Low-Profile Ceiling Fan With PCB Stator Axial-Flux Motor
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Solution Overview
Problem
Existing ceiling fans with traditional motors have a high profile that can project into spaces with low ceilings, limiting their use in areas where a reduced height is desired, and axial flux motors are costly and structurally incompatible with ceiling fan configurations.
Innovation Solution
A low-profile ceiling fan design utilizing an axial flux motor with a printed circuit board (PCB) stator and magnetic-plate rotor assembly, integrated blade mounts, and a compact motor housing to achieve a ultra-low-stack-height configuration, incorporating a single bearing for rotational support.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If a traditional motor assembly is used in a ceiling fan, then the motor provides sufficient rotational force to drive the fan blades, but the high profile of the motor assembly causes it to project into spaces with low ceilings, limiting its usability
Solution Approach 1:
The patent transitions from a conventional radial flux motor design to an axial flux motor design, fundamentally changing the dimensional arrangement of magnetic components. The magnetic rotor plates are positioned axially above and below the stator assembly, with magnetic flux traveling parallel to the rotation axis rather than radially. This dimensional reconfiguration enables the motor to achieve the required rotational force while maintaining a compact profile suitable for low-ceiling installations.
Solution Approach 2:
The patent employs composite construction by integrating the magnetic rotor plates directly with the blade assembly, creating a unified rotating component. The rotor plates are coupled to the blade iron or blade mount, forming a composite structure that eliminates the need for a separate traditional motor housing and reduces overall motor assembly height while maintaining mechanical strength and rotational efficiency.
2Length of stationary object
If an axial flux motor is used to reduce the profile height, then the motor achieves a lower profile suitable for low ceilings, but traditional axial flux motors are costly and structurally incompatible with ceiling fan configurations
Solution Approach 1:
The patent divides the axial flux motor into discrete, manufacturable components: a stator assembly with stationary motor shaft and stator, magnetic rotor plates that can be separately manufactured and then coupled to the blade assembly. This segmentation allows each component to be produced using standard manufacturing processes and assembled into the final motor configuration, reducing overall manufacturing cost and improving structural compatibility with existing ceiling fan designs.
Solution Approach 2:
The motor assembly is designed with universal compatibility features, allowing it to integrate with various ceiling fan blade configurations. The rotor assembly can be coupled to different blade iron or blade mount designs, and the motor housing can accommodate different stator and rotor plate configurations. This multi-functionality enables the same basic motor design to serve various ceiling fan applications without requiring custom manufacturing for each configuration.
3Length of stationary object
If a compact motor housing is used to achieve ultra-low-stack-height, then the ceiling fan profile is significantly reduced for low-ceiling spaces, but the motor assembly requires innovative bearing integration to maintain rotational support
Solution Approach 1:
The patent merges the bearing assembly with the stator assembly, integrating the rotational support function directly into the stationary motor shaft structure. The bearing is positioned within the motor housing and rotationally couples the rotor assembly to the stationary motor shaft, eliminating the need for separate bearing housings or additional structural components. This merging reduces the overall stack height while maintaining reliable rotational support for the fan blades.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution provides a ceiling fan with a significantly reduced profile, enhancing usability in low-ceiling spaces while leveraging the higher power density of axial flux motors without the cost barriers, and allowing for efficient heat dissipation and secure mounting of light kits.
Implementation Method 1
a bearing assembly having a single bearing rotationally coupling the stationary motor shaft to the rotor assembly
Implementation Method 2
A low-profile ceiling fan design utilizing an axial flux motor with a printed circuit board (PCB) stator and magnetic-plate rotor assembly
Data Source
AI summary
A ceiling fan includes a motor housing and a motor enclosed by the motor housing. A set of blades can extend from the motor housing and be operably coupled to the motor. The motor can include a rotor assembly and a stator assembly. The motor further includes a stationary motor shaft about which the rotor assembly rotates. A bearing rotatably supports the rotor assembly to the stationary motor shaft.