A blade for a ceiling fan and a method of forming a blade for a ceiling fan

Abstract

A ceiling fan or similar air-moving device may include a motor for rotating one or more blades to drive a large volume of air around a space. The blades may include a body having an outer surface and side edges, the outer surface being a flat top surface and a flat bottom surface. Performance features may be included in the body to improve efficiency. Due to manufacturing deformation, there may be misalignments between the performance features and other parts of the body. Transition portions may be formed at these misalignments to remedy the inefficiencies caused by these deformations.

Description

Technical Field

[0001] This application relates to ceiling fans and devices for moving airflow throughout a space such as a room, and more specifically, to blades for a ceiling fan. Background Technology

[0002] A ceiling fan is a machine traditionally suspended from a structure to move a large volume of air around an area. A ceiling fan includes a motor with a rotor and a stator, which is suspended from and electrically connected to the structure. A set of blades is mounted to the rotor such that the blades are rotatably driven by the rotor and can be positioned at an angle to move a large volume of air around the area. As energy costs become increasingly important, there is a need to improve the efficiency of ceiling fan operation. Summary of the Invention

[0003] In one aspect, this disclosure relates to a blade for a ceiling fan having a motor for rotating the blade, the blade comprising: a body extending between a root and a tip to define a spanwise direction, and extending between a first side edge and a second side edge to define a chordwise direction; an upper surface disposed on the body; a performance feature disposed between the first side edge and the upper surface; and a transition portion disposed between the performance feature and at least one of the first side edge and the upper surface.

[0004] In another aspect, this disclosure relates to a blade for a ceiling fan, the blade comprising: a body including an upper surface and a lower surface; a side edge spaced apart from the upper surface and the lower surface; a performance feature formed in one of the upper surface and the lower surface and extending along the side edge; and a transition portion configured to transition between the performance feature and the side edge along the performance feature.

[0005] In another aspect, this disclosure relates to a method of forming blades for a ceiling fan, the method comprising forming a transition portion on the blade between a performance feature portion and a surface of the blade. Attached Figure Description

[0006] In the attached diagram:

[0007] Figure 1 This is a schematic diagram of a ceiling fan structure that is suspended from a structure and includes a set of blades.

[0008] Figure 2 Is it from this group of blades or Figure 1 A top view of a blade with a curved surface transitioning to the edge of the blade.

[0009] Figure 3 yes Figure 2 A cross-sectional view of the blade shows the curved transition to the blade edge on the top and bottom surfaces.

[0010] Figure 4 yes Figure 3 An enlarged cross-sectional view of one edge of the blade shows the elliptical curved surface of the blade.

[0011] Figure 5 This is a flowchart illustrating the method of forming blades. Detailed Implementation

[0012] This disclosure relates to ceiling fans and ceiling fan blades that can be used, for example, in residential and commercial applications. These applications can be indoors, outdoors, or both. While this description is primarily directed to residential ceiling fans, it is also applicable to any environment that utilizes a fan or air movement to cool an area, such as industrial, commercial, residential, or agricultural environments.

[0013] As used herein, the term "group" or "set" of elements can refer to any number of elements, including the case of a single element. All orientation markings (e.g., radial, axial, proximal, distal, upper, lower, upward, downward, left, right, lateral, front, rear, top, bottom, above, below, vertical, horizontal, clockwise, counterclockwise, upstream, downstream, forward, backward, etc.) are for identification purposes only to aid the reader's understanding of this disclosure and are not intended to be limiting, particularly regarding the location, orientation, or use of aspects of the disclosure described herein. Unless otherwise stated, connection markings (e.g., attachment, coupling, connection, and combination) should be interpreted broadly and may include intermediate members between sets of elements and relative movement between these elements. Therefore, connection markings do not necessarily indicate that two elements are directly connected or fixedly connected to each other. Exemplary figures are for illustrative purposes only, and the dimensions, positions, order, and relative sizes shown in the accompanying figures may vary.

