Note: Descriptions are shown in the official language in which they were submitted.
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CEILING FAN WITH EASY INSTALLATION FEATURES
Field of the Invention
The present invention is directed to the general field of electrical
fixtures, and to the more specific field of ceiling fans with features that
make easier the
tasks of hanging and electrically connecting the fan, and the task of
installing the fan
blades.
Background of the Invention
The installation of a suspended electrical fixture, particularly a ceiling
fan, to an overhead support can be a difficult task for a single installer.
For example,
to install a conventional ceiling fan, the fan is lifted to just below the
electrical junction
box and held there while connecting the fan wires to the electrical supply
wires. After
the electrical connection is finished, the fan is lifted further to place the
fan bell over
the junction box and held in that position while the fan is attached to the
box or a
ceiling hanger in some manner, typically with screws or bolts. The combined
operation takes several minutes and usually requires two persons, one to lift
and hold
and the other to make the wire and screw connections.
Installing a suspended electrical fixture can also pose a risk of electrical
shock to the installer and/or short-circuiting the electrical supply circuit.
Some
installers, particularly do-it-yourself homeowners, are prone to either forget
or neglect
to shut off the supply of electricity to the circuit they are installing the
fixture in. Most
conventional fixtures have bare-ended wires meant to be spliced to supply
wires
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located in an overhead junction box. An installer who fails to shut off the
electricity
and splices live wires is destined to receive an electrical shock. Even if the
fixture
were supplied with a conventional electrical plug, an installer could get an
electrical
shock by touching one of the plug's prongs when the plug is partially inserted
into a
live receptacle. If the installer were to touch two of the partially inserted
prongs
simultaneously with a finger, tool or other conductive object, the supply
circuit would
also be short-circuited.
Some electrical fixture installations are subject to water infiltration,
particularly those having junction boxes mounted in a ceiling adjacent a
leaking roof,
adjacent the underside of a roof on which condensation forms, under a bathroom
or
other area having leaking plumbing or the like: The infiltrating water can
cause an
electrical short, which could start a fire.
To reduce the weight and profile of the fan while making the electrical
and ceiling attachment, the fan blades are usually attached by screws to the
drive ring
hub after the fan is hung from the ceiling. Once the fan blades are attached
to the fan,
they are not easily removed.
Summary of the Invention
The present invention provides an easily installed electrical fixture. The
fixture includes a quick connect device for electrically and physically
mounting the
fixture to a ceiling, and in the case of a ceiling fan, an articulating blade
assembly that
allows the blades to be hung from the drive ring hub in a collapsed vertical
orientation
before the fan is hung from the ceiling, and then quickly snapped into the
extended
operating position.
A quick connect device of the present invention includes a first plate
that is attachable to an electrical junction box and a second plate that is
attachable to
an electrical fixture. The first plate contains a first electrical contact and
the second
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plate contains a second electrical contact. The second plate is rotatably
coupled to the
first plate to provide an electrical connection therebetween.
In a preferred embodiment, the quick connect device includes a
receptacle plate wherein the first electrical contact is an electrical
receptacle that can
be connected to supply wires in the electrical junction box and a plug plate
wherein the
second electrical contact is an electrical plug of the type that mates with
the receptacle,
such as a three- or four-prong plug. The plug is rotatably mounted in the plug
plate
and is connected to electrical conductors for supplying electricity to the
motor and any
accessories. The receptacle plate and the plug plate are configured to secure
one plate
to the other by rotating one of the plates when the plug is inserted in the
receptacle to
align flanges in the ends of the plug plate to be inside of slots in the ends
of the
receptacle plate.
An articulating fan blade assembly of the present invention includes a
drive ring hub, a fan blade and a lock. The drive ring includes at least one
receiving
1 S slot. The fan includes a mounting portion extending from one end of the
fan blade.
The mounting portion includes a shaft configured for being received in the
receiving
slot. The lock retains the fan blade shaft within the receiving slot upon
insertion of the
shaft into the receiving slot.
More particularly, the articulating fan blade assembly includes a
cylindrical rotary drive ring hub with fan blade receiving slots in the wall
of the ring.
The receiving slots are positioned equidistantly about the ring. Each fan
blade has a
mounting bracket extending from a root end of the blade. The mounting bracket
includes a shaft configured for insertion into the receiving slot.
Brief Description of the Drawings
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For purposes of illustrating the invention, the drawings show one or
more forms in which the invention can be embodied. The invention is not,
however,
limited to the precise forms shown unless such limitation is expressly made in
a claim.
Figure 1 is an elevation view of a ceiling fan according to the present
invention.
Figure 2 is a perspective, partial section view of the quick connect
device of the present invention.
Figure 3 is a perspective view of a receptacle plate of the quick connect
device of Figure 2.
Figure 4 is a exploded view of the quick connect~device of Figure 2.
Figure S is a perspective view of the quick connect device of Figure 2
after initial engagement between the receptacle and plug.
Figure 6 is a perspective view of a quick connect device of the present
invention attached to a ceiling fan bell.
Figure 7 is a bottom plan view of the plug plate of the quick connect
device.
