blade span 106, blade chord 116, and blade thickness 122 rotating at a certain speed can determine the maximum wind speed and volume flow rate generated by the fan. Alternatively, the wind speed generated by the fan 10 can be determined based on consumer preferences, which can be determined by the need for fan-driven airflow. For example, a hotter or less ventilated environment will require a larger wind speed to maintain an appropriate temperature, while a colder or open environment will require a smaller wind speed to maintain temperature. It can be appreciated that by improving temperature management, volumetric airflow, or airspeed and simultaneously minimizing energy consumption, adjusting the span 106, chord 116, thickness 122, chord-to-thickness ratio, speed, or other aspects can maximize the efficiency of the fan 10.

[0060] It will be appreciated that blade 20 has a thickness to chord ratio of approximately 13.8% and includes an airfoil shape to maximize the efficiency of blade 20. Blade span 106, chord 116, thickness 122, rotational speed, and pitch may be adjusted to maximize efficiency, airspeed, and airflow volume during operation of ceiling fan 10.

[0061] Steering Figure 4A, focusing on the blade support 18, the blade support 18 includes a first end 150 and a second end 152 opposite the first end 150. The first end 150 can have a first cross-section, such as a circular cross-section 140, and the second end 152 can have a second cross-section, such as an elliptical cross-section 142. The first and second cross-sections 140, 142 can be different from each other, while it is also contemplated that they can be the same. In addition, the height of the first cross-section 140 can be greater than the height of the second cross-section 142. The cross-sections 140, 142 can each define a cross-sectional area of ​​the first and second ends 150, 152. The cross-sections 140, 142 can have the same area but different shapes. Alternatively, the cross-sectional areas of the shapes can be different. The first and second ends 150, 152 can be connected by a transition section 154. The transition section 154 can have a cross-section 144 that transitions from the first cross-section 140 to the second cross-section 142, such as from a circle to an ellipse.

[0062] The blade support 18 may comprise a single machined piece, or may be a combination of multiple parts, such as by welding the first and second ends 150, 152 to the transition section 154. The second cross-section 142 may be formed from an initial shape by stamping. For example, the entire blade support 18 may be machined to have a circular cross-section. The second end 152 and a portion of the transition section 154 may be stamped or compressed to form the appropriate second cross-sections 142, 144.

[0063] The first end 150 may have a push lock assembly 156 that closes the first end 150. The motor assembly 16 having a rotating blade hub may have a first receiver that may include Figure 5A The second end 152 may have a mounting aperture 158 that is complementary to the mounting aperture 100 of the blade 20, such that the second end 152 is received within the interior cavity 117 of the blade 20 as a second receiver. Thus, the blade 20 may be coupled to the motor assembly 16 using the blade bracket 18. The interconnections between the blade 20, the blade bracket 18, and the blade hub will be discussed below. Figure 5B Further description during this period.

[0064] The first end 150 includes an opening 160 for receiving the push lock assembly 156. The push lock assembly 156 may further include an index 157 having a biasing stop, such as a spring loaded pin 162 extending radially from one side of the push lock assembly 156. Figure 4B, shows a push-lock assembly 156 separated from the main body of the blade bracket 18, the push-lock assembly 156 being mounted to the first end 150 at the opening 160, such as by welding, and mounted relative to the blade bracket 18 to orient the blade bracket 18 at an angle relative to the pin 162. For example, the second cross-section 142 at the second end 152 can define a major axis 164. The push-lock assembly 156 can be mounted to the first end 150 to orient the pin 162 at an angle of five degrees offset from the major axis 164. Thus, the blade 20 mounted to the second end 152 can be positioned at an angle that is five degrees offset from the pin 162 and can define the pitch of the blade 20 when the blade bracket 18 is mounted to the motor housing 198. The pitch is the angle of attack of the blade 20 into the air to control the generation of the air flow swept by the blade 20.

[0065] Watch Now Figure 4C , an exploded view shows the components included in the push lock assembly 156. The push lock assembly 156 includes a body 170 having an interior 172. The interior 172 is defined by a top 174 and a bottom 176 of the body 170, with two shelves 178 disposed between the top 174 and the bottom 176 on either side of the interior 172. Each shelf 178 includes a fastener aperture 180. The top 174 includes a circular extension 182 that is adapted to be received at the opening 160 of the first end 150 for mounting thereto. The inner body 184 is sized to be received within the interior 172 of the body 170. A pin interior 186 is disposed in the inner body 184 for receiving insertion of the pin 162. The pin 162 includes a pin extension 163. Insertion of the pin 162 into the pin interior 186 and insertion of the inner body 184 into the interior 172 positions the pin 162 to extend outwardly through the opposite end of the body 170, as shown. Figure 4B As shown. A plate 188 positioned behind the inner body 184 secures a spring 190 behind the pin 162 within the inner body 184. The spring 190 is positioned around the pin extension 163 and sandwiched between the pin 162 and the plate 188. The pin extension 163 has an arcuate surface shaped to abut against the plate 188. The arcuate surface of the pin extension 163 and the concave inner end 189 of the plate 188 provide for slight movement of the pin 162 beyond linear motion. This facilitates insertion of the pin 162 into the mounting 204 on the motor housing 198 during installation of the blade bracket 18. Additionally, the arcuate outer surface 191 of the plate 188 complements the body 170 to form the cylindrical outer surface of the push-lock assembly 156. A fastener 192, such as a screw, may be inserted into a second fastener aperture 194 in the plate 188 to mount the plate 188 at the shelf 178, securing the spring 190 behind the pin 162 within the body 170, and forming a Figure 4B The complete push-lock assembly 156 can be seen in FIG. The spring 190 allows actuation of the pin 162 for coupling the blade bracket 18 to the motor assembly 16 using the push-lock assembly 156.

[0066] It will be appreciated that the blade bracket 18 facilitates mounting the blades 20 to the motor assembly 16. The size and shape of the blade bracket 18 minimize system weight while maximizing structural integrity, which improves overall efficiency. For example, the blade bracket 18 may be thin-walled steel to minimize weight and maximize integrity. The blade bracket 18, including the push-lock assembly 156 with the pin 162, determines the blade pitch. Thus, based on blade characteristics such as span, the push-lock assembly 156 can be manufactured to orient the blades 20 at the optimal pitch to maximize efficiency without requiring the installer or customer to make such a determination.

[0067] Figure 5A The upper portion 200 of the rotatable motor housing 198 is shown and comprises a portion of the outer shell of the motor assembly 16. The upper portion 200 further comprises a blade hub 202 having a central hub 203 integral with the rotatable motor housing 198. The upper portion 200 comprises five mounts 204 for receiving the blade brackets 18 for mounting the blades 20. Although five mounts 204 are shown, any number of mounts 204 are contemplated. The upper portion 200 further comprises a blade hub 202 for mounting to the lower portion (see FIG. Figure 6 ) with a plurality of mounting apertures 206 and having a central aperture 208 for use in Figure 2B or Figure 2C The motor assembly 16 is mounted to the boom assembly 14 at a coupling 52 .

[0068] Figure 5A Also shown is a close-up view of a mount 204. The mount 204 includes a split sleeve 210 defining a sleeve interior 212. The split sleeve 210 has two sets of compression fittings 214 for tightening or loosening the split sleeve 210. The split sleeve 210 and the compression fittings 214 are integrally formed with the rotatable motor housing 198. The split sleeve 210 further includes a slot 216 extending along one side of the longitudinal length of the mount 204. The slot 216 terminates at a pin lock aperture 218 and is sized to receive a Figures 4A to 4C The push lock assembly 156 is then inserted into the pin 162. The pin lock aperture 218 acts as a blade rotation stop to prevent rotation of the attached blade 20 about the longitudinal axis, which could otherwise change the pitch of the blade during operation.

[0069] Steering Figure 5BTo connect the blade 20 to the motor assembly 16 via the blade bracket 18, a push-lock assembly 156 is mounted on the first end 150 of the blade bracket 18, orienting the pin 162 at an angle to determine the pitch of the blade 20. The mounting member 204 may be a first receptacle for receiving the first end of the blade bracket 18. The pin 162 slides into the slot 216 and inside the compression fitting 214, thereby pressing the pin 162 into the push-lock assembly 156. The first end 150 slides into the sleeve interior 212, and the pin 162 is received within the slot 216 by rotating the blade bracket 18. After rotation, the blade bracket 18 moves inward until the pin 162 is received in the pin-lock aperture 218, and the spring 190 pushes the pin 162 outward, thereby locking the blade bracket 18 to the mounting member 204. Alternatively, the blade bracket 18 may be fully inserted into the mounting member 204 and rotated until the pin 162 is received in the pin-lock aperture 218. Fasteners (not shown), such as screws or bolts, are inserted into compression fittings 214 of mount 204 , thereby tightening compression fittings 214 of split sleeve 210 to secure blade support 18 to mount 204 and prevent pin 162 from sliding out of pin lock aperture 218 .

[0070] After blade bracket 18 is inserted into motor housing 198, the arrangement of the pins 162 mounted to indexing portion 157 fixes the rotation of annular first cross-section 140 and orients second end 152 of blade bracket 18 at an angle relative to a horizontal plane, which angle may be defined, for example, relative to a horizontal plane such as a ceiling or floor of a building in which fan 10 is mounted. Alternatively, pin 162 may orient blade 20 relative to blade hub 202.

