Fan mounting system

Abstract

A fan mounting system (30) may include supplemental mounting components for installations where fan (10) will be located in a geographic region that encounters frequent seismic activity. These supplemental components may provide additional reinforcement and stability to fan (10), enabling fan (10) to remain secured to a ceiling or other structure during seismic events. Such a supplemental system may comprise cables (410) extending between and connecting the fan (10) to structures, such as ceiling joists (450). Related methods are also disclosed.

Claims

1. An apparatus for mounting a ceiling fan including a support to one or more ceiling structures, comprising; a plurality of mounts, each adapted for connecting to the ceiling structure; and a plurality of cables, each for extending between the ceiling fan and one of the mounts, whereby the cables provide additional reinforcement and stability, enabling the fan to remain secured to the ceiling structure during seismic events, wherein the mounts comprise a pair of mounting brackets, and an adjustable bar for connecting the mounting brackets, wherein the adjustable bar comprises multiple bolt holes, and the brackets comprise slots adapted for receiving a bolt extending within any of the multiple bolt holes.

2. The apparatus of claim 1, wherein the mounts comprise a mounting bracket for connecting to one end of the cable.

3. The apparatus of claim 1, wherein the mounts comprise an eye bolt for connecting to a first end of the cable.

4. The apparatus of claim 1, further including a turnbuckle for connecting to the ceiling fan at one end and to the cable at the other end.

5. The apparatus of claim 1, wherein the ceiling structure comprises a plurality of joists, and each mount is adapted for enveloping a portion of one of the joists.

6. The apparatus of claim 5, wherein each joist comprises angle-iron members, and each mount comprises generally L-shaped brackets for being arranged in an opposing relationship relative to the angle-iron members, and further including a fastener for connecting the L-shaped brackets.

7. The apparatus of claim 1, wherein each mount comprises a bolt having a looped head for connecting to a first end of at least one cable of the plurality of cables.

8. The apparatus of claim 1, wherein at least one of the cables comprises a hook for engaging at least one of the mounts.

9. An apparatus for providing air circulation in a room including joists, comprising: a fan; and a plurality of mounting brackets, each for connecting to one joist; and a plurality of cables, each for connecting the fan to one of the mounting brackets; whereby the cables provide additional reinforcement and stability, enabling the fan to remain secure during seismic events, wherein the cables are connected to the fan by way of turnbuckles attached to a bracket located between a motor assembly and a gearbox of the fan.

10. The apparatus of claim 9, wherein the fan includes a support for supporting the fan from a ceiling of the room.

11. The apparatus of claim 10, wherein the support comprises an elongate, metal tube-like structure that couples the fan to the ceiling.

12. The apparatus of claim 9, wherein each mounting bracket is adapted to envelop a portion of the joist.

13. The apparatus of claim 9, wherein each mounting bracket comprises an adjustable bar, a pair of brackets, an eye bolt, bolts, and nuts.

14. The apparatus of claim 13, wherein each of the brackets includes a slot for receiving one of the bolts.

15. The apparatus of claim 9, wherein the fan comprises a hub assembly and fan blades, together having a diameter of between approximately 6 feet and approximately 24 feet.

16. The apparatus of claim 9, wherein each joist comprises angle-iron members, and the mounting bracket comprises generally L-shaped brackets for being arranged in an opposing relationship relative to the angle-iron members, and further including a fastener for connecting the L-shaped brackets.

17. The apparatus of claim 16, wherein the fastener comprises a bolt.

18. The apparatus of claim 16, wherein the fastener comprises an adjustable bar.

19. The apparatus of claim 9, further including a turnbuckle for connecting to one end of each cable.

20. The apparatus of claim 9, wherein a bracket on the fan is connected to one end of each cable.

21. An apparatus for providing air circulation in a room including joists, comprising: a fan; and a plurality of mounting brackets, each for connecting to one joist; and a plurality of cables, each for connecting the fan to one of the mounting brackets; whereby the cables provide additional reinforcement and stability, enabling the fan to remain secure during seismic events, wherein the cables are attached to the fan between a motor assembly and a gearbox of the fan.