Figure 8 is another bottom plan view of the plug plate of the quick
connect device.
Figure 9 is a top plan view of the plug plate of the quick connect device
of the present invention.
Figure 10 is a top plan view of the receptacle plate of the quick connect
device of the present invention.
Figure 1 I is a bottom plan view of the receptacle plate of the quick
connect device of the present invention.
Figure 12 is a side cross-sectional view of a first and a second plate of
another embodiment of a quick connect device of the present invention.
Figure 13 is a bottom plan view of the first plate of the embodiment of
Figure 12.
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Figure 14 is a top perspective view of the second plate of the
embodiment of Figure 12.
Figure 15 is a sectional view of the first and second plate of the
embodiment of Figure 12 taken along line 15-15.
Figure 16 is a perspective view of a first and a second plate of another
embodiment of a quick connect device of the present invention.
Figure 17 is a side view of the second plate ofthe embodiment ofFigure
16.
Figure 18 is a side view of the first plate of the embodiment of Figure
16.
Figure 19 is a side view of another embodiment of a quick connect
device of the present invention.
Figure 20 is a side view of another embodiment of a quick connect
device of the present invention.
1 S Figure 21 is a bottom plan view of an articulating fan blade assembly
of the present invention.
Figure 22 is a perspective view of the articulating fan blade assembly.
Figure 23 is a top plan view of a cover of a drive ring of a ceiling fan
of the present invention.
Figure 24 is a bottom plan view of the drive ring of Figure 23.
Figure 25 is a top plan view of a portion of a drive ring of a ceiling fan
in accordance with the present invention.
Figure 26 is a bottom plan view of the portion of the drive ring of
Figure 25.
Figure 27 is a partial elevation, section view of the drive ring and fan
blade of the present invention.
Figure 28 is an alternate embodiment of the drive ring and fan assembly
of the present invention.
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Figure 29 is a perspective view of an alternative embodiment of a quick
connect device according to the present invention.
Figure 30 is a perspective view of the upper side of the coupling plate
and plug of the alternative embodiment shown in Figure 29.
Figure 31 is a perspective view of the lower face of the mounting plate
and receptacle of the alternative embodiment shown in Figure 29.
Figure 32 is a plan view of the mounting plate and receptacle shown in
Figure 30.
Figure 33 is a cross-sectional view ofthe mounting plate and receptacle
as taken along line 16-16 of Figure 32.
Figure 34 is a plan view of the coupling plate and plug shown in Figure
30.
Figure 35 is a cross-sectional view of the coupling plate and plug as
taken along line 18-18 of Figure 34.
Figure 36 is a cross-sectional view of the coupling plate and plug as
taken along line 19-19 of Figure 34.
Figure 37 is a cross-sectional view of the quick connect device,
comprising a combination of the cross-sectional views of Figures 33 and 35,
showing
the plug and coupling plate engaging, respectively, the receptacle and
receiving plate.
Detailed Description of the Invention
Quick Connect Device
In the drawings, where like numerals indicate like elements, a ceiling
fan is generally indicated by the numeral 2. The fan elements are
conventional, the
particular type or design of these conventional elements not being material to
the
invention. These conventional elements include a drive housing 4 that encloses
a drive
motor (not visible in any of the drawings), a hanger tube 6 which provides a
conduit
for electrical wires; a bell 14 that covers the ceiling cut-out, a drive shaft
7 and a switch
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housing 9. The feature that is unique is a quick connect device by which the
fan is
easily hung from a ceiling 8 and connected to an electrical supply. Although a
ceiling
fan is illustrated in the drawings, any electrical fixture suspended from a
support
located above the fixture may be installed using the quick-connect device of
the present
invention. Examples of such suspended fixtures include chandeliers, speakers,
security
cameras, signs, television monitors and the like.
As shown in Figure l, an electrical junction box 10 is recessed in the
ceiling 8. The junction box 10 is of the type that supports a ceiling fan and
houses the
electrical wires. A general characteristic of a ceiling fan junction box is
that it has
some type of reinforced screw receptacles, such as threaded metal blocks or
threaded
shoulder rivets, to receive screws attaching the fan to the box. U.S: Pat.
Nos. 5,762,223
and 5,860,548, both to J. Russell Ken, Jr., describe exemplary boxes of this
type, and
a box sold by Angelo Fan Brace, LLC under the trade name SAF-T-BOX Model 1050
is an example of an electrical junction box that can be used with the present
invention.
The box may be fastened directly to a ceiling joist or be mounted between
joists on a
hanger.
A quick connect mounting device is used to connect the fan to the
electrical junction box and the electrical supply wires to the fan. In one
embodiment
of the mounting device, shown in Figures 2-I l, the weight of the fan is
transferred
from the hanger tube to the mounting device through the fan bell. In an
alternative
embodiment, shown in Figures 29-37, the weight of the fan is transferred
directly from
the hanger tube to the mounting device by means of a ball and socket joint.