[0071] The blade 20 may be a second receiver for receiving the second end 152 of the blade support 18 such that the second receiver is located within the interior of the blade 20. The blade 20 may be mounted to the blade support 18 such that the blade 20 slides over the second end 152 and into the interior chamber 117 and the mounting hole 100 is aligned with the mounting aperture 158. A fastener may secure the blade 20 to the blade support 18 by utilizing the mounting hole 100 and the mounting aperture 158. Depending on the orientation of the pin 162 and the push-lock assembly 156, the angle of the second end 152 defines the inclination of the blade 20. For example, to deviate from the Figure 4B Positioning the pin 162 five degrees about the major axis 164 of the ellipse shown in FIG. 1 may orient the pitch of the blade 20 at five degrees relative to the ceiling or floor of the building.

[0072] During operation, the torque generated by the motor assembly 16 can define the rotational speed of the fan 10. The combination of the rotational speed of the fan 10 and the blade pitch can determine the volumetric flow rate of air moved by the fan 10. The volumetric flow rate can be the volume of air moved by the fan 10 during operation based on the motor torque and blade pitch. The blade span 106 can proportionally increase or decrease the volumetric flow rate because longer blades 20 generate greater airflow while shorter blades 20 generate less. However, a longer blade 20 requires greater motor torque than a shorter blade at a desired rotational speed. To maximize airflow while operating within the motor's torque-generating capabilities, the blade pitch can be predetermined during manufacturing based on the blade span 106. For example, for a blade span 106 of approximately 12 feet or an overall diameter of 24 feet, the pins 162 can be oriented to define an 8-degree blade pitch, while a blade span 106 of approximately 6 feet or an overall diameter of 12 feet can have a 12-degree blade pitch. Thus, a fan having a smaller area swept by the blades can have a greater pitch to drive a greater volumetric airflow within the operating capabilities of the motor. It should be understood that the blade spans, blade diameters, and blade pitches described herein are exemplary, illustrating that the blade pitch can be determined by the blade diameter to maximize the volumetric airflow or airspeed based on the operating capabilities of the motor.

[0073] Thus, installing the push-lock assembly 156 to orient the pin 162 at a predetermined blade pitch angle can facilitate orienting the blades 20 at a pitch based on the blade span 106, thereby maximizing volumetric flow within the motor torque capacity. In this way, the need for the consumer or installer to determine the appropriate pitch or attempt to properly orient the blades 20 at a certain pitch to maximize flow is eliminated. This elimination is due to providing a corresponding blade bracket 18 for each fan blade 20, which has a predetermined blade pitch angle. It should be understood that the pitch is not dependent on the blade span 106. The pitch can be any angle and the blade span 106 can be any length. However, it should be appreciated that determining the pitch based on the span 106 is beneficial for maximizing volumetric airflow based on the motor's capabilities (such as torque).

[0074] It will be appreciated that the blade hub 202 facilitates attachment and improves the security of the blade support 18. The split sleeve 210 and the pin lock aperture 218 accurately align the blade pitch in all installed blades 20. The compression fitting 214 secures the blade support 18 to the blade hub 202 with a simple tightening of mechanical fasteners. The integral mounting 204 and rotating blade hub 202 enable rotary operation without the need for additional components to rotate the blades 20.

[0075] Figure 6An exploded view of the motor assembly 16 is shown, which includes an upper portion 200 of the motor housing 198 and a lower portion 230 of the motor housing 198, which enclose a stator 232 and a rotor 234. The stator 232 may include coil windings of conductive material, and the rotor 234 may include a plurality of magnets 240. Alternatively, the stator 232 may include the magnets 240 and the rotor 234 may include the windings. The upper and lower portions 200, 230 may be coupled and rotated together to define the rotating motor housing 198. The upper and lower portions 200, 230 may further include a magnet seat 238 as an annular surface for supporting the plurality of magnets 240 mounted to or forming part of the rotor 234. The magnet seat 238 may include complementary slots formed in each of the upper and lower portions 200, 230 of the motor housing 198 to collectively form the magnet seat 238. The magnets 240 may be permanent magnets or electromagnets comprising motor windings. The rotor 234 and the upper and lower portions 200, 230 can have a plurality of mounting holes 242 for mounting the rotor 234 to the motor housing 198 using, for example, mechanical fasteners (such as screws or bolts). The upper and lower portions 200, 230 can each have an edge 243. When the upper and lower portions 200, 230 are mounted, the horizontal edges 243 can abut each other. Alternatively, the upper and lower portions 200, 230 can be separated by a gap (not shown) between the edges 243, through which a portion of the rotor 234 is exposed.

[0076] During operation, current is provided to the stator 232, causing the rotor 234 to rotate about the stator 232. By mounting the rotor 234 to the upper and lower portions 200, 230, the motor housing 198 can rotate about the stator 232, thereby rotating any blade supports 18 and blades 20 attached thereto.

[0077] It should be appreciated that the motor housing 198 is a clamshell type housing having upper and lower portions 200, 230 for direct mounting to the rotor 234 to rotate the entire motor housing 198, the blade hub 202, and the blades 20 coupled thereto. The motor housing 198 allows the rotor 234 and stator 232 combination to be housed within the motor assembly 16 suspended from the boom assembly 14 without requiring the motor assembly 16 to be fully rotatably mounted. This minimizes operational wear, vibration, and shake while increasing service life.

[0078] Now refer to Figure 7A, shows an alternative motor assembly 400 including a rotatable housing portion 402 having an upper portion 404 and a lower portion 406 forming the rotatable housing portion 402. A rotating blade hub 408 is included on the rotatable housing portion 402 and may be integral with the upper portion 404. At least one blade mount 410 is provided on the blade hub 408, such as five blade mounts 410 in one example. Each blade mount 410 includes a pin aperture 412 and at least one fastener aperture 414. In one example, the pin aperture 412 may be substantially similar to Figure 5A The pin lock hole 218 is provided.

[0079] The blade mount 410 can define a generally cylindrical cavity 420. A slot 422 can be formed in the blade mount 410 such that the cavity 420 includes an enlarged portion 424 at the slot 422. In one example, the slot 422 can be used to guide the pin 162 toward the pin aperture 412 for locking the blade bracket 18 to the motor assembly 400 at the blade mount 410.

[0080] The fastener apertures 414 may each include an inserted fastener 432. For example, the fasteners 432 may be any suitable fasteners, such as set screws or headless screws. The fastener apertures 414 are provided in the surface 434. The fastener apertures 414 extend from the surface 434 through the blade mount 410 to the cavity 420. In addition, a plurality of housing fasteners 436 may be used to secure the upper portion 404 to the lower portion 406, as well as by similar Figure 6 The rotor is fixed with the mounting holes.

[0081] Now refer to Figure 7B , an exploded view shows a set of two fasteners 432 and two saddles 430. The fasteners 432 and saddles 430 can be separate or integral, or coupled to allow rotation of the fasteners 432 without rotating the saddles 430. The saddles 430 include a curved surface 438 and a post 439 opposite the fasteners 432. The fasteners 432 can have a hollow interior 437 adapted to receive the post 439 and enable the fasteners 432 to rotate about the post 439.

[0082] Surface 434 can be offset from vertical axis 416 by an angle 418 from surface axis 419. Angle 418 can be any suitable angle, such as 20 degrees in one non-limiting example, to radially align fastener aperture 414 with the center of cavity 420. Additionally, angled surface 434 provides a user with easier access to fastener 432 in fastener aperture 414.

[0083] Now refer to Figure 7CIn operation, the user can tighten or loosen the saddle 430 in the cavity 420 by tightening or loosening the fastener 432. The user places the blade bracket 18 (e.g. Figure 5B The blade bracket 18 is inserted into the blade mount 410. The pin 162 on the blade bracket 18 is aligned along the channel 422 and the blade bracket 18 is inserted until the pin 162 is fixed in the pin aperture 412.

[0084] After the blade bracket 18 is inserted, the fastener 432 can be used to tighten the saddle 430 against the first end 150 of the blade bracket 18 inserted into the blade mounting cavity 420. The tightened saddle 430 abuts the blade bracket 18 at the curved surface 438 to apply pressure to the first end 150 of the inserted blade bracket 18, thereby providing an additional securing measure for the blade bracket 18.

[0085] The saddle 430 is oriented at an angle 418, such as a 20 degree angle, as defined by surface 434, and may be oriented radially from the center of the blade support 18. The radial orientation of the saddle 430 against the inserted blade support 18 prevents rotation of the blade support 18 based on the insertion force from the saddle 430. This radial insertion further prevents rotational movement of the pin 162 inserted within the pin aperture 412 relative to the blade mount 410, which may otherwise tend to fracture the blade support 18.

[0086] It should be appreciated that the motor assembly 400 and the blade hub 408 may be substantially similar to Figure 5B The motor assembly 16 and blade hub 202 are configured to receive the insertion of the blade bracket 18 to couple the blades 20 to the motor assembly 400. The saddle 430 provides an auxiliary retention system for the blade hub 408 and can reduce vibration, noise or shaking of the ceiling fan, which can increase overall fan efficiency.

[0087] Figure 8A is an example of a non-rotating motor shaft 90. The motor shaft 90 includes an upper end 252 and a lower end 254 with a hollow interior 256. The outer surface of the upper end 252 includes a threaded connection 258 for coupling to a collar, which may include Figure 2B Coupling 52, Figure 2CThe motor shaft 90 may further include an upper collar 262 having an increasing outer diameter and a lower collar 264 having a further increasing outer diameter that is larger than the outer diameter of the upper collar 262. The upper collar 262 includes a gradually increasing outer diameter for the motor shaft 90, thereby defining an annular upper bearing stop 266. The upper collar 262 further includes a wire opening 269. The lower collar 264 includes a further gradually increasing diameter from the upper collar 262, thereby defining a stator stop 268 for supporting the stator winding 232. Below the lower collar 264 is a gradually decreasing diameter that defines a lower bearing stop 270.