22. An apparatus for providing air circulation in a room including joists, comprising: a fan; and a plurality of mounting brackets, each for connecting to one joist; and a plurality of cables, each for connecting the fan to one of the mounting brackets; whereby the cables provide additional reinforcement and stability, enabling the fan to remain secure during seismic events; wherein each mounting bracket comprises an adjustable bar, a pair of brackets, an eye bolt, bolts, and nuts; wherein each of the brackets includes a slot for receiving one of the bolts.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) While the specification concludes with claims which particularly point out and distinctly claim the invention, it is believed the present invention will be better understood from the following description of certain examples taken in conjunction with the accompanying drawings, in which like reference numerals identify the same elements and in which:

(2) FIG. 1 depicts a perspective view of an exemplary fan having a motor assembly, a hub assembly, a support, a plurality of fan blades, and a mounting system coupled with joists;

(3) FIG. 2 depicts a detailed perspective view of the fan of FIG. 1, showing the connection between the fan and the mounting system of FIG. 1;

(4) FIG. 3 depicts a detailed perspective view of a mounting bracket of the system of FIG. 1;

(5) FIG. 4 depicts a side view of a joist of FIG. 1, and the mounting system of FIG. 1;

(6) FIG. 5 depicts section view of the joist of FIG. 4, and of the mounting bracket in FIG. 3;

(7) FIG. 6 depicts a perspective view of the mounting bracket of FIG. 3; and

(8) FIG. 7 depicts an exploded view of the mounting bracket of FIG. 6.

(9) The drawings are not intended to be limiting in any way, and it is contemplated that various embodiments of the invention may be carried out in a variety of other ways, including those not necessarily depicted in the drawings. The accompanying drawings incorporated in and forming a part of the specification illustrate several aspects of the present invention, and together with the description serve to explain the principles of the invention; it being understood, however, that this invention is not limited to the precise arrangements shown.

DETAILED DESCRIPTION

(10) The following description of certain examples of the invention should not be used to limit the scope of the present invention. Other examples, features, aspects, embodiments, and advantages of the invention will become apparent to those skilled in the art from the following description, which includes by way of illustration, one or more of the best modes contemplated for carrying out the invention. As will be realized, the invention is capable of other different and obvious aspects, all without departing from the invention. Accordingly, the drawings and descriptions should be regarded as illustrative in nature and not restrictive.

(11) I. Exemplary Fan Overview

(12) Referring to FIG. 1, a fan (10) of the present example comprises a motor assembly (20), a support (30), a hub assembly (100), and a plurality of fan blades (200). In the present example, fan (10) (including hub assembly (100) and fan blades (200)) has a diameter of approximately 8 feet. In other variations, fan (10) has a diameter between approximately 6 feet, inclusive, and approximately 24 feet, inclusive. Alternatively, fan (10) may have any other suitable dimensions.

(13) Support (30) is configured to be coupled to a surface or other structure at a first end such that fan (10) is substantially attached to the surface or other structure. As shown in FIG. 1, one such example of a structure may be a ceiling joist (450). Support (30) of the present example comprises an elongate metal tube-like structure that couples fan (10) to a ceiling, though it should be understood that support (30) may be constructed and/or configured in a variety of other suitable ways as will be apparent to one of ordinary skill in the art in view of the teachings herein. By way of example only, support (30) need not be coupled to a ceiling or other overhead structure, and instead may be coupled to a wall or to the ground. For instance, support (30) may be positioned on the top of a post that extends upwardly from the ground. Alternatively, support (30) may be mounted in any other suitable fashion at any other suitable location. This includes, but is not limited to, the teachings of the patents, patent publications, or patent applications cited herein. By way of example only, support (30) may be configured in accordance with the teachings of U.S. Pat. Pub. No. 2009/0072108, entitled “Ceiling Fan with Angled Mounting,” published Mar. 19, 2009, the disclosure of which is incorporated by reference herein. As yet another alternative, support (30) may have any other suitable configuration. Furthermore, support (30) may be supplemented in numerous ways. One merely illustrative example is described in detail below, while other examples and variations will be apparent to those of ordinary skill in the art in view of the teachings herein.