Figures 2 to 11 show details of one embodiment of a quick connect
device 12 according to the present invention. The quick connect device 12
includes
a mounting plate 16 that attaches to an electrical junction box I 0. The
mounting plate
has two through holes 18, 20 to pass through two threaded screws 22, 24 that
are
received by the box's internally threaded shoulder rivets 26, 28 to attach the
mounting
plate 16 to the junction box 10. The screws 22, 24 and rivets 26, 28 secure
the
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mounting plate 16 to the electrical boa 10 and provide adequate support and
rigidity
to sustain the weight and torque of a ceiling fan.
In an alternative embodiment, not shown but easily understood from the
previous paragraph, the mounting plate has a pair of key slots in place of the
through
holes. The screws 22, 24 are initially threaded part way into the rivets 26,
28, and the
key slots of the mounting plate are aligned with barrel of the screws.
Thereafter, the
mounting plate is rotated to move the screws into the slots and the screws are
tightened
to secure the mounting plate to the junction box. Any configuration of the
mounting
plate that provides the same function is contemplated as another possible
alternative
embodiment. .
The mounting plate 16 holds an electrical receptacle 30. In the
embodiment depicted in Figures 1 to I 1, the electrical receptacle is a
conventional
three-prong receptacle. Electrical wires I 1 are connected to the terminals of
the
receptacle 30 to supply electricity to the fan 2.
Referring now to Figures 3 and 4, the upwardly facing side of the
mounting plate 16 is cut back to form flanges 34, 36 located on opposite ends
of the
mounting plate 16 and extending from its downwardly facing side. Bores 38, 40
(see
Figure 10) are formed in the top surface of each of the flanges 34, 36 and
extend into
the main body of the mounting plate 16, forming cut-outs in the flanges and
hollow
cylindrical cavities in the main body, as shown in Figure 4. The purpose of
the bores
is explained below.
Referring to Figures 4, 8 and 9; the quick connect device 12 also
includes a coupling plate 42 to which the bell 14 is attached. The coupling
plate 42
holds a conventional cylindrical three-prong plug 44, which is secured to the
coupling
plate 42 in a fashion that enables the coupling plate to rotate around the
plug (or the
plug to rotate inside the coupling plate). In the depicted example, the
coupling plate
42 has a central aperture 43 to hold the cylindrical body of the plug 44. The
central
aperture 43 has a diameter at the upwardly facing side of the coupling plate
42 that is
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slightly Less than the diameter of the plug 44 so that the plug cannot be
pulled through
the aperture 43 from the upwardly facing side of the coupling plate 42. The
downwardly facing side of the coupling plate 42 has a rabbet (similar to the
rabbet 45'
shown in Figure 32) adjacent the periphery of the aperture that has a diameter
slightly
larger than the diameter of the plug 44, which enables the plug to rotate
within the
rabbet.
As shown in Figure 7, a retaining ring 46 is attached to the downwardly
facing side ofthe coupling plate 42. 'The retaining ring 46 has a central
opening to pass
through electrical wires from the fan 2. The retaining ring 46 is fixed to the
coupling
plate 42, in this embodiment by a pair of screws 48, 50. This configuration
enables the
coupling plate 42 to rotate relative to the plug 44 about an axis normal to
the upwardly
facing side of the coupling plate 42.
A pair of latch slots 52, 54 are defined at opposite ends of the coupling
plate 42 by a pair of upwardly-extending end walls 56, 58 of the coupling
plate
1 S extending upwardly (as illustrated in Figure 4) and a pair of upper walls
60, 62 that
extend inwardly from the upper ends of the end walls 56, 58. The latch slots
52, 54 are
shaped and sized to receive the flanges 34, 36 of the receiving plate.
The coupling plate 42 has two pairs of screw holes 64, 66 (see Figure
9) to fasten the coupling plate 42 to the fan bell 14. Each pair of screw
holes 64, 66
has one hole formed in each end wall 56, 58. As illustrated in Figure 6, the
fan's bell
14 also has two pairs of screw holes 67, 68 that align with the coupling
plate's screw
holes 64, 66, respectively, when bell 14 is properly positioned with respect
to the
coupling plate 42. The second hole (not shown) of each pair of screw holes 67,
68 is
located diametrically opposite the corresponding hole 64, 66 shown in Figure
5. The
pair of screw holes 67, 68 receive screws 65, 70, which extend through the fan
bell 14
and into the coupling plate screw holes 64 and secure the coupling plate 42 in
the bell
14.
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When the mounting plate 16 and the coupling plate 42 are rotated into
their latched position (as shown in Figure 6 and described below), the second
set of
coupling plate screw holes 64, 66 align with the mounting plate bores 3 8, 40.
Once the
two plates are aligned, the second set of screw holes 64, 66 in the coupling
plate 42 and
the corresponding second set of screw holes 67, 68 in the bell receive screws
65, 70
which extend through the bell 14, through the end wall and into the bores 38,
40 in the
receiving plate.
The coupling plate may include a stop 72 along one side of the
mounting plate to facilitate alignment of the coupling plate and the receiving
plate, as
described below.
Installation of a Ceiling Fan with a Quick Connect Device
A ceiling fan is installed using the quick connect device of Figures 2-11
using the following steps. In a preferred embodiment, the fan is expected to
be sold
with the coupling plate 42 having the fan's electrical supply wires already
connected
to the proper conductors of the electrical plug 44. The mounting plate 16 will
be
included with the fan, but as an unattached item.