[0088] like Figure 8B , an upper bearing 272 and a lower bearing 274 are respectively disposed on an upper bearing stop 266 and a lower bearing stop 270. The upper bearing stop 266 and the lower bearing stop 270 are formed within the motor shaft 90 for positioning the bearings 272, 274 against the motor shaft 90 and allowing the motor housing 198 to rotate about the non-rotating motor shaft 90.

[0089] Watch Now Figure 8C , shows a cross-section of a portion of the motor assembly 16, illustrating the assembly of components associated with the non-rotating motor shaft 90. The non-rotating motor shaft 90 is disposed within the motor housing 198, which has bearings 272 and 274 disposed in upper and lower bearing stops 266 and 270. A spacer 280 may be placed between the upper bearing 272 and the stator to provide additional support during operation. The stator 232 is positioned on the stator stop 268 and secures the position of the stator 232 relative to the motor shaft 90. The rotor 234 surrounds the stator 232 and is mounted on a magnet mount 238 between the upper portion 200 and the lower motor housing portion 230 of the motor housing 198. Securing the stator 232 on the stator stop 268 secures the position of the stator 232 relative to the rotor 234, thereby maintaining an air gap between the two. The upper portion 200 further includes an upper bearing seat 284 that abuts the upper bearing 272 above the upper bearing stop 266. The lower portion 230 further includes a lower bearing seat 286 that abuts the lower bearing 274 below the lower bearing stop 270. The upper and lower bearing seats 284, 286 operate to sandwich the bearings 272, 274 between the upper and lower bearing stops 266, 270, respectively, thereby securing the bearings in place during operation. During operation, rotation of the rotor 234 about the stator 232 rotates the motor housing 198 and the blade bracket 18 attached thereto, thereby rotating the blades 20 of the ceiling fan 10.

[0090] The coupling 52 is mounted to the upper end 252 of the motor shaft 90, such as by a threaded connection 258. The coupling 52 is coupled to the hanger plate 50 using fasteners 54 or press bolts. The hanger plate 50 is coupled to or integral with the hanger assembly 14, thereby mounting the hanger assembly 14 to the motor shaft 90 via the coupling 52. The hanger assembly 14 thus suspends the motor shaft 90 from a building or ceiling. During operation, the rotor 234, the motor housing 198 including the upper and lower portions 200, 230, the mounting 204, the blade bracket 18, and the blades 20 can all rotate about the motor shaft 90 about the bearings 272, 274, while the motor shaft 90, the stator 232, the hanger plate 50, the motor coupling 52, and the hanger assembly 14 remain stationary and do not rotate.

[0091] Motor shaft 90 may further include a weep hole 288. Weep hole 288 may be positioned below opening 269, as electrical wiring may be routed through opening 269. During operation, such as in harsh climates where rain, snow, or precipitation are common, such as in agricultural environments, weep hole 288 may protect the wiring at opening 269. In one example, rainwater may enter the interior of motor shaft 90. Motor shaft 90 may fill with rainwater. Weep hole 288 allows rainwater to drain from the interior of motor shaft 90 before it can rise to the electronics, thereby enabling the ceiling fan to operate outdoors or in wind and rain.

[0092] The motor assembly 16 further includes one or more spring members 282, such as springs or spring fingers, disposed below the lower bearing 274 between the lower bearing 274 and the lower motor housing portion 230, thereby allowing the spring members 282 to rotate with rotation of the lower motor housing portion 230. The spring members 282 provide a downward force against the lower portion 230 of the motor housing 198 at the lower bearing seat 286, which is transferred to the upper housing portion 200, thereby providing a downward force against the upper bearing 272 at the upper bearing seat 284. During operation, the blades 20 push a volume of air downward, thereby also providing an upward force to the motor assembly 16. The spring members 282 provide a balancing force to counteract the forces generated during operation, thereby maintaining fan balance. As a result, the weight of the rotor 234 mounted to the motor housing 198 is transferred to the motor shaft 90 via the upper bearing 272 and is no longer solely carried by the motor housing 198.

[0093] It should be appreciated that the non-rotating motor shaft 90 facilitates coupling of the motor assembly 16 to the hanger assembly 14. The motor shaft 90, including the upper bearing stop 266, the stator stop 268, and the lower bearing stop 270, facilitates alignment of the bearings 272, 274 and functions in conjunction with the motor housing 198 to secure the bearings in position between the stops 266, 268 and the bearing seats 284, 286, thereby reducing vibration and movement (such as wobble of the fan 10 during operation) while allowing the motor housing 198 to rotate. The bearing stops 266, 270 and the stator stop 268 secure the position of the bearings 272, 274 and the stator 232 relative to the motor housing 198 and the stator 234. Mounting the stator 234 to the motor housing 198 secures the rotor 234 relative to the stator 232, the bearings 272, 274, and the motor shaft 90. Fixing these positions fixes the air gap between the stator 232 and the rotor 234, thereby determining the operating efficiency of the motor while maintaining stability during operation.

[0094] Additionally, spring member 282 creates a preload against lower portion 230 of motor housing 198 to balance the position of rotating motor housing 198 during operation, which further reduces vibration and movement of fan 10 .

[0095] Watch Now Figure 9A , retention system 300 includes a support cable 302 coupled to a retention rod 304 via a fastener 306. Support cable 302 can be mounted to a ceiling or building so that retention system 300 can provide redundancy to prevent the ceiling fan 10 from falling or collapsing in the event of a failure of the initial ceiling mounting structure 12. Fastener 306 can be, for example, a bolt having an aperture 307 for securing with a pin 308, or alternatively, a screw and nut system. Opposite support cable 302, retention rod 304 can be coupled to a retention plate 310 including an outer portion 312 and an inner portion 314. Inner portion 314 includes an offset opening 316 for receiving insertion of retention rod 304. Inner portion 314 has a mounting hole 318 for mounting to motor shaft 90.

[0096] exist Figure 9B , an exploded view shows the interconnection of the retention system 300. The mounting end 320 of the retention rod 304 can be inserted through an opening 316 in the retention plate 310, which is shaped to receive the shape of the mounting end 320. The mounting end 320 can include a flat surface with a mounting hole 322 that is adapted to be received by a connecting fork 324 on one end of the support cable 302. The retention rod 304 includes a top cover 326 opposite the mounting end 320 that abuts the bottom of the retention plate 310. The bottom of the retention plate 310 includes a recessed portion (see FIG. 1 ) that is adapted to receive the top cover 326. Figure 11A ).

[0097] It should be appreciated that the retention system 300 provides redundancy in the event of an initial ceiling mounting structure 12 failure. The retention rod 304 disposed within the hanger assembly 14 and the motor shaft 90 coupled to the retention plate 310 can allow continued rotation of the fan 10 during such a failure event. This continued rotation allows the fan 10 to decelerate without further damage to internal components and supports the fan 10 from falling. Without the ability to continue rotating, the internal components could otherwise contact each other, thereby damaging the fan 10 or its components, or otherwise causing the fan 10 to fall, even with the redundant measures in place to prevent such a fall.

[0098] Steering Figure 10A , a wiring harness 340 is shown having a conduit 342, a body 344, and wire leads 346. The conduit 342 extends from the body 344, electrically coupling the body 344 to the building power supply. The wire leads 346, which may include a hot wire 348 and a ground wire 350, are electrically coupled to the stator 232 for supplying power to the stator 232 to drive the rotor 234 during operation of the ceiling fan 10. It should be appreciated that the wiring harness 340 separates the ground wire 350 from the hot wire 348, thereby preventing the possibility of a short circuit.

[0099] Watch Now Figure 10B , the wire harness 340 can be slid into the stator 232. The wire harness 340 can terminate at an electrical connector 343, thereby facilitating plug-in connection of the wire harness 340 during installation of the fan 10. The stator 232 can have a central aperture 360 ​​with a slot 362 sized to accommodate the body 344 of the wire harness 340. Inserting the body 344 into the slot 362 positions the wire leads 346 along the bottom of the stator 232 to provide power to the stator 232.

[0100] Similarly, the opening 269 of the motor shaft 90 is sized to receive the end 364 of the body 344, thereby allowing the wire conduit 342 to extend through the interior 256 of the motor shaft 90. Thus, the wire conduit 342 can extend through the interior 256 of the motor shaft 90 such that the end 364 is inserted into the opening 269. The combined motor shaft 90 and wire harness 340 can be inserted into the stator 232 such that the extended body 344 of the wire harness 340 is inserted into the slot 362 of the stator 232, thereby providing the wire leads 346 to the stator 232.

[0101] It should be appreciated that the wiring harness 340 is internal to and passes through the non-rotating motor shaft 90 to provide power to the stator 232. Additionally, the arrangement of the motor shaft 90 and the retention system 300 isolates the retention rod 304 from the wiring harness 340, thereby minimizing the possibility of electrical shorts or wear caused by rubbing the two together during operation.

