DESC:FIELD OF THE INVENTION
[001] The present invention relates to a fan. More particularly, the present invention relates to a hub assembly for a fan.

BACKGROUND OF THE INVENTION
[002] Conventional domestic ceiling fans have long relied on rotating blades or vanes mounted on a hub to generate airflow. Typically, these fans incorporate a motor-driven impeller to draw air from above the fan and expel it downwardly through the rotating blades. Further, existing fans often feature bulky motor assemblies, contributing to their overall height. This elevated height in the fan is undesirable, particularly in settings where space is limited, or aesthetic considerations are important. The conventional motor assemblies in ceiling fans are not only bulky and large which restricts placement options, but also result in obstruction of views, resulting in user inconvenience.
[003] Moreover, the dimensions of traditional fan motor assemblies tend to be substantial, occupying significant space within the fan housing. This bulkiness of the fan motor restricts the design versatility of the fan and increases manufacturing costs due to the need for larger housings and associated components. Additionally, the size of the motor assembly detracts from the sleekness and portability of the fan, posing challenges for storage and transportation.
[004] Furthermore, conventional fan motor assemblies typically rely on screws for assembly of various components within the fan, including securing the motor within the housing and fastening additional elements such as light guards and diffusers along with their related circuit boards. The extensive use of screws not only adds complexity to the manufacturing process but also increases the risk of assembly errors, maintenance challenges, and potential safety hazards. Additionally, the presence of visible screws detracts from aesthetics of the fan, undermining its appeal to the users.
[005] Thus, there is a need in the art for a hub assembly for a fan, which addresses at-least the aforementioned problems.

SUMMARY OF THE INVENTION
[006] In an aspect, the present invention relates to a hub assembly for a fan. The hub assembly has a rotor and a stator assembly. The rotor is disposed in the housing. The stator assembly is disposed radially inside the rotor in the housing. The stator assembly has a top insulator and a bottom insulator for insulating a plurality of stator windings from a stator core. The bottom insulator has one or more protrusions adapted to receive at least one electrical component and one or more fastening provisions for receiving a cover member which is adapted to cover at least one electrical component.
[007] In an embodiment of the invention, the hub assembly has a power supply box which is configured to house a power Printed Circuit Board (PCB), wherein the power PCB is configured to regulate and control the operation of the fan. Further, the housing has a motor section and a bearing section. The motor section houses the rotor and the stator assembly. The housing is attached to a shaft at the bearing section, wherein the bearing section extends upwardly from the motor section. The bearing section of the housing is disposed at least partially enclosed by the power supply box.
[008] In a further embodiment of the invention, the bottom insulator has a first portion and a second portion. The first portion is configured to surround the stator core, and the second portion extends axially from the first portion.
[009] In a further embodiment of the invention, the second portion of the bottom insulator has a radial outer side, a radial inner side and a recess formed in a peripheral wall of the second portion.
[010] In a further embodiment of the invention, the radial outer side of the second portion has one or more fastening provisions. The one or more fastening provisions are configured to enable coupling of the cover member to the bottom insulator.
[011] In a further embodiment of the invention, the one or more fastening provisions for coupling the cover member to the bottom insulator include one or more of a threading mechanism, or a snap fit mechanism, or a press fit mechanism.
[012] In a further embodiment of the invention, the radial inner side of the second portion has one or more protrusions. The one or more protrusions are configured to receive at least one of the one or more electrical components.
[013] In a further embodiment of the invention, the recess of the bottom insulator is configured to accommodate a connector PCB. The connector PCB is configured to operably connect the power PCB to at least one of the one or more electrical components.
[014] In a further embodiment of the invention, the electrical component has a light unit having a light housing, an illumination device, and a digital PCB. The digital PCB is housed within the light housing, and the light housing has one or more vertical slots which are configured to mesh with the one or more protrusions on the bottom insulator.
[015] In a further embodiment of the invention, the hub assembly has a bottom canopy. The bottom canopy is positioned above the power supply box. The bottom canopy is snap fitted to the power supply box.
[016] In a further embodiment of the invention, the housing includes a plurality of mounting flanges. The plurality of mounting flanges extend radially outwardly from the housing and are configured to receive a plurality of blades.

BRIEF DESCRIPTION OF THE DRAWINGS
[017] Reference will be made to embodiments of the invention, examples of which may be illustrated in accompanying figures. These figures are intended to be illustrative, not limiting. Although the invention is generally described in context of these embodiments, it should be understood that it is not intended to limit the scope of the invention to these particular embodiments.
Figure 1 illustrates a sectional view of a hub assembly for a fan, in accordance with an embodiment of the invention.
Figure 2 illustrates an exploded view of the housing of the hub assembly, in accordance with an embodiment of the invention.
Figure 3 illustrates an exploded view a stator assembly of the hub assembly, in accordance with an embodiment of the invention.
Figure 4 illustrates another exploded view of the hub assembly, in accordance with an embodiment of the invention.
Figure 5 illustrates various views a light unit of the hub assembly, in accordance with an embodiment of the invention.
Figure 6A and 6B illustrate perspective views of the hub assembly with a cover member, in accordance with an embodiment of the invention.
Figure 6C illustrates an exploded view of the cover member of the hub assembly, in accordance with an embodiment of the invention.
Figure 7 illustrates a sectional view of the hub assembly with a bottom canopy, in accordance with an embodiment of the invention.