(14) Motor assembly (20) of the present example comprises an AC induction motor having a drive shaft, though it should be understood that motor assembly (20) may alternatively comprise any other suitable type of motor (e.g., a permanent magnet brushless DC motor, a brushed motor, an inside-out motor, etc.). In the present example, motor assembly (20) is fixedly coupled to support (30) and rotatably coupled to hub assembly (100). Furthermore, motor assembly (20) is operable to rotate hub assembly (100) and the plurality of fan blades (200). By way of example only, motor assembly (20) may be constructed in accordance with at least some of the teachings of U.S. Pat. Pub. No. 2009/0208333, entitled “Ceiling Fan System with Brushless Motor,” published Aug. 20, 2009, the disclosure of which is incorporated by reference herein. Furthermore, fan (10) may include control electronics that are configured in accordance with at least some of the teachings of U.S. Pat. Pub. No. 2010/0278637, entitled “Ceiling Fan with Variable Blade Pitch and Variable Speed Control,” published Nov. 4, 2010, the disclosure of which is incorporated by reference herein. Alternatively, motor assembly (20) may have any other suitable components, configurations, functionalities, and operability, as will be apparent to those of ordinary skill in the art in view of the teachings herein.

(15) Hub assembly (100) may be constructed in accordance with at least some of the teachings of U.S. Patent Application Publication No. 2010/0278637, entitled “Ceiling Fan with Variable Blade Pitch and Variable Speed Control,” published Nov. 4, 2010, the disclosure of which is incorporated by reference herein. Alternatively, hub assembly (100) may be constructed in accordance with any of the teachings or other patent references cited herein. Still other suitable ways in which hub assembly (100) may be constructed will be apparent to those of ordinary skill in the art in view of the teachings herein. It should also be understood that an interface component (not shown) may be provided at the interface of each fan blade (200) and hub assembly (100). By way of example only, such an interface component may be configured in accordance with the teachings of U.S. Pat. Pub. No. 2009/0081045, entitled “Aerodynamic Interface Component for Fan Blade,” published Mar. 26, 2009, the disclosure of which is incorporated by reference herein. Of course, such an interface component may be omitted if desired.

(16) Fan blades (200) may further be constructed in accordance with some or all of the teachings of any of the patents, patent publications, or patent applications cited herein. For example, fan blades (200) may be configured in accordance with the teachings of U.S. Pat. No. 7,284,960, entitled “Fan Blades,” issued Oct. 23, 2007; U.S. Pat. No. 6,244,821, entitled “Low Speed Cooling Fan,” issued Jun. 12, 2001; and/or U.S. Pat. No. 6,939,108, entitled “Cooling Fan with Reinforced Blade,” issued Sep. 6, 2005. The disclosures of each of those U.S. patents are incorporated by reference herein. As another merely illustrative example, fan blades (200) may be configured in accordance with the teachings of U.S. Pat. Pub. No. 2008/0008596, entitled “Fan Blades,” published Jan. 10, 2008, the disclosure of which is also incorporated by reference herein. As yet another merely illustrative example, fan blades (200) may be configured in accordance with the teachings of U.S. Pat. Pub. No. 2010/0104461, entitled “Multi Part Modular Airfoil Section and Method of Attachment Between Parts,” published Apr. 29, 2010, the disclosure of which is incorporated by reference herein. Alternatively, any other suitable configurations for fan blades (200) may be used in conjunction with the examples described herein. In the present example, fan blades (200) are formed of aluminum through an extrusion process such that each fan blade has a substantially uniform cross section along its length. It should be understood that fan blades (200) may alternatively be formed using any suitable material, or combination of materials, by using any suitable technique, or combination of techniques, and may have any suitable cross-sectional properties or other properties as will be apparent to one of ordinary skill in the art in view of the teachings herein.

(17) Fan blades (200) of the present example may further include a variety of modifications. By way of example only, fan blade (200) of the present example further comprises a winglet (220) coupled to the second end (204) of fan blade (200). Winglets (220) may be constructed in accordance with some or all of the teachings of any of the patents, patent publications, or patent applications cited herein. For instance, winglets (220) may be configured in accordance with at least some of the teachings of U.S. Pat. No. 7,252,478, entitled “Fan Blade Modifications,” issued Aug. 7, 2007, the disclosure of which is incorporated by reference herein. As another merely illustrative example, winglets (220) may be configured in accordance with the teachings of U.S. Pat. Pub. No. 2008/0014090, entitled “Cuffed Fan Blade Modifications,” published Jan. 17, 2008, the disclosure of which is incorporated by reference herein. As yet another merely illustrative example, winglets (220) may be configured in accordance with the teachings of U.S. Pat. No. D587,799, entitled “Winglet for a Fan Blade,” issued Mar. 3, 2009, the disclosure of which is incorporated by reference herein. Of course, any other suitable configuration for winglets (220) may be used as will be apparent to those of ordinary skill in the art in light of the teachings herein.