[0102] Watch Now Figure 11A , a cross-sectional view shows the combined motor shaft 90, retaining rod 304, retaining plate 310, and wire harness 340. Retaining plate 310 is mounted to motor shaft 90 by aligning mounting holes 318 with complementary fastener apertures 370 in motor shaft 90. The offset orientation of opening 316 in retaining plate 310 positions retaining rod 304 toward one side of interior portion 256 of motor shaft 90. Retaining plate 310 is mounted to motor shaft 90 such that opening 316 of retaining plate 310 is positioned on the opposite side of opening 269 in motor shaft 90. In this manner, wire harness 340 is positioned on the opposite side of interior portion 256 of motor shaft 90 from retaining rod 304, spacing the two apart and preventing any potential contact that could short-circuit wire harness 340 or cause wear on each other during operation.

[0103] Now turn Figure 11B , the combination of the motor assembly 16 can be appreciated. From the bottom, the retaining rod 304 is inserted through the retaining plate 310 until the top cover 326 abuts the inner portion 314 of the retaining plate 310. The inner portion 314 is mounted to the bottom of the motor shaft 90 through an aperture 380 in the lower motor housing portion 230. The motor shaft 90 is non-rotating, and therefore the retaining plate 310 is non-rotating and spaced apart from the lower motor housing portion 230 to allow rotation of the motor housing portion 230 during operation. The wire harness 340 is inserted into the opening 269 of the motor shaft 90, thereby extending the wire conduit 342 upward through the interior 256 of the motor shaft 90. The lower bearing 274 is positioned at the lower bearing stop 270, thereby securing the lower bearing 274 between the motor shaft 90 and the lower bearing seat 286. The spring member 282 ( Figure 8C ) can be positioned between the bottom of the lower bearing 274 and the lower motor housing portion 230, thereby providing a downward force on the lower motor housing portion 230. The rotor 234 and stator 232 can be positioned about the motor shaft 90, with the rotor 234 resting on the magnet seat 238 of the lower housing portion 230 and the stator 232 resting on the stator stop 268 of the motor shaft 90. The upper bearing 272 can be positioned on the upper bearing stop 266, thereby securing the upper bearing seat 284 against the motor shaft 90. The upper housing portion 200 can be mounted to the lower housing portion 230 through the rotor 234 using a plurality of fasteners, thereby enclosing the rotor 234, stator 232, motor shaft 90, bearings 272, 274, and wiring harness 340. The support cable 302 can be coupled to the mounting end 320 of the retention rod 304 extending through the top of the upper motor housing portion 200 at the connecting fork 324. The coupling 52 is disposed about the support cable 302 and is coupled to the motor shaft 90. The coupling 52 may be mounted to the hanger plate 50, thereby suspending the motor assembly 16 from the hanger assembly 14 and the building.

[0104] In operation, power is provided to stator 232 via wiring harness 340, thereby inducing rotation of rotor 234. Rotor 234 is coupled to motor housing 198 and rotates about stator 232, thereby rotating blade support 18 and blades 20 attached thereto.

[0105] It should be appreciated that the ceiling fan 10 described herein provides numerous advantages. These advantages may be combined in one embodiment or utilized individually in any particular embodiment. The following are examples of some of these advantages. The hanger assembly 14 utilizes a hanger plate 50 to mount to a coupling 52 for mounting to a motor shaft 90. The combination of the hanger plate 50 and coupling 52 facilitates mounting the hanger assembly 14 to the motor shaft 90 for suspending the motor assembly 16 from the ceiling. Furthermore, the hanger plate 50 and coupling 52 allow the motor shaft 90 to be non-rotating without requiring the hanger assembly 14 or the entire motor assembly 16 to rotate. Furthermore, the hanger assembly 14 includes a guy wire fitting 58 for mounting the hanger assembly 14 to the ceiling independently of the primary ceiling mounting structure 12. Furthermore, the non-rotating nature of the hanger assembly 14 facilitates mounting the guy wire fitting 58 directly to the hanger assembly 14 without requiring a separate, non-rotating element for mounting to the guy wire 22. The guy wire system provides redundancy in the event that the fan 10 might fall from the ceiling mounting structure and reduces operational vibration and rotational tilt.

[0106] Furthermore, stud bolts 94 or press bolts facilitate alignment and installation of the hanger plate 50 and the coupling 52. Bolts 94 allow the hanger assembly 14 to be quickly installed to the motor shaft 90 via the coupling 52. Additionally, the use of locknuts 92 facilitates sliding insertion of the motor shaft 90 into the coupling 52 and can provide a redundant connection for attaching the motor shaft 90 to the coupling 52.

[0107] Still further, the blade 20 may have a thickness-to-chord ratio of approximately 13.8% and include an airfoil shape to maximize the efficiency of the blade 20. Moreover, the blade span 106, chord 116, thickness 122, rotational speed, and pitch may be adjusted to maximize efficiency, airspeed, and airflow volume during operation of the ceiling fan 10.

[0108] Further still, the blade bracket 18, including cross sections 140, 142 at the first end 150 and the second end 152, facilitates mounting the blade 20 on the mounting member 204. The size and shape of the blade bracket 18 minimize system weight while maximizing structural integrity, which improves overall efficiency. The blade bracket 18 includes a push-lock assembly 156 having a pin 162, which determines the blade pitch. Thus, based on blade characteristics such as span, the push-lock assembly 156 can be manufactured to orient the blade 20 at the optimal pitch to maximize efficiency without requiring the installer or customer to make such a determination.

[0109] Still further, the blade hub 202 with multiple mounting elements 204 facilitates attachment and improves the security of the blade support 18. The split sleeves 210 and the pin-lock apertures 218 accurately align the blade pitch in all installed blades 20. The compression fittings 214 facilitate securing the blade support 18 to the blade hub 202 using mechanical fasteners. The integrated mounting elements 204 and rotating blade hub 202 enable rotary operation without the need for additional components to rotate the blades 20.

[0110] Furthermore, the motor housing 198 is a clamshell-type housing having upper and lower portions 200, 230 for direct mounting to the rotor 234 to rotate the entire motor housing 198, the blade hub 202, and the blades 20 coupled thereto. The motor housing 198 combines the rotor 234 and the stator 232 to be housed within the motor assembly 16. Thus, the motor housing 198 can rotate to drive the blades 20 without requiring rotation of the entire motor assembly 16. Operational wear, vibration, and shake are minimized while increasing service life.

[0111] Still further, the non-rotating motor shaft 90 facilitates coupling of the motor assembly 16 to the hanger assembly 14. The motor shaft 90, including the upper bearing stop 266, the stator stop 268, and the lower bearing stop 270, facilitates alignment of the bearings 272, 274 and functions in conjunction with the motor housing 198 to secure the bearings in place between the stops 266, 268 and the bearing seats 284, 286, thereby reducing vibration and wobble of the fan 10 during operation while allowing the motor housing 198 to rotate. The stator stop 268, in conjunction with mounting the rotor 234 to the motor housing 198, secures an air gap between the stator 232 and the rotor 234, thereby determining operating efficiency and maintaining operational stability of the motor assembly 16. Additionally, spring member 282 creates a preload against lower portion 230 of motor housing 198 to balance the position of rotating motor housing 198 during operation, which further reduces vibration and wobble of fan 10 and counteracts the upward force generated by the rotation of fan blades 20 .

[0112] Still further, the retention system 300 provides redundancy in the event of a failure of the initial ceiling mounting structure 12. The retention rod 304 disposed within the hanger assembly 14 and the motor shaft 90 coupled to the retention plate 310 can allow continued rotation of the fan 10 during such a failure event. This continued rotation allows the fan to decelerate without further damaging internal components and supports the fan 10 from falling. Without the ability to continue rotating, the internal components could otherwise contact each other, thereby damaging the fan 10 or its components, or otherwise causing the fan 10 to fall, even with the redundant measures in place to prevent such a fall.

[0113] Still further, a wiring harness 340 is internal to and passes through the non-rotating motor shaft 90 to provide power to the stator 232. Additionally, the arrangement of the motor shaft 90 and the retention system 300 isolates the retention rod 304 from the wiring harness 340, thereby minimizing the possibility of electrical shorts or wear caused by rubbing the two against each other during operation.

[0114] Still further, the combination of elements provides for utilizing a non-rotating motor shaft 90 in conjunction with the non-rotating hanger assembly 14, thereby suspending the motor assembly 16 from the hanger assembly 14. The combination of elements disclosed herein maximizes fan efficiency while providing redundancy in the event that the fan 10 may fall, which may occur in an industrial environment due to typical industrial operations (which may impact the fan). Furthermore, the disclosed fan 10 is easy to install due to the easily interconnected elements. Additionally, the overall vibration and wobble of the fan 10 are reduced, thereby further increasing efficiency while minimizing noise and power consumption.

[0115] Now refer to Figure 12 , another exemplary ceiling fan 510 is shown. The ceiling fan 510 includes a motor housing 512. A central aperture 520 can be formed in the center of the motor housing 512 and extend through the motor housing 512. The motor housing 512 can serve as a rotating blade hub for mounting a set of blades 514, shown as four blades, and can be mounted to the motor housing 512 via mounting posts 516. For example, the blades 514 can be similar to the blades described herein, such as Figures 3A to 3C A set of hub slots 518 may be formed in the motor housing 512 adapted to couple with mounting posts 516 for mounting the blades 514 to the motor housing 512 .