The first step is to connect the wires 11 from the electrical supply to the
corresponding terminals of receptacle 30 in the mounting plate 16. The
mounting plate
16 is then attached to the electrical box 10 by the screws 22, 24.
Next, the fan is lifted to the junction box and the plug 44 is rotated to
a position where it can be inserted into the receptacle 42, as in Figure 5. In
this
position, the coupling plate 42 will be across the mounting plate 16 at a
sufficient angle
that the flanges 34, 36 of the mounting plate 16 do not contact the coupling
plate. The
fan is then raised to push the prongs of the plug 44 fully into the receptacle
30, and the
fan is then rotated (as shown by arrow A in Figure 5) to align and interlock
the two
plates, that is, the flanges 34, 36 in the mounting plate 16 are in the latch
slots 52, 54
of the coupling plate 42. If the coupling plate 42 has a stop ?2, the fan is
rotated until
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the mounting plate 16 contacts the stop 72, at which position the respective
screw holes
64, 66 on the coupling plate will be aligned with bores 38, 40 on the mounting
plate.
The screws 70 are then tightened to fix the coupling plate 44 to the mounting
plate 16.
The screws 70 hold the plates 16, 42 securely together and prevent them from
separating regardless of the direction that the fan blades rotate.
Thus, the required time and difficultly of hanging and electrically
connecting the fan is greatly reduced, and the operation can be easily done by
one
person.
One skilled in the art will readily understand that the installation of
electrical fixtures other than ceiling fans would be similar to that described
above, as
would installation of an electrical fixture using the embodiment ofthe
mounting device
depicted in Figures 12-20. In addition, the mounting device may be sold
separately
from the electrical fixture, in which case the plug would include terminals
for attaching
the fan wires to the plug.
The present invention may be embodied in other specific forms.
Accordingly, reference should be made to the following claims, rather than to
the
foregoing embodiments, to appreciate the scope of the invention.
Alternative Embodiments of the Quick Connect
Alternative embodiments of the quick connect device may be made by
reversing some of the parts, such as a fixed plug and a rotatable receptacle.
Any
operable permutation of the plates and the rotatable pluglreceptacle is
considered to
be within the scope of the present invention. Further, the preferred
embodiment of the
invention discloses a plug plate and a receptacle plate having a generally
rectangular
main body with curved ends, as illustrated, but the invention is not intended
to be
limited to that configuration.
In some alternative embodiments, the quick connect device does not
include a plug/receptacle type of electrical connection. Referring to Figures
12-15, the
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quick connect device includes a first plate 200 and a second plate 202, and
each plate
200, 202 includes electrical contact strips 204 in the face of the plate 200,
202 that is
adjacent to the other plate when the plates are connected. Each contact strip
204 is
slightly bowed outwardly from the face of the plate to provide a good
electrical contact
between the corresponding strips. The first plate strips 204a connect
electrically to a
power supply (not shown) in the electrical junction box and the second plate
strips
204b connect electrically to the fan motor.
The second plate 202 also includes a key 206 centrally positioned on
the face 208 of the second plate 202. The key 206 is formed by a stem 210
extending
from the plate face 208 and a head 212 at the end of the stem 210.. The head
212 may
have an oval or oblong shape, The first plate 200 has an key slot opening 214
that has
a shape corresponding to the shape of the key head 212. The key stem 210 has a
height equal to or slightly greater than the thickness of the first plate 200.
When the
key 206 is inserted into the key slot 214 and the second plate rotated to turn
the key
head 212 transverse to the key slot 214, the first plate 200 and the second
plate 202 are
locked in proximity to each other to establish and preserve an electrical
connection
between the first plate strips 204a and the second plate strips 204b.
Referring to Figures 12 and 13, the first plate 200 may also include a
spring loaded shock protector 216 to prevent an installer from unintentionally
touching
the contact strips 204a after the first plate 200 has been electrically
connected to the
junction box. The shock protector 216 includes a base 218 and divider walls
220
extending perpendicularly from the base 218. The base 218 is positioned on the
back
side 219 of the first plate 200, opposite the plate's face 209. The divider
walls 220
extend through and past the first plate 200 a distance sufficient to prevent
an average
adult's finger from engaging the strips 204a.
A pair of coil springs 222 are attached to the back side 219 of the first
plate 200 and to the base 218 of the shock protector. When the springs 222 are
relaxed,
the dividers 220 are in an extended position away from the first plate 200.
Referring
,. , ,
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to Figure 1 S, the dividers 220 have an end 224 that is sloped to present a
"V"- shaped
tip. When the key 206 is inserted into the slot 214 and the second plate 202
is rotated
to engage the contact strips 204, a side 226 of the second plate 202 engages
the sloped
end wall 224 and forces the shock protector 216 away from the back side 219 of
the
first plate 200, stretching the springs 222. When the first and second plates
200, 202
are separated, for example to uninstall the fan, the springs 222 contract and
the shock
protector 216 is pushed back towards the back side 219 of the first plate 200.
