Note: Descriptions are shown in the official language in which they were submitted.
n _ .I
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FAN BLADE CONNECTOR COMPONENT WITH SKELETON
AND METHOD OF MANUFACTURING SUCH
TECHNICAL FIELD
The present invention relates to connectors components for attaching fan
blades to fan motors. More particularly, the present invention relates to the
interior
structures for embedding in fan blade connectors components and a method of
manufacturing such.
BACKGROUND OF THE INVENTION
Electrically powered ceiling fans typically have a motor mounted within a
stationary housing that is suspended from a ceiling. In operation, the motor
rotates an
annular array of connectors coupled to blades. The blade connectors of ceiling
fans are
typically mounted to the blade through a series of mounting bolts or screws
that pass
through holes in the fan blade and thread within threaded mounting holes in
the blade
connector. Alternatively, the blade connector includes a medallion which is
positioned
against the blade opposite the blade mounting portion of the blade connector,
thereby
sandwiching the blade therebetween.
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Blade connectors are typically made of die cast metal. These materials allow
for limited aesthetic flexibility and provide the rigidity and support needed
to support a
fan blade that is spinning upwards of 200 rpm. The use of these materials
however is
costly due to the tooling process needed to manufacture the blade connector
and because
of the costs of the raw material.
Accordingly, there is a need in the art for an improved blade connector
component, such as a blade connector or blade connector medallion, that
readily provides
aesthetic flexibility yet is strong enough to support the fan blades of fans.
It is to such
that the present invention is directed.
SUMMARY OF THE INVENTION
A skeleton for a cast fan blade connector component comprises at least two
posts having a threaded bore for receiving a fastener, and a link that
interconnects
adjacent posts.
A method of manufacturing a fan blade connector component comprises the steps
of providing a skeleton having at least two posts having a threaded bore for
receiving a
fastener and a link spanning the posts, and forming an ornamental housing
about the
skeleton so as to encase the link and at least a portion of the posts yet
allowing the bore
of each post to remain exposed from the housing.
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BRIEF DESCRIPTION OF THE DRAWINGS
Fig. I illustrates in perspective partially cut-away view a skeleton for a fan
blade connector component embodying principles of the invention in a preferred
form.
Fig. 2 illustrates in perspective view of a skeleton for a fan blade connector
component in another preferred form of the invention.
Fig. 3 illustrates a perspective view of a skeleton shown partially encased
within a blade connector medallion.
Fig. 4 illustrates in perspective exploded view the skeleton shown partially
encased in a fan blade connector for attaching a fan blade to a fan motor.
DETAILED DESCRIPTION
With reference to the drawings in which like parts have like reference
numerals, Fig. 1 illustrates in perspective partially cut-away view of a
skeleton 10 for a
fan blade connector component 12, which may be utilized to form a blade
connector or a
blade connector medallion. The skeleton shown in Fig. 1 is preferably designed
to be
utilized specifically with a blade connector medallion. The skeleton 10
includes a hub 14
from which a plurality of elongated links 16 extend radially. In the
illustrated
embodiment, the skeleton 10 is made of a cast metal, such as zinc, but may
also be made
of a stamped sheet metal or other similarly formed metal. The skeleton 10 may
be made
of any substantially rigid material capable of supporting a fan blade and
withstanding the
force exerted upon the blade connector during the revolution of the fan blade.
The
skeleton 10 is of sufficient overall dimension to support fan blades of
varying length and
weight.
The links 16 may be spaced-apart equidistantly or may be oriented at varying
angles. In the illustrated embodiment the skeleton has three links wherein two
pairs of
the links 16 are approximately 130 degrees apart as indicated at 18 and one
pair is
approximately 100 degrees apart as indicated at 20. It is understood, however,
that there
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may be varying numbers of links at various lengths. Each link 16 terminates at
a post 22
having a threaded bore 24 therein and a closed bottom 26.
Each links 16 has opposing side walls 28 and a land 30 spanning
therebetween. The land 30 and the side walls 28 cooperatively define a first
valley 32
and an opposing second valley 34. A top wall 35 extends between the tops of
the side
walls 28. The top wall 35 has a plurality of spaced apart openings 36
extending
therethrough. In the present embodiment, the openings 36 on each link 16
provide
cavities or spaces through which resin, upon hardening during fabrication, may
embed.
This, in turn, helps secure the skeleton 10 within the blade connector 12.