[0116] Figure 13 Shown Figure 12FIG2 is an enlarged view of the motor housing 512. The motor housing 512 can have an upper surface 530. The hub slot 518 can have a bottom wall 532, with a tapered wall 534 extending between the upper surface 530 and the bottom wall 532. The bottom wall 532 can be horizontal. The tapered wall 534 can have a variable cross-sectional area, defining an inner wall 536 that extends into a neck 538 terminating at a throat 540. The mouth 542 extends from the throat 540 to a terminal edge 544 of the motor housing 512. Fasteners 546 can couple the mounting posts 516 to the motor housing 512 and the blades 514 to the mounting posts 516. As shown, two fasteners 546 couple each mounting post 516 to the motor housing 512, and two fasteners 546 couple each blade 514 to each complementary mounting post 516. Although two fasteners 546 are shown at each location, any number of fasteners is contemplated. The fastener 546 may be any suitable fastener, such as a screw or bolt, as a non-limiting example.

[0117] Ceiling fan 510 further includes a motor shaft 550 disposed within motor housing 512 and partially extending therefrom for coupling to the interior of the motor within motor housing 512. Nut 598 redundantly secures motor housing 512 to motor shaft 550. Coupling 552 is coupled to motor shaft 512 for suspending ceiling fan 510. Additionally, a second suspension system 554 can be seen for redundantly suspending ceiling fan 510 from a building via motor shaft 552.

[0118] Now refer to Figure 14 ,along Figure 13 FIG1 is a cross-section of ceiling fan 510 taken along section XIV-XIV of FIG1. ​​Fasteners 560 couple upper motor housing portion 562 and lower motor housing portion 564 to form motor housing 512. Upper motor housing portion 562 and lower motor housing portion 564 enclose a motor assembly 566, which includes a stationary stator 568 and a rotor 570 that is rotatable about stator 568. The stator is non-rotating and slidably coupled to motor shaft 550. Fasteners 560 couple rotor 570 to motor housing 512, causing motor housing 512 to rotate with rotor 570. Stator 568 is fixed to motor shaft 550, causing motor shaft 550 to be non-rotatable. Rotor 570, motor housing 512, and any other rotating parts of the ceiling fan enclosed within motor housing 512 may define a rotor assembly that rotates about motor shaft 550.

[0119] The motor shaft 550 may include an upper shoulder 556 and a lower shoulder 558. Two bearings 572 are slidably mounted to the motor shaft 550 to allow the motor housing 512 to rotate about the motor shaft 550. The bearings 572 abut the rotor assembly at the motor housing 516. The upper bearing 572 may be positioned at the upper shoulder 556, and the lower bearing 572 may be positioned at the lower shoulder 558. Each bearing 572 includes an inner housing 574 and an outer housing 576 that encloses a set of bearing balls 578. In this manner, the outer housing 576 can rotate with the motor housing 512 via the bearing balls 578, while the inner housing 574 can remain stationary at the motor shaft 550.

[0120] Bearings 572 placed on shoulders 556, 558 can support motor assembly 566. In this way, motor coupler 552 can suspend motor shaft 550 from the building and motor shaft 550 can support the remainder of ceiling fan 510, including motor assembly 566 or any blades attached thereto.

[0121] A set of shims 580 are slidably mounted to the motor shaft 550. The shims 580 can space the bearings 572 from the stator 568. The shims 580 can be positioned against the inner housing 574 of the bearing, which serves as a non-rotating element, and the stator 568. The upper shim 580 can circumscribe the upper shoulder 556. The shims 580 secure the sliding position of the first and second bearings 572 relative to the stator along the motor shaft 550. In this manner, the stator 568 is compressively held between the first and second shims 580, and the bearings 572 compressively hold the shims 580, thereby retaining the stator 568. The shims 580 maintain the bearings 572 in position against the motor housing 512, minimizing any wobble or vibration of the motor assembly 566. A spring member 582 is provided on the opposite side of the lower bearing 572 to load the bearing 572 against the motor housing 512. The spring member 582 can be positioned between the housing 512, between the two rotating components, against the outer housing 576 of the bearing 572. Thus, the spring member 582 can also be a rotating member. The spring member 582 also minimizes wobble or vibration from the motor assembly 566. At the bottom of the lower motor housing 564, a plate 583 can be secured to the motor housing 512 to enclose the motor assembly 566 at the bottom.

[0122] An electrical aperture 584 is provided in the motor shaft 550, with an electrical conduit 586 extending through the electrical aperture 584. The electrical conduit 586 can provide electrical power to the stator 568 for powering the motor assembly 566 to drive the rotor 570.

[0123] A coupling 552 is coupled to the motor shaft 512 for suspending the ceiling fan 510 from the building. A pin aperture 588 is formed in the motor shaft 550, while a seat 590 is disposed within the motor shaft 550 opposite the pin aperture 588. Alternatively, the seat 590 may be an additional pin aperture 588 extending through the motor shaft 550. An insert pin 592 is inserted through the pin aperture 588 and secured in the seat 590. A retaining rod 594 may be attached to the pin 592 and include a retaining aperture 596. The retaining aperture 596 may be secured to a redundant system, such as, for example, a wire rope extending through a connecting hanger rod. In this manner, the retaining rod 594 may be coupled to the motor shaft 550 via the pin aperture 588 and the insert pin 592 in the seat 590.

[0124] A nut 598 with a lock washer 600 may be disposed around the top of the motor shaft 550 within the coupling 552. The nut 598 may redundantly secure the coupling 552 to the motor shaft 550. Additionally, the nut 598 may secure the pin 592 within the pin aperture 588.

[0125] The combination of the pin 592, the hook 596, and the nut 598 can define an auxiliary suspension system 554. The auxiliary suspension system 554 provides a redundant mounting for the ceiling fan 510. With the auxiliary suspension system 554 mounted to a non-rotating portion of the ceiling fan 510, such as the motor shaft 550, the redundant operation of the auxiliary suspension system 554 allows the ceiling fan 510 to continue rotating during use, thereby minimizing potential damage to the ceiling fan 510 during operation of the auxiliary suspension system 554.

[0126] Figure 15 yes Figure 14 , including the exploded mounting post 516. In assembly, the motor assembly 566 can be coupled to the motor shaft 550. Figure 14 An electrical conduit 586 can be mounted to the motor assembly 566 within the motor shaft 550. Spacers 580 can be mounted on either side of the motor assembly 566 along the motor shaft 550. Bearings 572 can be mounted on either side of the spacers 580. At the bottom, a spring member 582 can be positioned against the bearings 572. At the top, a coupling 552 and an auxiliary suspension system 554 can be mounted above the motor shaft 550. Mounting posts 516 can be mounted to the motor housing 512 for mounting the blades.

[0127] Now turn Figure 16, an exemplary mounting post 516 is shown. For example, the mounting post 516 can be hollow and made of steel, thereby reducing weight while maintaining structural integrity. The mounting post 516 includes a first portion as a hub portion 610 and a second portion as a blade portion 612. The hub portion 610 and the blade portion 612 can have a non-constant cross-sectional area along the length of the post 516, but it is contemplated that the cross-sectional area can be constant. The hub portion 610 can be mounted to Figure 15 The motor housing 512 and the blade portion 612 can be mounted to Figure 12 612. A plurality of mounting apertures 616 may be formed in the mounting strut 516, shown as two apertures 616 in each portion 610, 612. A flexure 614 is formed in the mounting strut 516. The flexure 614 orients the mounting strut 516 so that the hub portion 610 and the blade portion 612 are rotationally offset from each other by an offset angle 616. For example, the offset may be between 1 degree and 45 degrees. The offset angle 616 may be used to orient a blade attached to the mounting strut 516 at an inclination angle or angle of attack relative to the chord of the blade. The flexure 614 enables the hub portion 610 and the blade portion 612 to abut against the horizontal bottom wall 532 ( Figure 13 ) and a flat, flush mount of the blades 514. The specific offset angle 616 can be adjusted based on the specific ceiling fan 510 to maximize efficiency. For example, the offset angle 616 can be increased or decreased based on the length of the blades or the speed of the ceiling fan 510.

[0128] It should be realized that Figures 12 to 16 The ceiling fan 510 and related components described herein provide a ceiling fan with improved efficiency. The ceiling fan 510 is capable of maximizing air movement while minimizing energy consumption. Additionally, the auxiliary suspension system 554 provides a redundant mounting system for the fan. Components are optimized to reduce weight, further improving efficiency and minimizing the weight burden on the suspension structure.

[0129] Figure 17 A blade bracket, which may be the blade bracket 18 described herein, is shown having an alternative push-lock assembly 650 for mounting the blade bracket 18 to a ceiling fan motor housing, such as a motor hub, such as Figure 1B The push-lock assembly 650 includes an end cap 652 that includes a pin aperture 654. A pin 656 is disposed in the pin aperture 654. The blade support 18 includes a spring pin aperture 658. A spring pin 660 is disposed in the spring pin aperture 658. The spring pin 660 couples the push-lock assembly 650 to the blade support 18. During assembly, the push-lock assembly 650 can be inserted into the blade support 18 and the spring pin 660 can be inserted into the spring pin aperture 658 to secure the push-lock assembly 650 to the blade support 18.

[0130] Now refer to Figure 18 , in order to provide a view of the internal components of the push lock assembly 650, the end cap 652 is shown in phantom. The end cap 652 further includes a locking end 670 and a mounting end 672. The mounting end 672 includes a smaller diameter than the locking end 670 to allow insertion into the blade iron 18 ( Figure 17 The mounting end 672 also has a pair of opposing apertures 674 for receiving the spring pin 660 .