In this
manner, a person removing the fan will not be able to accidently touch the
contact
strips. In all other regards, the embodiment illustrated in Figures 12 to 15
is identical
to the embodiment described in Figures 2 to 11.
Figures 16, 17, and 18 illustrate how the embodiments of Figures 2-1 S
may be enhanced to accommodate multiple size fan bells. This feature would
typically
be used in quick connect devices that are retrofit to existing ceiling fans.
As illustrated,
the second or plug plate 300 includes a bottom section 302 and a top section
304. A
plurality oftabs 306 are attached and extend from opposing sides of the bottom
section
302. The bottom section 302 includes a cut out section 308. The top section
304 has
a height that snugly fits into the cut-out section 308 as guided by the tabs
306.
This embodiment includes a plug 310 that has a collar 312 and a lip 311
positioned thereabout. Both the bottom section 302 and the top section 304
include a
central opening 314, 316, which may be rectangular or oblong. The central
opening
314 of the bottom section 302 has a width generally equal to the diameter of
the plug
312 while the central opening 316 of the top section 304 has a width equal to
the
diameter of the lip 311. In this manner, the plug 310 resides within the
central
openings 314, 316 with the lip 311 resting on the bottom section 302 and the
collar 312
resting on the top section 304.
Depending upon the size of the fan bell, the top and bottom sections
302, 304 may be pulled apart or pushed together. As the second plate 300 is
fit into
the fan bell, the first set of screws 68 may be inserted through the fan bell
and into the
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receiving holes 64 to fix the second plate to the fan bell, as described
above. Once the
second plate 300 is fixed to the fan bell , the plug 310 can be adjusted to
the center of
the second plate, as allowed by the central openings 314, 316 and thereafter
the collar
312 fixed to the top section 304 by a set of screws 307. The collar 312 is
attached to
the plug 310 in a manner that permits the second plate 300 to rotate about the
plug 310. '
The first or receptacle plate 320 includes a top section 322 and a bottom
section 324. Each section 322, 324 includes a cut-out. When fully engaged, the
two
sections form a unit equivalent to the receptacle plate described above. This
embodiment includes a receptacle 326 having a collar 328 thereabout. The
receptacle
326 resides in a opening 330, 332 in each section 322, 324, respectively, with
the collar
328 resting on the top section 324. Each receptacle plate section 322, 324
includes a
first set of slots 334 that receive screws 336 for fixing the two sections
322, 324 to
each other once the sections have been sized to correspond to the size of the
plug plate
sections 302, 304. Each receptacle plate section 322, 324 also includes a
second set
of slots 338 that receive screws (not shown) for attaching the receptacle
plate to the
electrical junction box once the sections 322, 324 have been sized and fixed
to each
other.
This embodiment is otherwise identical to the first embodiment
described above in all material respects.
Figure 19 illustrates another alternate embodiment of the quick connect
device. In this embodiment, the quick connect device includes a disk 400 that
is
attachable to an electrical junction box 402. The disk 400 carries a first
electrical
contact element 404. The first contact element 404 is wired to electrical
supply in the
junction box 402. The first contact element 404 may be either the plug or the
receptacle of a,plug/receptacle connection or a contact strip. The disk 400
includes a
pair of receiving slots 406 that are positioned on opposing sides of the disk
400 and
have a generally "L" shaped co~iguration.
t
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The quick connect device also includes a pair of locking pins 408
mounted on the inside of a fan bell 410. The locking pins 408 are mounted on
opposing sides of the fan bell 4I0 corresponding to the receiving slots. A
second
contact element 412 is also mounted inside the fan bell 410. The second
contact
element 412 may be the other of the plug/receptacle connection or a second
contact
strip. The second contact element is positioned such that when fan bell 410 is
brought
to the disk 400 bring the locking pins into the receiving slots 406 and the
fan bell 410
is rotated to secure the locking pins 408 in the receiving slots 406, the
second contact
element 412 engages the frst contact element 404. Once the fan bell 410 is
mounted
to the disk 400 a pair of set screws may be used to secure the fan bell 410 to
the disk
400 to prevent rotational movement between the two.
Figure 20 illustrates an alternate embodiment for connecting a plug
plate 500 to the fan. A bracket 502 couples the plug plate 500 to a ball 504.
The
bracket 502 may be connected to the plug plate 500 or formed integrally
therewith.
The bracket 502 serves as a socket allowing the ball to rotate. A down rod 506
is
connected to the ball 504. The down rod 506 connects to a motor housing (not
shown).
Once the ball 504 has been secured in the bracket 502, a fan bell 508 may be
installed.
The fan bell 508 may be attached to the plug plate 500, the electrical
junction box or
the ceiling. The bracket may also be used in conjunction with an embodiment
incorporating the contact strips.
Fan Blade Assembly
A second feature of the easily installed ceiling fan of the present
invention is its articulating fan blade assembly. The blade assembly allows
the blades
to be hung from the drive ring in a collapsed vertical orientation before
hanging the fan
from the ceiling, and then easily snapped into the extended operating
position. A
related advantage is that the blades can later be lowered while still attached
to the drive
ring for cleaning and maintenance.