[0014] Now for reference Figure 1 The ceiling fan 10 is suspended from the structure 12. In a non-limiting example, the ceiling fan 10 may include one or more fan components, including a hanger bracket 14, a top cover 16, a lower rod 18, a motor adapter 20, a motor housing 22 that at least partially surrounds a motor 24 having a rotor 26 and a stator 28, a lamp assembly 30, and a set of blade irons 32. In other non-limiting examples, the ceiling fan 10 may include one or more of a controller, a wireless receiver, a ball mount, a hanger ball, a lamp glass, a lamp cage, a main shaft, a pointed top, a switch housing, blade forks, blade tips or blade covers, or other fan components. A set of blades 34 may extend radially from the ceiling fan 10 and may be rotatable to drive a large amount of fluid (e.g., air) within the space defined by the structure 12. The blades 34 may be operatively coupled to the motor 24 at the rotor 26, for example, via the blade irons 32. The blades 34 may include a set of blades 34 having any number of blades (including the case of a single blade).

[0015] For example, structure 12 may be a ceiling to which ceiling fan 10 is suspended. It should be understood that structure 12 is shown schematically and by way of example only, and the structure may include any suitable building, structure, home, commercial, or other environment where it is appropriate or desirable to move air using a ceiling fan. Structure 12 may also include a power source 36 electrically connected to ceiling fan 10 to power ceiling fan 10 and the motor 24 therein. In a non-limiting example, it is also contemplated that the power source originates somewhere outside structure 12, such as a battery or generator.

[0016] Controller 38 may be electrically connected to power supply 36 to control the operation of ceiling fan 10 via power supply 36. Alternatively, controller 38 may be wirelessly or communicatively connected to ceiling fan 10, configured to remotely control the operation of ceiling fan 10 without a dedicated connection. Non-limiting examples of controlling ceiling fan 10 may include fan speed, fan direction, or the operation of lights. Furthermore, a separate wireless controller 40 (alone or together with wired controller 38) may be communicatively connected to a controller or wireless receiver in ceiling fan 10 to control the operation of ceiling fan 10. In an alternative example, it is also envisioned that the ceiling fan is operated independently by wireless controller 40 and is not operatively connected to wired controller 38.

[0017] exist Figure 2 In the middle, the blade 34 includes three fastener holes 50 for directly or indirectly fastening the blade 34 to the motor 24 so that the blade 34 surrounds the motor 24. Figure 1 The ceiling fan 10 rotates, while any number of fastener holes or any blade attachment method is contemplated. The blade 34 includes a body 52 having an outer surface 54. The blade 34 extends between a root 56 and a tip 58 to define a spanwise direction therebetween, and the blade extends between a first side arranged as a first edge 60 and a second side arranged as a second edge 62 to define a chordal direction extending between the first edge 60 and the second edge 62, which can be either leading or trailing edges based on the rotational direction of the blade 34. A curved corner 64 transitions between the tip 58 and the side edges 60, 62, and a sharp corner 66 transitions between the root 56 and the side edges 60, 62; however, it should be understood that any type of corner can be utilized. As the blade 34 extends toward the tip 58 in the spanwise direction, the blade can widen in the chordal direction, while any top-to-bottom shape for the blade is contemplated. Non-limiting examples of blade shapes can include square, rectangular, trapezoidal, linear, curved, angular, circular, converging, diverging, or combinations thereof.

[0018] Furthermore, the blade 34 may include performance features 68 disposed along one or more of the first side edge 60, the second edge 62, and the tip 58, wherein the performance features 68 extend along the root 56 only at the first edge 60 and the second edge 62. It should be understood that the performance features are not limited thereto and may extend along the root 56, the tip 58, the first side edge 60 and the second edge 62, or any combination thereof.