[0131] Within locking end 670 is a pin assembly 676. Pin assembly 676 includes pin 656, spring 680, and washer 682. A seat 684 is formed within the interior of locking end 670 as part of end cap 652. Washer 682 can be positioned at seat 684 to secure spring 680 there. Spring 680 abuts pin 656 opposite seat 684 and washer 682. Pin 656 further includes pin end 686 and an actuation end 688. Actuation end 688 includes a widened diameter and abuts spring 680. As such, pin 656 can be actuated via spring 680 to move pin end 686 in and out of pin aperture 654.

[0132] In operation, the pin 656 can be actuated via the spring 680 to retract during insertion of the push-lock assembly 650 for inserting the blade bracket 18 ( Figure 17 ) is connected to the ceiling fan or motor housing. During insertion, the pin 656 retracts into the end cap 652. When fully inserted, the pin 652 will extend into the receiving aperture, such as Figure 5A The push lock assembly 650 is attached to the ceiling fan in such a receiving aperture to mount the blade bracket 18. Blades, such as those described herein, can be mounted to the opposite ends of the blade bracket 18 to mount the blade to the ceiling fan.

[0133] The push-lock assembly 650 provides a reinforced assembly for attaching the blade bracket to a ceiling fan or motor housing. The push-lock assembly 650 also provides a simplified assembly that facilitates sliding insertion of the blade bracket 18 for installation on the motor housing. Removal of the blade bracket 18 is also simplified by depressing the pin 656 and slidingly removing it from the blade bracket 18. Thus, it should be appreciated that the push-lock assembly provides a simplified assembly for attaching blades and blade irons to a ceiling fan, thereby reducing cost and providing ease of use for the user or installer.

[0134] In addition to the concepts covered by the above, the following concepts may also provide a basis for the scope of protection in any possible combination:

[0135] A ceiling fan includes a motor assembly having a non-rotating motor shaft and a rotating blade hub that rotates about the non-rotating motor shaft; a plurality of blades mounted to the rotating blade hub; and a hanger having an upper end configured to be mounted to a building and a lower end mounted to the non-rotating motor shaft.

[0136] A ceiling fan assembly further includes a coupling coupled to the non-rotating motor shaft and a hanger plate coupled to a lower end of the hanger, wherein the coupling and the hanger plate are secured to one another.

[0137] A ceiling fan assembly in which a coupling is located above the rotating blade hub.

[0138] A ceiling fan in which a coupling is located on the upper end of a non-rotating motor shaft.

[0139] A ceiling fan assembly wherein the coupling includes a collar having a central opening that receives a non-rotating motor shaft.

[0140] A ceiling fan assembly in which a collar slides on a non-rotating motor shaft.

[0141] A ceiling fan assembly in which a collar slides on a non-rotating motor shaft.

[0142] A ceiling fan assembly wherein a collar is indexed relative to a non-rotating motor shaft.

[0143] A ceiling fan assembly wherein the indexing comprises: one of the collar and the non-rotating motor shaft including a key and the other including a keyway to receive the key.

[0144] A ceiling fan assembly further includes a locknut threaded onto a portion of the non-rotating motor shaft.

[0145] A ceiling fan assembly wherein at least one of the coupling and the boom plate has a stud and at least one other of the coupling and the boom plate has an opening for receiving the stud.

[0146] A ceiling fan assembly further includes a nut threaded onto the stud to secure the coupling and the boom plate together.

[0147] A ceiling fan assembly further includes a guy wire fitting mounted to the hanger rod.

[0148] A ceiling fan assembly wherein a guy wire fitting is located above the lower end of the hanger rod.

[0149] A ceiling fan assembly wherein a guy wire assembly includes a plate having a plurality of openings.

[0150] A ceiling fan assembly wherein the disk has an inner ring and an outer ring with an opening between the inner ring and the outer ring.

[0151] A ceiling fan assembly further includes at least one turnbuckle having a hook extending through one of the openings and hooking onto the outer ring.

[0152] A ceiling fan assembly in which the pan is welded to the hanger rod.

[0153] A ceiling fan includes a motor assembly having a rotating blade hub; a plurality of blades mounted to the rotating blade hub; a hanger having an upper end configured to be mounted to a building and a lower end mounted to the motor assembly; and a guy wire assembly mounted to the hanger.

[0154] A ceiling fan assembly wherein a guy wire fitting is located above the lower end of the hanger rod.

[0155] A ceiling fan assembly wherein a guy wire assembly includes a plate having a plurality of openings.

[0156] A ceiling fan assembly wherein the disk has an inner ring and an outer ring with an opening between the inner ring and the outer ring.

[0157] A ceiling fan assembly further includes at least one turnbuckle having a hook extending through one of the openings and hooking onto the outer ring.

[0158] A ceiling fan assembly in which the pan is welded to the hanger rod.

[0159] A ceiling fan includes: a motor assembly having a rotating blade hub and a hanger mount; a plurality of blades mounted to the rotating blade hub; a hanger having an upper end configured to be mounted to a building and a lower end having a motor mounted thereon; and a plurality of studs disposed in one of the hanger mount or the motor mount, with corresponding openings disposed in the other of the hanger mount or the motor mount, with the studs received within the openings to help secure the hanger to the motor assembly.

[0160] A ceiling fan further includes a motor assembly plate coupled to the motor assembly and a hanger plate coupled to a lower end of the hanger, wherein the stud is provided on one of the motor assembly plate or the hanger plate and the opening is provided in the other of the motor assembly plate and the hanger plate.

[0161] A ceiling fan wherein the motor assembly includes a non-rotating shaft about which a rotating blade hub rotates and which has a coupling forming a motor assembly plate.

[0162] A ceiling fan in which the coupling is located above the rotating blade hub.

[0163] A ceiling fan in which a coupling is located on the upper end of a non-rotating motor shaft.

[0164] A ceiling fan wherein the coupling includes a collar having a central opening for receiving a non-rotating motor shaft.

[0165] A ceiling fan in which a collar slides on a non-rotating shaft.

[0166] A ceiling fan in which the collar is indexed relative to a non-rotating shaft.

[0167] A ceiling fan wherein the index comprises: a collar and a non-rotating shaft, one of the collar and the non-rotating shaft including a key and the other including a keyway for receiving the key.

[0168] A ceiling fan further includes a locknut threaded onto the threaded portion of the non-rotating motor shaft.

[0169] A ceiling fan in which the studs are double-ended bolts.

[0170] A ceiling fan assembly further includes a nut threaded onto the stud to secure the coupling and the boom plate together.

[0171] A ceiling fan includes: a motor assembly having a rotating blade hub, the rotating blade hub having a first receiver; at least one fan blade, the fan blade having a second receiver; and a blade bracket having a first end and a second end, the first end having a first cross-section and the second end having a second cross-section different from the first cross-section, the first end being received in the first receiver and the second end being received in the second receiver to couple the blade to the blade hub.

[0172] A ceiling fan assembly wherein the first and second cross-sections have a height and a width, and the height of the second cross-section is less than the height of the first cross-section.

[0173] A ceiling fan assembly wherein the first and second cross-sections have the same area.

[0174] A ceiling fan assembly wherein the first and second cross-sections are not identical.

[0175] A ceiling fan assembly wherein the area of ​​the second cross-section is greater than the area of ​​the first cross-section.

[0176] A ceiling fan assembly wherein the first cross-section is a circle and the second cross-section is an ellipse.

[0177] A ceiling fan assembly, wherein a blade support comprises a circular segment defining a circle, an elliptical segment defining an ellipse, and a transition segment connecting the circular segment and the elliptical segment, wherein the transition segment transitions from a circular shape to an elliptical shape.

[0178] A ceiling fan assembly wherein the blade support is a single piece.

[0179] A ceiling fan assembly wherein the blade bracket is formed by stamping.

[0180] A ceiling fan assembly wherein an oval-shaped segment has a plurality of mounting openings.

[0181] A ceiling fan assembly wherein a second receiver is located inside the blade and the oval segment is received within the second receiver.

[0182] A ceiling fan assembly wherein a fastener extends through a plurality of openings and a blade.

[0183] A ceiling fan assembly wherein the first receiver includes at least one sleeve and the circular segment is received within the sleeve.

[0184] A ceiling fan assembly further includes an index portion that fixes the rotational position of the circular segment relative to the sleeve.

[0185] A ceiling fan assembly wherein the index portion includes a biased stop.

[0186] A ceiling fan assembly wherein a biased stop comprises a biasing pin on one of a circular segment and a sleeve and a recess on the other of the circular segment and the sleeve that receives the pin.

[0187] A ceiling fan assembly wherein the blade includes a hollow interior and an open end forming at least a portion of a second receptacle.

[0188] A ceiling fan assembly wherein the first receiver includes at least one split sleeve and the first end is received within and compressively retained by the at least one split sleeve.

[0189] A ceiling fan assembly further includes an index portion that fixes the rotational position of the blade relative to the blade hub.

[0190] A ceiling fan assembly further includes a mechanical fastener passing through the blade and the second end to secure the blade to the blade support.

[0191] Aspects of the present disclosure described herein relate to a ceiling fan comprising: a motor assembly having a rotating blade hub; and at least one blade mount disposed on the blade hub and having a split sleeve and a compression fitting closing the split sleeve.

[0192] A ceiling fan wherein a motor assembly includes a rotatable housing portion and a blade hub is disposed on the rotatable housing portion.

[0193] A ceiling fan wherein the motor assembly includes a non-rotating motor shaft about which a rotatable housing portion rotates.

[0194] A ceiling fan in which a blade hub is integrally formed with a rotatable housing portion.