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Referring to Figure 1, the ceiling fan 2 has a drive shaft 7 connecting
the fan motor to a drive ring usually called the blade hub 80. A plurality of
fan blades
82 is positioned equidistantly about the hub 80.
In conventional fans, the blade has an airfoil portion or paddle, usually
of wood or plastic construction, and a decorative metal mounting bracket
attached to
the root end of the paddle. The mounting bracket is attached by screws to the
hub.
When the blade is mounted to the hub, it is in its fixed operating position
(some may
permit minor adjustments to the blade angle). As shown in Figures 21 and 22,
the fan
blades 82 of the present invention also have a paddle 84 and a mounting
bracket 86,
but the mounting bracket connects differently to the hub, as described below.
The hub 80 includes a top plate 90 (from the perspective of Figure 22
and shown in plan in Figures 23 and 24) and a bottom plate 92 (shown in plan
in
Figures 21, 25 and 26). The two plates 90, 92 are connected by screws 94.
Referring
to Figure 24, the top plate 90 includes a receiving slot 96 for each of the
fan blades 82.
' Each blade's mounting bracket has a shaft 88 that is used to connect the
bracket to the hub. The shaft 88 can be integral with the bracket, or
alternatively could
be a separate plain metal piece that is attached to a decorative mounting
bracket. The
shaft terminates with a pair of retaining tabs 97 extending laterally from its
end, such
that the width of the shaft at the retaining tabs is slightly greater than the
width of the
neck portion 87 of the shaft.
The slots 96 in the hub include an opening 98 in the outer wall 100 of
the top plate 90. The width of the opening 98 is substantially the same as the
width of
the neck portion 87 of the shaft but less than the width of the end with the
retaining.
tabs. The portion of the slot inside the outer wall of the hub has a width
substantially
the same as the retaining tab end of the shaft. Thus, the reduced width of the
slot
opening forms a retaining ridge 102 in the hub radially inward of the slot
opening 98.
With the portion of the shaft including the retaining tabs positioned
within the slot, the bottom plate 92 is attached to the top plate 90. The
bottom plate
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90 includes, for each blade, a cutout or notch 104 corresponding in position
to each slot
in the top plate. The notch 104 has a width equal to the width of the shaft
without the
retaining tabs. When the fan blades are in an extended position (as
illustrated by the
bottom blades in Figures 21 and 24, and by the right-most blade in Figure 22)
the
S retaining tabs are supported by the top of the bottom plate and the fan
blades may
articulate downward in the direction of arrow B, as illustrated in Figure 22.
The shaft's
neck is received in the bottom plate notch and the fan blades hang vertically.
The slot
configuration also allows the shaft to move radially back and forth along the
slot.
In an alternate embodiment, the hub 80 may be a one-piece unit. As a
one-piece unit, the hub 80 still includes a receiving slot 96 for each of the
fan blades
82. In this embodiment, the retaining tabs 97 are spring loaded enabling the
tabs 97
to be forced into the shaft 88. With the tabs 97 forced into the shaft 88, the
shaft 88
is inserted into the receiving slot 96. Once the shaft 88 is within the
receiving slot, the
tabs 97 are forced out of the shaft by the spring thereby holding the shaft in
the
receiving slot.
Referring to Figures 24 and 27, the top plate 90 also includes a retaining
pin 106. The retaining pin 106 is attached to a metal strip 108 that is
fixedly attached
to the top plate by, for example, a rivet 110. The metal strip 108 acts as a
spring for
the pin 106, and holds the pin in a first position extending through a hole
112 in the top
plate 90 and into the slot 96. When the pin is forced in the direction of
arrow C, the
strip108 allows the pin 106 to move into the hole 112. Vdhen the force is
removed
from the pin 106, the metal strip forces the pin 106 back into the slot 96. In
a preferred
embodiment, the retaining pin 106 is accessed through a hole 112 in the bottom
plate
92, and can by depressed with a pen or small bladed screw driver. The shaft 86
includes a hole 126 that receives the retaining pin 106 when the fan blade is
fully
inserted into the slot.
To place the fan blades into their operable position, a hanging blade
(illustrated in Figure 22, lower right blade) is articulated up in the
direction of arrow
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B. The retaining pin 106 is accessed through the hole I 12 in the bottom plate
and
pushed out of the slot 96. In an alternate embodiment, the pin 106 includes an
angled
face. When the shaft 86 engages the pin 106, the shaft 86 itself forces the
pin 106.
The fan blade is then moved into the slot in the direction of arrow D. The
shaft slides
over the depressed pin until the hole 126 is in registry with the pin, and the
spring 108
then forces the pin 106 into the hole 126. Once the retaining pin is secured
in the
receiving hole, the blade is f xed in its extended position and ready for
operation. The
blade can be moved back to the collapsed vertical position by depressing the
pin and
pulling the blade outward until the retaining tabs engage the notch of the
bottom plate.
The blade is then allowed to articulate downward in the direction of Arrow B.
The metal strip I08 may be replaced by a coil spring or any other
element which will provide a similar function as described above.