(18) It should also be understood that winglet (220) is merely optional. For instance, other alternative modifications for fan blades (200) may include end caps, angled airfoil extensions, integrally formed closed ends, or substantially open ends. By way of example only, an angled extension may be added to the free end of each fan blade (200) in accordance with the teachings of U.S. Pat. Pub. No. 2008/0213097, entitled “Angled Airfoil Extension for Fan Blade,” published Sep. 4, 2008, the disclosure of which is incorporated by reference herein. Other suitable structures that may be associated with second end (204) of each fan blade (200) will be apparent to those of ordinary skill in the art in view of the teachings herein.

(19) II. Exemplary Supplement to Mounting System

(20) It may be desirable to provide added support beyond the exemplary mounting system (30) referred to above. By way of example only, an otherwise standard mounting system (30) may include supplemental mounting components for installations where fan (10) will be located in a geographic region that encounters frequent seismic activity. These supplemental components may provide additional reinforcement and stability to fan (10), enabling fan (10) to remain secured to a ceiling or other structure during seismic events. As shown in FIG. 1, such a supplemental system may comprise one or more flexible connectors, such as cables (410), extending between and connecting the fan (10) to structures, such as ceiling joists (450).

(21) As shown in FIG. 2, the cables (410) may be connected to the fan (10) directly, or as shown by way of adjustable connectors, such as turnbuckles (412). The turnbuckles (412) may be attached to a bracket (414) connected to the fan (10), such as between the motor assembly (20) and the gearbox (40). However, any other suitable structures/methods of connecting the fan (10) to the cables (410) may be used, and the cables (410) may be connected to any of the above mentioned exemplary fans.

(22) The cables (410) are also connected to ceiling joists (450) by way of an exemplary mounting bracket (400) as shown in FIGS. 1 and 3. The cable (410) attaches to the mounting bracket (400) by way of a connector, such as an eye bolt (407), as shown in FIG. 3. In the case where the ceiling joists (450) are comprised of web members (454), the angle iron members (452) when assembled form an “I-beam” type structural member as shown in FIGS. 1, 3, 4, and 5. The angle iron members (452) may come in many different widths and depths, depending upon the particular application.

(23) As shown in FIGS. 3, 5, 6, and 7; the exemplary mounting bracket (400) comprises an adjustable member, such as bar (402) for connecting brackets (404). The eye bolt (407) may be connected to brackets (404). Bolts (408) and nuts (409) may be used to complete the assembly. When completely assembled, the exemplary mounting bracket (400) envelops a ceiling joist (450) as shown in FIGS. 1, 3, and 5. In such case, the brackets (404) form opposing right angles which complement the “T” shape formed by the angle iron members (452) of the ceiling joist (450) as shown in FIGS. 3 and 5.

(24) The brackets (404) may be placed below the flanges of the angle iron members (452) and coupled together by a fastener, which may comprise a bolt (406) and a separable connector (405), which together form the eye bolt (407) (but a conventional single piece eye bolt with a nut would work as well). An adjustable member (402) is then placed in a position above the flanges of the angle iron members (452) and secured with bolts (408) to the brackets (404) below the flanges of the angle iron members (452) as shown in FIGS. 3 and 5. Although the adjustable member (402) of the exemplary mounting bracket utilizes tapped bolt-holes (405), other configurations may utilize nuts (409) as shown.

(25) Because the angle iron members (452) may come many in different widths and depths, the mounting bracket (400) is adjustable in the present example. As best shown in FIG. 7, bolts (408) may be inserted through the brackets (404) and adjustable bar (402) at several different locations to accommodate multiple angle iron member (452) widths. This is accomplished by providing an elongated slot (403) in the bracket (404) and multiple bolt holes (405) in the adjustable bar (402). Also, an eye bolt (407) may be inserted through the brackets (404) at different positions to accommodate multiple angle iron member (452) depths. This is accomplished by providing multiple bolt holes (401) in the brackets (404).

(26) Having shown and described various embodiments of the present invention, further adaptations of the methods and systems described herein may be accomplished by appropriate modifications by one of ordinary skill in the art without departing from the scope of the present invention. Several of such potential modifications have been mentioned, and others will be apparent to those skilled in the art. For instance, the examples, embodiments, geometrics, materials, dimensions, ratios, steps, and the like discussed above are illustrative and are not required. Accordingly, the scope of the invention should be considered in terms of claims that may be presented, and is understood not to be limited to the details of structure and operation shown and described in the specification and drawings.