[0195] A ceiling fan in which a split sleeve and a compression fitting are integrally formed with a rotatable housing portion.

[0196] A ceiling fan wherein the motor assembly includes upper and lower motor housings and one of the upper and lower motor housings forms a rotatable housing portion.

[0197] A ceiling fan further includes a pair of axially spaced compression fittings closing the split sleeve.

[0198] A ceiling fan in which a compression fitting is integrally formed with a split sleeve.

[0199] A ceiling fan wherein the compression fitting comprises a split ring.

[0200] A ceiling fan further includes a rotation index portion.

[0201] A ceiling fan wherein the rotation index comprises a detent in the sleeve.

[0202] A ceiling fan wherein the stop is aligned with a crack in the split sleeve.

[0203] A ceiling fan wherein the stop is on the inside of the compression fitting.

[0204] A ceiling fan wherein at least one blade mount comprises a plurality of blade mounts radially spaced about a blade hub.

[0205] A ceiling fan wherein the motor assembly includes a rotatable housing portion having a central hub and blade mounts extend radially from the hub.

[0206] A ceiling fan wherein the motor assembly includes a non-rotating shaft and a hub surrounds and rotates about the non-rotating shaft.

[0207] A ceiling fan wherein the motor assembly comprises an upper motor housing and a lower motor housing and one of which forms a rotatable housing portion.

[0208] A ceiling fan in which a blade mount is integrally formed with one of an upper motor housing and a lower motor housing.

[0209] A ceiling fan includes an upper motor housing, a lower motor housing, and magnet seats formed in a portion of the upper and lower housings, configured to accommodate a rotor and mount the rotor to the upper and lower motor housings.

[0210] A ceiling fan wherein the magnet comprises a permanent magnet.

[0211] A ceiling fan wherein the magnet comprises an electromagnet.

[0212] A ceiling fan wherein the electromagnet comprises a motor winding.

[0213] A ceiling fan wherein the magnet mount comprises facing channels formed in each of an upper housing and a lower housing which together form the magnet mount when the upper and lower housings are secured together.

[0214] A ceiling fan in which an upper housing and a lower housing are secured together by mechanical fasteners.

[0215] A ceiling fan in which at least one of an upper housing or a lower housing rotates to define a rotating housing.

[0216] A ceiling fan further includes a blade assembly coupled to the blade mount.

[0217] A ceiling fan, wherein a blade assembly includes a blade and a blade bracket for coupling the blade to the blade bracket.

[0218] A ceiling fan further includes a non-rotating motor shaft about which the rotating housing rotates.

[0219] A ceiling fan in which a rotating housing is rotatably mounted to a non-rotating motor shaft.

[0220] A ceiling fan further includes a stator winding mounted to the non-rotating shaft and located within the interior defined by the upper and lower housings.

[0221] A ceiling fan in which the magnet forms part of the rotor of the motor.

[0222] A ceiling fan in which an upper housing and a lower housing rotate about a non-rotating axis.

[0223] A ceiling fan further includes an upper bearing and a lower bearing, wherein the non-rotating shaft has an upper bearing stopper and a lower bearing stopper for supporting the bearings against which the upper housing and the lower housing abut respectively.

[0224] A ceiling fan wherein an upper housing and a lower housing are offset relative to their corresponding housing seats.

[0225] A ceiling fan in which the stator windings are fixed relative to a non-rotating shaft and about a housing base.

[0226] A ceiling fan comprises: a non-rotating motor shaft having an upper bearing stop and a lower bearing stop; a stator mounted to the non-rotating motor shaft; a rotor surrounding the stator; a motor housing having an upper bearing seat spaced above the upper bearing stop and a lower bearing seat spaced below the lower bearing stop; an upper bearing seated in the upper bearing seat; a lower bearing seated in the lower bearing seat; and a hanger connector disposed on the non-rotating shaft; wherein when the ceiling fan assembly is hung from a building using the hanger connector, the weight of the rotor presses the upper bearing against the upper bearing stop, so that the weight of the rotor is transferred to the non-rotating shaft through the upper bearing.

[0227] A ceiling fan assembly further includes a spring positioned within the lower bearing housing and biasing the lower bearing against the lower bearing stop.

[0228] A ceiling fan assembly wherein the non-rotating motor shaft is hollow and further comprising a retaining rod extending through the hollow motor shaft.

[0229] A ceiling fan assembly wherein the lower end of a retaining rod has a cap abutting a retaining plate adjacent a lower portion of a non-rotating shaft.

[0230] A ceiling fan assembly wherein the upper end of the retaining rod is positioned above the upper end of the non-rotating shaft.

[0231] A ceiling fan assembly wherein the upper end of the retaining rod terminates at a connecting fork.

[0232] A ceiling fan assembly wherein a rotor comprises an upper housing and a lower housing secured together, the upper housing having an upper bearing seat and the lower housing having a lower bearing seat.

[0233] A ceiling fan assembly wherein an upper housing and a lower housing define a magnet seat in which magnets of a rotor are located.

[0234] A ceiling fan assembly wherein a magnet base includes facing channels formed in each of an upper housing and a lower housing.

[0235] A ceiling fan assembly wherein an upper housing and a lower housing are secured together by mechanical fasteners.

[0236] A ceiling fan assembly further includes a plurality of blade mounts disposed on one of the upper housing and the lower housing.

[0237] A ceiling fan assembly wherein a blade mount includes at least one split sleeve.

[0238] A ceiling fan assembly wherein a blade mount includes at least two axially aligned split sleeves.

[0239] A ceiling fan assembly wherein the blade mount further includes a blade rotation stop.

[0240] A ceiling fan assembly wherein a non-rotating shaft has a stator stop positioned between upper and lower bearing blocks.

[0241] A ceiling fan assembly in which a stator stop and a lower bearing seat are formed by one or more collars on a non-rotating shaft.

[0242] A ceiling fan assembly wherein the non-rotating motor shaft includes a weep hole.

[0243] A ceiling fan includes a motor assembly having a hollow, non-rotating motor shaft; and a retaining rod extending through the motor shaft; wherein the retaining rod provides a redundant mounting system for the ceiling fan.

[0244] A ceiling fan further includes a retaining plate, wherein the retaining rod secures the retaining plate and the retaining plate is secured to the non-rotating motor shaft.

[0245] A ceiling fan wherein a non-rotating motor shaft is hollow and a retaining rod extends into at least the hollow portion of the non-rotating motor shaft.

[0246] A ceiling fan wherein the lower end of a retaining rod has a cap abutting a lower portion of a non-rotating shaft.

[0247] A ceiling fan in which the upper end of the retaining rod is located above the upper end of the non-rotating shaft.

[0248] A ceiling fan in which the upper end of the retaining rod terminates at a connecting fork.

[0249] A ceiling fan further includes a coupling coupled to the non-rotating shaft and a hanger plate coupled to a lower end of the hanger, wherein the coupling and the hanger plate are fixed to each other.

[0250] A ceiling fan in which a coupling is located on the upper end of a non-rotating motor shaft.

[0251] A ceiling fan wherein the coupling includes a collar having a central opening for receiving a non-rotating motor shaft.

[0252] A ceiling fan in which a collar slides on a non-rotating motor shaft.

[0253] A ceiling fan in which the collar is indexed relative to the non-rotating motor shaft.

[0254] A ceiling fan wherein the indexing comprises: one of the collar and the non-rotating motor shaft including a key and the other including a keyway to receive the key.

[0255] A ceiling fan further includes a locknut threaded onto the threaded portion of the non-rotating motor shaft.

[0256] A ceiling fan wherein at least one of the coupling and the boom plate has a stud and at least one other of the coupling and the boom plate has an opening for receiving the stud.

[0257] A ceiling fan further includes a nut threaded onto the stud to secure the coupling and the boom plate together.

[0258] A ceiling fan includes a motor assembly having a non-rotating hollow motor shaft; a stator winding carried by the motor shaft; and a wire harness passing through the hollow portion of the motor shaft and electrically coupled to the stator winding.

[0259] A ceiling fan further includes a hollow hanger mounted to the motor shaft, and the wiring harness passes through the hollow portion of the hanger and the non-rotating shaft.

[0260] A ceiling fan further includes a retaining rod extending through the hollow hanger rod and secured to at least one of the non-rotating motor shaft and the motor assembly.

[0261] A ceiling fan further includes a coupling coupled to the non-rotating shaft and a hanger plate coupled to a lower end of the hanger, wherein the coupling and the hanger plate are fixed to each other.

[0262] A ceiling fan in which a coupling is located on the upper end of a non-rotating motor shaft.

[0263] A ceiling fan further includes a locknut threaded onto the threaded portion of the non-rotating motor shaft.

[0264] A ceiling fan wherein the lower end of a retaining rod has a cap abutting a lower portion of a non-rotating shaft.

[0265] A ceiling fan in which the upper end of the retaining rod is located above the upper end of the non-rotating shaft.

[0266] A ceiling fan in which the upper end of the retaining rod terminates at a connecting fork.

[0267] A ceiling fan further includes an outlet passage extending from the hollow portion through the exterior of the motor shaft and through which the wiring harness passes.

[0268] A ceiling fan wherein the non-rotating shaft includes a stator stop against which the stator windings are placed.

[0269] A ceiling fan wherein the stator stop comprises a collar surrounding a non-rotating shaft.