By enabling these fan blades to be articulated between a collapsed,
vertically hanging position and an extended operable position, a fan with this
fan blade
assembly can be installed with the fan blades attached to the hub and in a
collapsed
hanging position. After the fan is electrically connected and attached to the
ceiling, the
blades are raised and locked into the extended operating position. This blades
can be
lowered thereafter for easy cleaning.
Referring to Figure 28, an alternate embodiment of the easy install fan
blade assembly has fan blades with a mounting bracket shaft 130 that does not
include
the retaining tabs. The top plate 90 includes a slot having a width that is
the same as
the width of the neck 130. Since the neck 130 does not include the retaining
tabs, the
fan blades are completely removable from the hub 80. The fan blades of this
embodiment are installed in a fashion virtually identical to the embodiment
described
above.
The present invention may be embodied in other specific forms.
Accordingly, reference should be made to the following claims, rather than to
the
foregoing embodiments, to appreciate the scope of the invention.
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Mounting Device with Safety Features
Figures 29-3 7 show an alternative, presently-prefer ed mounting device
of the present invention that includes many of the same features shown and
described
with respect to the embodiment of Figures 2-28. However, the presently-
preferred
embodiment includes features, such a safety features that protect against
electrical
shocks and short circuits, which are not presenf in the embodiment shown in
Figures
2-28.
The mounting device comprises a mounting plate 16' and a coupling
plate 42' that retain, respectively, an electrical receptacle 30' and an
electrical plug 44'
adapted to engage the receptacle 30'. Referring to Figures 29, 31, 33, and 37,
the
mounting plate 16' includes two grooves 68', 70' and two slotted holes 72',
74' adapted
to receive fasteners 76', 78' for attaching the mounting plate 16' to a
junction box.
Typically, these fasteners will be either headed screws that engage the
junction box or
threaded studs that engage the junction box and have nuts to hold the mounting
plate
on the studs. The grooves 68', 70' allow the screw heads or nuts to be
recessed within
the mounting plate 16' to avoid interference with the coupling plate 42'. The
slotted
holes 72', 74' allow the mounting device to be used with various junction
boxes having
different fastener spacings.
A central aperture in 43' the mounting plate l 6' allows the receptacle 30'
to pass from one side of the mounting plate 16' to the other. The upper side
(when the
mounting device is in its installed position) of the mounting plate 16' has a
rabbet 45'
adjacent the periphery of the aperture 43' for engaging a flange 80' on the
receptacle
30'. The receptacle 30' is secured to the mounting plate 16' by three screws
82' that
pass through the flange 80' and into the mounting plate 16'. Similar to the
embodiment
shown in Figures 2-11, the embodiment illustrated in Figures 29-37 has flanges
34', 36'
for engaging the coupling plate 42' and bores 38', 40' for receiving threaded
fasteners
used to secure a fan bell to the mounting device.
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Referring now to Figures 29, 30, and 35-7, the coupling plate 42' holds
the electrical plug 44', which is secured to the coupling plate 42' in a
manner that
enables the plug 44' and coupling plate 42' to rotate relative to one another.
In the
depicted example, the coupling plate 42' has a relatively large central
aperture 4T that
S allows the plug 44' to pass therethrough. The plug 44' is mounted to the
coupling plate
42' by upper and lower mounting plates 86', 88', which are attached to the
coupling
plate 42' by four screws 90'. However, other means of fastening the upper and
lower
plates to the coupling plate, such as bolts, rivets, weld, adhesive or the
like, may be
used:
Each of the upper and lower plates 86', 88' has a central circular aperture
92', and the lower plate 88' has an L-shaped retaining flange 94' around the
periphery
of the aperture 92'. An annular boss 96' on the plug 44' is sandwiched between
the
upper plate 86' and the lower leg of the retaining flange 94', allowing the
plug 44' to
rotate relative to the coupling plate 42'.
Similar to the embodiment shown in Figures 2-11, the coupling plate
42' of the embodiment illustrated in Figures 29-37 includes a pair of latch
slots 52', 54'
for receiving the flanges 34', 36' of the receptacle plate 16'. The latch
slots 52', 54' are
defined by a pair of upwardly-extending end walls 56', 58' attached to
opposite ends
of the coupling plate 42' and a pair of inwardly extending upper walls 60',
62' attached
to the end walls 56', 58' at their upper ends. Each of the ends walls 56', 58'
also
includes a pair of screw holes 64', 66' for fastening the coupling plate 42'
to a fan bell.
The coupling plate 42' includes a generally annular ball socket 98' for
forming a ball and socket joint with a ball attached to the upper end of a fan
hanger
tube. The ball socket 98' is attached to the coupling plate 42' by two pairs
of hangers
100',102' attached to the coupling plate 42' adjacent opposite ends thereof. A
stiffener
104' is attached to each pair of hangers 100', 102' to prevent the ball socket
98' from
swaying due to an unbalanced fan and/or the hangers from racking due to torque
caused by the fan's motor. Preferably, the socket 98' includes an opening 106'
that
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enables a ball and hanger tube assembly to be inserted into the socket 98'
from one side
of the coupling plate 42'.