[0019] Figure 3 It shows crossing Figure 2 Section III-III is a cross-sectional view of the blade 34 taken along the chord direction to show the cross-section of the blade 34. The body 52 also includes an upper surface and a lower surface arranged as a top surface 70 and a bottom surface 72, the body having a rounded edge 74 transitioning between the bottom surface 72 and the first edge 60 and the second edge 62. The first edge 60 and the second edge 62 may include a thickness that spaces the top surface 70 and the bottom surface 72, such that the first edge 60 and the second edge 62 define the edges of a plane, while a nominal thickness is envisioned such that the first edge 60 and the second edge 62 define a line extending in the spanwise direction.

[0020] As used herein, a performance feature may include a feature disposed adjacent to one or more of a plurality of first edges. In a non-limiting example, a performance feature may include a chamfer, a curved surface (defined by an elliptical, parabolic, hyperbolic, or logarithmic geometry), or a curved feature such that the curvature defined by the performance feature is arranged tangent to the curvature of the performance feature at one or both of the upper surface and the side edges. Where a performance feature is adjacent to another performance feature, it is contemplated that the performance features may be arranged as a group of performance features, wherein at least one performance feature is adjacent to a side edge and another performance feature is adjacent to the upper surface.

[0021] The performance feature section provides improved aerodynamic performance to the fan blades, resulting in increased total airflow or reduced energy demand compared to blades without the performance feature section, while maintaining the aesthetic appearance of traditional fan blades as desired by consumers.

[0022] For example, performance feature 68 may include a curved surface, such as defining a portion of an airfoil profile. In another example, the profile of performance feature 68 (as shown) may be defined by an elliptical curvature. That is, the curvature may include a portion of an ellipse, such as a portion extending from one end of the major axis to the other end of the minor axis. Furthermore, it is contemplated that the ellipse defined by performance feature 68 may include a major axis parallel to one or both of the top surface 70 and the bottom surface 72.

[0023] More specifically, performance characteristic 68 can be represented by equation (1) written in standard form:

[0024]

[0025] In the Cartesian coordinate system, x represents the x-axis, and y represents the y-axis. Figure 3 The document provides exemplary x-axis and y-axis. The x-axis can be defined as the direction extending from the top surface 70 to the bottom surface 72, and the y-axis can be defined as the chord direction. Furthermore, 'a' represents the length of the ellipse on the x-axis, and 'b' represents the length of the ellipse on the y-axis. It should also be understood that when a = b, the ellipse can be circular, and since the diameter of a circle is equal, the major or minor axis is not defined. Furthermore, when a is not equal to b, all other ellipses can be non-circular, with the major and minor axes defined as the maximum and minimum diameters, respectively. Therefore, it is conceivable that the performance feature section 68 can be defined as an elliptical shape, a non-circular elliptical shape, a parabolic shape, or a hyperbolic shape.

[0026] In another example, performance feature 68 may be parabolic, and the equation representing at least a portion of the curvature of performance feature 68 may be expressed in standard form as follows:

[0027] (xh) 2 =4p(yk)(4)

[0028] The focus can be defined as (h, k+p) and the directrix as y = kp. x can represent the x-axis and y can represent the y-axis.

[0029] In another example, when performance feature 68 is a hyperbola, the equation representing at least a portion of the curvature of performance feature 68 can be expressed in standard form as follows:

[0030]

[0031] or

[0032]

[0033] Equation (5) is based on the horizontal axis, and equation (6) is based on the vertical axis, which ultimately depends on the local coordinate system that defines the performance feature 68. (h, k) can be used to define the foci of the hyperbola, where x can represent the x-axis and y can represent the y-axis.