Fig. 2 illustrates in perspective exploded view the skeleton 10 shown encased
in a fan blade connector component in the form of a blade connector medallion.
The fan
blade connector medallion includes an exterior ornamental shape or housing 37.
Fig. 4
illustrates in perspective view of the skeleton 10 shown encased in a fan
blade connector
41. It should be understood that the skeleton may be used with a fan blade
connector or a
fan blade connector medallion as shown in U.S. Patent No. 5,304,037, which is
specifically incorporated herein. The blade connector is coupled to a fan
motor 42
through additional links which extend to the motor, shown in phantom lines. In
the
illustrated embodiment, the blade connector 12 has a motor mounting flange or
portion
44 and a blade mounting portion 46. The motor mounting flange 44 connects the
blade
connector 12 to the motor 42 by unshown mounting bolts. The blade mounting
portion
46 encases the skeleton 10 and secures the blade connector 12 to the fan blade
40.
During fabrication, the cast metal skeleton 10 is placed in a mold and over-
molded with a resin or other suitable moldable material in a desired
ornamental shape.
This may be done to form the blade mounting portion 46 of the blade connector
41, as
shown in Fig. 4, or to form the blade connector medallion, as shown in Fig. 3.
It is
understood, however, that the skeleton may be encased in any polymerized
synthetic or
chemically modified natural resin including thermoplastic materials such as
polyvinyl,
polystyrene, and polyethylene or thermosetting materials such as polyesters,
epoxies, and
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silicones. Resin has the advantage of providing aesthetic flexibility and cost
efficiency in
comparison to metals such as zinc or brass or other metal alloy.
Each blade connector medallion or blade connector attaches one ceiling fan
blade 40 to the motor. Each ceiling fan blade 40 has a plurality of mounting
holes 43 that
correspond to the posts 22 on the skeleton 10. In the illustrated embodiment,
three
mounting holes 43 are aligned with the three posts 22 of the skeleton 10. A
mounting
screw 48 inserts through a respective one of the mounting holes 43 and into
the threaded
bore 24 of each post 22 to secure the blade connector medallion to a blade
connector.
Each post of the skeleton 10 has a short enough height to allow the skeleton
10 to be
completely molded with resin with the exception of the post ends, yet
sufficient height to
allow mounting screws 48 to engage the threaded bore 24 of each post 22.
Fig. 3 illustrates in perspective view an alternate embodiment of the skeleton
10a for the fan blade connector medallion 12. The skeleton l0a includes at
least two
posts 22 each having the threaded bore 24 for receiving a fastener such as a
screw. Each
of the posts 22 includes the closed bottom 26.
In the illustrated embodiment, the links 16 form a triangular-like structure.
The skeleton l0a includes three posts 22 interconnected by three links 16. The
link 16
interconnects adjacent posts 22. The skeleton l0a includes two links 16 of a
first length
and a third link of a second length less than the first length. The links 16
may have
varying lengths in comparison to each other and may include varying numbers of
links 16
and posts 22 so as to form a variety of polygon-type structures.. Each link 16
includes
openings 36 therein.
The skeleton 10a illustrated in Fig. 3 is similarly encased in the moldable
fan
blade connector or blade connector medallion 12 for attaching the fan blade
40. During
fabrication, the metal cast skeleton l0a is over molded with a resin and
encased therein.
It is understood, however, that the skeleton may be encased in any polymerized
synthetic
or chemically modified natural resin including thenmoplastic materials such as
polyvinyl,
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polystyrene, and polyethylene or thermosetting materials such as polyesters,
epoxies, and
silicones.
Each blade connector or medallion 12 attaches to one of the ceiling fan blades
40. The mounting holes 43 in the fan blade 40 align with the posts 22 of
skeleton 10a.
The mounting screws 48 insert through the respective mounting holes 43 and
into the
threaded bores 24 of the posts 22. Each post of the skeleton 10 has a short
enough height
to allow the skeleton l0a to be completely molded with resin and encased
within the fan
blade connector 12, yet sufficient height to allow mounting screws 48 to
engage the
threaded bore 24 of each post 22.
It thus is seen that a skeleton and the encompassing blade connector or
medallion is now provided which is not only cost efficient but esthetically
alterable thus
overcoming the shortcomings of the existing art. It should be understood that
many
modifications, additions and deletions, in addition to those expressly
recited, may be
made thereto without departure from the spirit and scope of the invention as
set forth in
the following claims.