The electrical plug 44' and receptacle 30' are specially designed for safe
and easy connection to one another. The plug 44' includes a generally circular
base
108 made of a non-conductive material. However, the base may be any shape
desired,
such as rectangular, oval or the like. A skirt 110' is attached to and extends
away from
one end of the base 108'. The skirt 110' is made of the same non-conductive
material
as the base 108' and is formed integrally therewith. However, the skirt may be
made
of another material, formed separately from the base and/or attached to the
base by
chemical bonding, heat bonding, adhesive bonding, mechanical fastening or the
like.
The inner periphery of the skirt 110' and the portion of the base 108'
surrounded by the skirt 110' define a cavity 112'. A plurality of electrical
conductors
114' engage the base 108' and extend from the base 108' into the cavity 1 I2'.
In the
embodiment shown, the conductors 114' are blade-type conductors. Other types
of
conductors, however, such as cylindrical, tubular or the like, may be used.
Although
four conductors 114' are shown, any number of conductors may be provided.
Moreover, the conductors may be arranged in any pattern desired.
When the plug 44' and receptacle 30' are engaged with one another, the
skirt 110' sleevedly engages a like-shaped receiver 116' on the receptacle
30'. The
configuration of the skirt 110' and receiver 116' prevents a user from
touching the
conductors 114' with a finger, tool or other object when the plug 44' and
receptacle 30'
are being engaged with one another and when they are only partially engaged
with one
another, protecting the user from an electrical shock and/or the electrical
supply circuit
from short-circuiting.
In a preferred embodiment, the inner periphery of the skirt 110' and the
outer periphery of the receiver 116' define a shape that has no more than one
axis of
symmetry so that the shape defines the relative alignment ofthe plug 44' and
receptacle
30' necessary to engage the two parts. In addition, a non-circular or a
circular and
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keyed skirt and receiver would prevent rotation of the engaged parts relative
to one
another to avoid damaging the conductors. This is particularly advantageous
when the
coupling plate 42' is rotated relative to the mounting plate 16' while
engaging the
coupling plate 42' to the mounting plate 15' or disengaging the coupling plate
42' from
the mounting plate 16'.
The conductors 114' have tenminals 118' for connecting the plug 44' to
an electrical circuit. In the embodiment shown, the terminals 118' are screw-
type
terminals having screws 120' for connecting the plug 44' to bare-ended fan
wires 121'.
Other type of terminals, such as spring loaded, soldered, compression or the
like, may
alternatively be used. Each terminal 118' is located within a recess 122' in
the base
108' that allows access to the terminal screw 120' by a screw driver and
egress of a wire
from the base 108'. Alternatively, the terminals may extend into one large
recess,
beyond the terminal end of the base, out the side of the base yr the like. In
an
alternative embodiment, the plug may be pre-molded with the conductorlwire
connection molded into the base, eliminating the need for terminals.
The receptacle 30' has a generally circular base 124' attached to the
receiver 116'. The base, however, may be any shape desired, such as polygonal,
oval
or the like. In the preferred embodiment, the base and the receiver are made
of a
non-conductive material and are formed integrally with one another. However,
the
base and the receiver may be made of different materials, formed separately
from one
another and/or attached to one another by chemical bonding, heat bonding,
adhesive
bonding, mechanical fastening or the like.
The receiver 116' has a face 126' and four sockets 128' for receiving the
conductors 114' when the plug 44' is engaged with the receptacle 30'. Each
socket 128'
contains an electrical contact 130' that engages a corresponding one of the
conductors
114' and a terminal 132' for connecting the contact 130' to an electrical
circuit. The
terminals 132' are screw-type terminals having screws 134' for connecting the
receptacle 30' to bare-ended supply wires 13 5'. Other type of terminals, such
as spring
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loaded, soldered, compression or the like, may alternatively be used. Each
terminal
132' is located within a recess 136' the base 124' that allows access to the
terminal
screw 134' by a screw driver and side egress of a wire conductor from the base
124'.
Alternatively, the terminals may extend into one large recess, beyond the
terminal end
of the base, out the side of the base or the like.
The terminals 132' and the bare ends of the wires 135' are covered by
a cap 138' made of a non-conductive material. The cap 138' comprises a cover
140'
and a skirt 142' that forms a friction fit with the circular periphery of the
base 124.
Openings 144' are provided in the skirt 142' to allow the wires 135' to pass
from
outside the cap 138' to the terminals 132'.
The cap 138' is particularly suited for preventing fingers, tools and other
objects from touching the terminals and/or bare ends of the conductor wires to
prevent
electrical shocks and shorts. For example, if the receptacle were mounted to
an
electrical junction box containing spliced wires that have lost their wire
nuts or other
insulation, the cap would prevent the open splices from contacting the
terminal and/or
bare ends of the wires attached to the terminals. In alternative embodiments,
the cap
may be eliminated and/or another cap may be provided to cover the terminals of
the
plug. The cap 138' also protects the terminals from water falling from above
the cap
138'.
The present invention may be embodied in other specific forms.
Accordingly, reference should be made to the following claims, rather than to
the
foregoing embodiments, to appreciate the scope of the invention.