[0034] In another example, the performance feature 68 is envisioned as a planar chamfer extending between the first edge 60 and the top surface 70. In yet another example, the performance feature 68 may be formed on both the top and bottom surfaces of the blade, and on both the first edge 60 and the second edge 62. That is, the performance feature may be disposed between the side edge of the blade 34 and one or both of the top and bottom surfaces of the blade. Furthermore, it is envisioned that the use of multiple performance features may be complementary or different from each other. For example, the performance features may be identical in the first edge 60 and the second edge 62. In another example, depending on the intended direction of rotation of the blade, the performance feature may differ in the first edge 60 and the second edge 62, such that the leading edge may differ from the trailing edge, or may differ relative to the top surface 70 or the bottom surface 72.

[0035] Transfer to Figure 4 A transition portion may be provided between the performance feature 68 and at least one of the top surface 70 and the first edge 60. Due to manufacturing deformation, a misalignment 78 may be created between the performance feature 68 and at least one of the top surface 70 and the first edge 60. More specifically, the performance feature 68 may be machined into the body 52 of the blade 34 such that the performance feature 68 is not aligned with the rest of the body 52, thereby creating the misalignment 78. Although the misalignment is only shown at the top surface 70 and the first edge 60, it should be understood that the misalignment 78 may be provided at the first edge 60, the second edge 62, the top surface 70, the bottom surface 72, or any other part of the body 52. ​​When the performance feature 68 includes curvature, the curvature may not be tangent to the rest of the body 52 at the location where the performance feature 68 intersects with the rest of the body 52. ​​For example, this misalignment may be formed as a step, and the specific geometry of the misalignment 78 may be specific to the manufacturing method or geometry of the performance feature 68.

[0036] As shown in the figure, a first transition portion 80 is provided between the top surface 70 and the performance feature portion 68, and a second transition portion 82 is provided between the first edge 60 and the performance feature portion 68. The first transition portion 80 provides a smooth transition from the performance feature portion 68 to the top surface 70. The first transition portion 80 may be planar, with the plane it defines deviating from the top surface 70 by an offset angle 84, and similarly, the first transition portion may deviate from the plane or line defined by the performance feature portion 68 by a second angle 86. More specifically, the offset angles 84 and 86 may be defined as the angle between the plane defined by the transition portion 80 and the plane defined by the top surface 70, and the angle between the plane defined by the transition portion 80 and the performance feature portion 68. In one example, the angle may be defined along a plane defined as passing through a section of the blade 34, such as... Figure 4The cross-section is shown in the diagram. For example, this cross-section can be defined as a top surface 70 perpendicular to the plane or a bottom surface 72 of the plane. In another example, the deviation angles 84 and 86 can be 179 degrees to 91 degrees, or 179 degrees to 135 degrees, while other ranges are contemplated. Since the performance feature 68 can be curved, the plane defined by the performance feature 68 can be a line tangent to the curvature of the performance feature at the location where the performance feature 68 intersects with the first transition portion 80.

[0037] Similarly, the second transition portion 82 can provide a smooth transition from the performance feature 68 to the first edge 60 to transition from the offset portion 78 to the first edge 60. The second transition portion 82 can be planar, with the plane defined by the second transition portion 82 offset from the first edge 60 to the performance feature 68. Since the performance feature 68 can be curved, the plane defined by the performance feature 68 can be tangent to the curvature of the performance feature at the location where the performance feature 68 intersects with the second transition portion 82. Although the transition portion is only shown at the first edge 60 and the top surface 70, it should be understood that other transition portions can be provided between any performance feature and any of the first edge 60 or the second edge 62, or the top surface 70 or the bottom surface 72.

[0038] During operation, transition sections 80, 82 provide a smooth transition between the performance feature section 68 and the rest of the blade body 52. ​​This smooth transition reduces turbulence and other inefficiencies that would occur without the transition sections. Furthermore, deformation during manufacturing, such as when cutting or extruding the blade, can create deviations between the performance feature section and the rest of the blade body. These deviations result in lower efficiency during operation. The transition sections described herein mitigate the inefficiencies caused by these deviations, thereby improving the efficiency of the ceiling fan.