[0270] A ceiling fan includes: a motor assembly having a rotating blade hub; a plurality of blades; at least one blade bracket for mounting the plurality of blades to the blade hub; at least one blade mount disposed on the blade hub for receiving the blade bracket and having at least one fastener aperture and at least one pin aperture; at least one saddle disposed in the fastener aperture; and at least one fastener for selectively tightening or loosening the saddle.

[0271] A ceiling fan wherein a motor assembly includes a rotatable housing portion and a blade hub is disposed on the rotatable housing portion.

[0272] A ceiling fan wherein the motor assembly includes a non-rotating motor shaft about which a rotatable housing portion rotates.

[0273] A ceiling fan in which a blade hub is integrally formed with a rotatable housing portion.

[0274] A ceiling fan wherein the motor assembly includes upper and lower motor housings and one of the upper and lower motor housings forms a rotatable housing portion.

[0275] A ceiling fan wherein at least one blade mount comprises a plurality of blade mounts radially spaced about a blade hub.

[0276] A ceiling fan wherein the motor assembly includes a rotatable housing portion having a central hub and blade mounts extend radially from the hub.

[0277] A ceiling fan wherein the motor assembly includes a non-rotating shaft and a hub surrounds and rotates about the non-rotating shaft.

[0278] A ceiling fan wherein blade mounts extend radially from a motor shaft to selectively define a horizontal plane.

[0279] A ceiling fan wherein the fastener apertures are oriented at an angle relative to the horizontal plane.

[0280] A ceiling fan wherein the angle is 20 degrees.

[0281] A ceiling fan wherein the blade mount defines a cylindrical cavity and the fastener aperture extends radially from the cylindrical cavity.

[0282] A ceiling fan wherein a saddle is adapted to anchor a blade bracket along a radial extension of a fastener aperture.

[0283] A ceiling fan wherein the motor assembly includes an upper motor housing and a lower motor housing, one of which forms a rotatable housing portion.

[0284] A ceiling fan in which a blade mount is integrally formed with one of an upper motor housing and a lower motor housing.

[0285] A ceiling fan wherein at least one fastener is a set screw.

[0286] A ceiling fan wherein the blade mount further includes an inlet, with the channel extending from the inlet to the pin aperture.

[0287] A ceiling fan in which the saddle is aligned along a channel.

[0288] A ceiling fan wherein the at least one saddle comprises two saddles.

[0289] A ceiling fan assembly includes: a stator assembly having a non-rotating motor shaft and a stator slidably and non-rotatably coupled to the non-rotating motor shaft; a rotor assembly; a first bearing slidably mounted to the non-rotating motor shaft and rotatably coupling the rotor assembly to the stator assembly; and a first washer positioned between the first bearing and the stator assembly to fix a sliding position of the first bearing relative to the stator along the non-rotating motor shaft.

[0290] A ceiling fan assembly further includes, in addition to a first bearing and a first washer, a second bearing and a second washer located on opposite sides of a stator, the second bearing being slidably mounted to a non-rotating motor shaft, the second washer being located between the second bearing and the stator.

[0291] A ceiling fan assembly wherein a second bearing rotatably couples the rotor assembly to the stator assembly.

[0292] A ceiling fan assembly wherein a stator is held in compression between a first spacer and a second spacer.

[0293] A ceiling fan assembly wherein a first gasket and a second gasket are compressively retained between a first bearing and a second bearing.

[0294] A ceiling fan assembly wherein a rotor assembly abuts at least one of a first bearing and a second bearing.

[0295] A ceiling fan assembly wherein a rotor assembly abuts both a first bearing and a second bearing.

[0296] A ceiling fan assembly wherein a rotor assembly includes a housing abutting both a first bearing and a second bearing.

[0297] A ceiling fan assembly wherein a stator assembly is compressively retained by at least one of a first washer and a first bearing.

[0298] A ceiling fan assembly wherein a first gasket is compressively retained between a first bearing and a stator assembly.

[0299] A ceiling fan assembly wherein a stator assembly abuts a first bearing.

[0300] A ceiling fan assembly wherein a first bearing is compressively retained between a stator assembly and the first bearing.

[0301] A ceiling fan assembly wherein a rotor assembly includes a housing compressively retaining a first bearing.

[0302] A ceiling fan assembly wherein the non-rotating motor shaft has a shoulder and at least one of a first bearing and a first washer abuts the shoulder.

[0303] A ceiling fan assembly wherein the first bearing abuts the shoulder.

[0304] A ceiling fan assembly wherein a spacer surrounds the shoulder.

[0305] A ceiling fan assembly wherein a gasket is held in compression between a bearing and a stator.

[0306] A ceiling fan comprises: a motor assembly having a rotating blade hub; at least one hub slot formed in the blade hub; a blade having a body, the body having the blade slot and the body extending from a root to an end to define an airfoil cross-section defined by the body along a span-wise axis and a chord-wise axis; and a strut having a hub portion received in the hub slot and a blade portion received in the blade slot to couple the blade to the hub; wherein at least one of the blade portions is rotatably offset from the hub portion or the blade slot is rotatably offset from the blade so that the blade is set at an angle of attack relative to the chord-wise axis when the blade portion is received in the blade slot.

[0307] A ceiling fan wherein the hub slot has a horizontally oriented bottom wall.

[0308] A ceiling fan wherein a blade portion is rotatably offset from a hub portion.

[0309] A ceiling fan wherein the cross-sectional area of ​​the strut is non-constant along the length of the strut.

[0310] A ceiling fan wherein the hub socket includes a bottom wall and at least one fastener aperture is formed in the bottom wall.

[0311] A ceiling fan wherein the hub slot further includes a tapered wall between the bottom wall and the remainder of the blade hub.

[0312] A ceiling fan wherein the hub slot further includes a mouth at a distal edge of the rotating blade hub.

[0313] A ceiling fan wherein the hub socket further includes a neck portion and a throat portion defined at the intersection of the mouth portion and the neck portion.

[0314] This written description uses examples to disclose the invention, including the best mode, and to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims and may include other examples that a person skilled in the art can think of. Other examples fall within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or include equivalent structural elements that do not differ substantially from the literal language of the claims.

Claims

1. A ceiling fan comprising: a motor assembly having a rotating blade hub and a boom mount; a plurality of blades mounted to the rotating blade hub; a boom having an upper end configured to be mounted to a building and having a lower end including a motor mount; a plurality of studs disposed in one of the hanger mount and the motor mount, and corresponding openings disposed in the other of the hanger mount and the motor mount, the studs being received within the openings to help secure the hanger to the motor assembly; and a motor assembly plate coupled to the motor assembly and a hanger plate coupled to a lower end of the hanger, wherein the stud is provided on one of the motor assembly plate and the hanger plate and the opening is provided in the other of the motor assembly plate and the hanger plate; Wherein the motor assembly further comprises a non-rotating motor shaft about which the rotating blade hub rotates, and the non-rotating motor shaft has a coupling forming the motor assembly plate, wherein the coupling is directly coupled to the non-rotating motor shaft.

2. The ceiling fan of claim 1, wherein the coupling is located above the rotating blade hub.

3. The ceiling fan of claim 1 , wherein the coupling is located on an upper end of the non-rotating motor shaft.

4. The ceiling fan of claim 1 , wherein the coupling comprises a collar having a central opening that receives the non-rotating motor shaft.

5. The ceiling fan of claim 4, wherein the collar slides on the non-rotating motor shaft.

6. The ceiling fan of claim 4, wherein the collar is indexed relative to the non-rotating motor shaft.

7. The ceiling fan of claim 6, wherein the index comprises a key and a keyway to receive the key, one of the collar and the non-rotating motor shaft comprising the key and the other comprising the keyway.

8. The ceiling fan of claim 1, further comprising a locknut threaded onto the threaded portion of the non-rotating motor shaft.

9. The ceiling fan of claim 1, wherein the stud is a stud bolt.

10. The ceiling fan of claim 9, further comprising a nut threaded onto the stud for securing the coupling and the hanger plate together.

11. The ceiling fan of claim 1 , further comprising a swivel mount on an upper end of the hanger rod.

12. A ceiling fan comprising: a motor assembly having a non-rotating motor shaft, a rotating blade hub rotatably coupled to the non-rotating motor shaft, and a hanger mount including a coupling directly coupled to the non-rotating motor shaft and having a plurality of spaced-apart openings; a plurality of blades mounted to the rotating blade hub; a hanger having an upper end including a swivel configured to be mounted to a building and a lower end including a motor mount, the swivel including a hanger plate having a plurality of spaced-apart openings corresponding to the spaced-apart openings on the coupling; and A plurality of studs extend through the spaced apart openings of the coupling and the spaced apart openings of the hanger plate to secure the coupling to the hanger plate and are configured to be secured by a plurality of nuts fitted onto the studs.

13. The ceiling fan of claim 12, wherein the motor assembly includes a non-rotating motor shaft, and the coupling is located on an upper end of the non-rotating motor shaft about which the rotating blade hub rotates.

14. The ceiling fan of claim 13, wherein the coupling comprises a collar having a central opening that receives the non-rotating motor shaft.

15. The ceiling fan of claim 14, wherein the collar slides on the non-rotating motor shaft.

16. The ceiling fan of claim 14, wherein the collar is indexed relative to the non-rotating motor shaft.

17. The ceiling fan of claim 16, wherein the index comprises a key and a keyway to receive the key, one of the collar and the non-rotating motor shaft comprising the key and the other comprising the keyway.

18. The ceiling fan of claim 13, further comprising a locknut threaded onto the threaded portion of the non-rotating motor shaft.

Images