[0039] It should also be understood that the transition portions 80, 82 may leave additional deformable portions 88 between the transition portions 80, 82 and one or more of the first edge 60, performance feature portion 68, or top surface 70, or any other portion of the adjacent transition portions 80, 82 of the blade 34. These deformable portions 88 can be shaped to further mitigate additional inefficiencies. These deformable portions 88 can be shaped to provide a shaped joint 90, for example by grinding or polishing, thereby providing a smooth transition between the transition portions 80, 82 of the blade 34 and adjacent portions.

[0040] refer to Figure 5The method 100 for forming ceiling fan blades may include: in step 102, providing a roughly machined blade portion. The roughly machined blade portion may be a blade that has not yet been machined to form performance features into the blade. In step 104, performance features may be formed on the blade or formed into the blade, for example, Figures 3 to 4 Performance feature section 68. For example, a cutting machine can cut off a portion of the roughly machined blade section to form the performance feature section. In another example, the blade can be formed by extruding the roughly machined blade section to form the performance feature section; however, any suitable method for forming the performance feature section is also envisioned.

[0041] Due to printing or other manufacturing deformations, a deviation may occur between the performance feature and the rest of the blade. When the performance feature includes curvature, this curvature may not be tangent to the rest of the blade body at the point where the performance feature intersects with it. For example, this deviation may be formed as a step; however, any geometry at the deviation is also contemplated.

[0042] In step 106, at least one transition portion may be formed on or into the blade at the offset, such as transition portions 80, 82 as described herein. In a non-limiting example, forming the transition portion may include any suitable method for removing some portion of the blade, such as grinding or cutting.

[0043] In step 108, method 100 may further include smoothing the edges at the transition portion. Forming the transition portion may leave additional deformation, such as hard and sharp edges at the junction between the transition portion and another surface (e.g., a top or bottom surface, or a first or second edge). Smoothing these edges (e.g., by grinding) can remove these additional deformations, thereby further smoothing the blade.

[0044] Forming the transition section, and smoothing the transition section as described below, can improve efficiency by eliminating the deformation generated during the formation of the performance feature section, which would otherwise produce unintended turbulence or wake that reduces fan blade efficiency. The benefits of the performance feature section are achieved by utilizing the transition section with the performance feature section, without suffering from defects caused by manufacturing deformation.

[0045] The blades and their cross-sections described in this article provide increased total airflow to ceiling fans, thereby increasing efficiency while maintaining the aesthetic appearance desired by consumers. More specifically, in addition to the performance features, the transition section also provides increased downward force on the air, which increases the total airflow, while the flat upper and lower surfaces of the blades match the traditional fan blade style, providing a pleasing or attractive user aesthetic.

[0046] Within the scope not yet described, different features and structures of various characteristics can be combined as needed. The fact that a feature is not shown in all aspects of this disclosure is not to be construed as meaning it cannot be found in all aspects of this disclosure, but rather for the sake of brevity. Therefore, the various features of the different aspects described herein can be combined and matched as needed to form new features or aspects of this disclosure, whether or not such new aspects or features are explicitly described. All combinations or arrangements of the features described herein are covered by this disclosure.

[0047] This written description uses these examples to illustrate in detail the aspects disclosed herein, including the best mode, and to enable any person skilled in the art to implement the aspects described herein, including making and using any apparatus or system and performing any combined methods. The scope of patentability for these aspects described herein is defined by the claims and may include other examples that would occur to a person skilled in the art. Such other examples are intended to be included within the scope of the claims if they have structural elements that are not indistinguishable from the literal language of the claims, or if they include equivalent structural elements that are not substantially indistinguishable from the literal language of the claims.

Claims

1. A blade for a ceiling fan, the ceiling fan having a motor for rotating the blade, the blade comprising: The body extends between the root and the apex to define the spanwise direction, and extends between the first and second side edges to define the chordwise direction; The upper surface of the plane is defined by the body; A performance feature portion is disposed between the first side edge and the upper surface of the plane, and the performance feature portion defines a curved surface having an elliptical profile, the curved surface extending between the first side edge and the upper surface of the plane; as well as The transition portion of the plane is disposed between the upper surface of the plane and the performance feature portion.

2. The blade according to claim 1, wherein the blade further comprises a shaped joint located between the transition portion and the performance feature portion.

3. The blade according to claim 1, wherein, The transition portion is arranged at an angle relative to the upper surface of the plane.

4. The blade according to claim 3, wherein, The angle is between 179 degrees and 135 degrees.

5. The blade according to claim 4, wherein, The transition portion is arranged at a second angle relative to the performance feature portion.

6. The blade according to claim 5, wherein, The second angle is 179 degrees to 135 degrees.

7. The blade according to claim 1, wherein, The transition portion is formed as a first transition portion located between the performance feature portion and the first side edge, and a second transition portion located between the performance feature portion and the upper surface of the plane.

8. The blade according to claim 7, wherein, The first transition portion and the second transition portion are formed along both the first side edge and the second side edge.

9. The blade according to claim 1, wherein, The performance feature extends entirely between the root and the tip.

10. The blade according to claim 9, wherein, The transition portion extends along the performance feature portion and is complementary to the performance feature portion.

11. The blade of claim 6, further comprising a second transition portion between the performance feature portion and the first side edge, wherein, The second transition section is planar.

12. The blade according to claim 11, wherein, The first side edge is planar.

13. The blade according to claim 1, further comprising a second performance feature portion between the upper surface of the plane and the second side edge, wherein, The second performance characteristic defines a surface that is different from the curved surface.

14. The blade according to claim 13, wherein, The surface of the second performance feature is curved.

15. The blade according to claim 14, wherein, The curved surface of the second performance feature defines at least one of a parabolic profile and a hyperbolic profile.

16. The blade according to claim 13, wherein, The surface of the second performance feature is planar.

17. The blade according to claim 16, wherein, The second side edge is planar.

18. A method for forming blades for a ceiling fan, the method comprising: A transition portion is formed on the blade between the performance feature portion of the blade and the upper surface of the plane, wherein the performance feature portion defines a curved surface with an elliptical profile, and a planar transition portion is provided between the performance feature portion and the upper surface of the plane.

19. The method of claim 18, further comprising forming the performance feature portion prior to forming the transition portion.

20. The method of claim 18, further comprising shaping the blade at a junction between at least one of the performance feature portion and the surface of the blade and the transition portion.

21. The method according to claim 18, wherein, The surface of the blade is one of the top surface and the side edge.

22. The method according to claim 18, wherein, The blade includes a deviation portion located between the performance feature portion and the surface, and at the deviation portion, the transition portion transitions between the performance feature portion and the surface.

23. A blade for a ceiling fan, the ceiling fan having a motor for rotating the blade, the blade comprising: The body extends between the root and the apex to define the spanwise direction, and extends between the first and second side edges to define the chordwise direction; The upper surface of the plane is defined by the body; A performance feature portion is disposed between the first side edge and the upper surface of the plane, and the performance feature portion defines a curved surface having a parabolic profile, the curved surface extending between the first side edge and the upper surface of the plane; as well as The transition portion of the plane is disposed between at least one of the first side edge and the upper surface of the plane and the performance feature portion.

24. A blade for a ceiling fan, the ceiling fan having a motor for rotating the blade, the blade comprising: The body extends between the root and the apex to define the spanwise direction, and extends between the first and second side edges to define the chordwise direction; The upper surface of the plane is defined by the body; A performance feature portion is disposed between the first side edge and the upper surface of the plane, and the performance feature portion defines a curved surface having a hyperbolic profile, the curved surface extending between the first side edge and the upper surface of the plane; as well as The transition portion of the plane is disposed between at least one of the first side edge and the upper surface of the plane and the performance feature portion.

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