DETAILED DESCRIPTION OF THE INVENTION
[018] The present invention is directed towards a hub assembly for a fan. While the present invention has been explained in the context of the fan being a ceiling fan, it should be understood that the present invention is capable of being applied to any fan for both domestic and industrial uses. The present invention provides a hub assembly for a fan whereby height of the hub assembly is reduced resulting in reduced dimensions of a motor assembly in the fan. The components of the hub assembly are assembled in a way that eliminates the requirement of fasteners thereby minimizing the risk of assembly errors and reduces production time, resulting in cost savings and improved overall quality.
[019] Figure 1 illustrates a hub assembly 100 for a fan in accordance with an embodiment of the invention. The hub assembly 100 comprises a power supply box 102, a housing 106, and a motor assembly 116. The power supply box 102 houses a power Printed Circuit Board (PCB) 112 therein. The power PCB 112 includes a microcontroller configured to control electrical power to various components within the hub assembly 100. The power PCB 112 receives power input from an external source and regulates the voltage and current to ensure proper operation of the motor assembly 116. In an embodiment, the power PCB 112 is configured to modulate and convert an alternating current supply into a direct current for operating the motor assembly 116. The power PCB 112 includes circuitry for controlling and regulating the operation of the fan such as adjusting fan speed and setting timer functions. The motor assembly 116 then receives electrical energy from the power PCB 112 and converts electrical energy into rotational motion, which in turn drives fan blades to create airflow. The microcontroller comprises one or more input/output ports to receive user commands. In addition, the power PCB 112 is also communicably coupled to at least one electrical component 108 and is configured to control the at least one electrical component 108. In an embodiment, the power supply box 102 is a polymer-based enclosure with internal ribs and guides so as to accommodate the power PCB 112.
[020] The power supply box 102 further comprises a plate member 104. The plate member 104 is adapted to be disposed below the power PCB 112 for supporting the power PCB 112 and mounting the power PCB 112 within the power supply box 102. The plate member 104 includes a plurality of slots corresponding to the internal ribs and guides on the power supply box 102 to fasten the plate member 104 onto the power supply box 102. In alternative embodiment, the power supply box 102 comprises a plurality of bosses provided therein for directly supporting the power PCB 112 through one or more fasteners, thereby supporting the power PCB 112 inside the power supply box 102 without requiring the plate member 104. In an embodiment, the power supply box 102 is guided and fastened on a shaft 114 via screws. The shaft 114 extends along the length of the hub assembly 100, whereby a top end of the shaft 114 is configured to be attached to a mounting provision provided on a ceiling, thereby attaching the hub assembly 100 to the ceiling.
[021] As illustrated in the embodiment depicted in Figure 1 and Figure 2, the housing 106 of the hub assembly 100 houses the motor assembly 116 and is provided below the power supply box 102. In an embodiment, as illustrated in Figure 1 and Figure 2, the housing 106 has a motor section 106a and a bearing section 106b. Herein, the bearing section 106b extends upwardly from the motor section 106a. The motor section 106a houses the motor assembly 116 including a rotor 120 and a stator assembly 130. Further, the housing 106 is attached to the shaft 114 at the bearing section 106b, thus supporting the motor assembly 116 onto the shaft 114. Herein, one or more bearings are provided within the bearing section 106b for attaching the housing 106 to the shaft 114.
[022] In an embodiment, as shown in Figure 1, at least a portion of the bearing section 106b of the housing 106 is enclosed by the power supply box 102. In other words, the bearing section 106b of the housing 106 is disposed at least partially enclosed by the power supply box 102. The provision of at least a portion of the housing 106 within the power supply box 102 allows for reduction of overall height of the hub assembly 100.
[023] The motor assembly 116 comprises the rotor 120 that is fixedly disposed inside and is attached to the housing 106. The rotor 120 includes an annular rotor core and a plurality of magnets 122 disposed equidistant from one another. The plurality of magnets 122 are arranged around an inner circumference of the housing 106. In an embodiment, the rotor 120 comprises plurality of magnets 122 are made of neodymium. In another embodiment, the plurality of magnets 122 may be made of any other ferromagnetic alloy or any other alloy that exhibits magnetic properties In an embodiment, the housing 106 is made of aluminium. In another embodiment, the housing 106 may be made of any other metal or composite compound as per requirement. The housing 106 further comprises a blade mounting arrangement. The blade mounting arrangement includes a plurality of mounting flanges 126 that are provided on the housing 106 onto which a plurality of blades (not shown) is received and attached. The plurality of mounting flanges 126 extend radially outwardly from the housing 106. The plurality of blades is fastened to the mounting flanges 126. In an embodiment, the housing 106 includes a plurality of bolts 128 that facilitate mounting of the plurality of blades.
[024] As illustrated in the embodiment depicted in Figure 1 and Figure 3, the housing 106 of the hub assembly 100 further houses the stator assembly 130 that is held inside the housing 106 so as to be disposed radially inside the rotor 120. The stator assembly 130 includes a top insulator 134, a bottom insulator 140 and a stator core 136. The stator core 136 is fixedly mounted to the shaft 114 and comprises a plurality of stator teeth 156. The stator assembly 130 further comprises a plurality of stator windings 138. The plurality of stator windings 138 are wound around the plurality of stator teeth 156. In an embodiment, the plurality of stator windings 138 are made of copper or aluminium or coated wire. During operation, the plurality of stator windings 138 carry electric current to generate the magnetic field in the stator core 136, with which the plurality of magnets 122 of the rotor 120 magnetically interact, thereby causing the rotation of the rotor 120. By virtue of the rotor 120 being attached to the housing 106, the housing 106 rotates by rotation of the rotor 120, thus causing fan blades to rotate with the housing 106. The current being supplied to the plurality of stator windings 138 is controlled by the power PCB 112.
[025] Referring to Figure 4 in conjunction with Figure 2 and 3, when power is supplied to the plurality of stator windings 138, the magnetic interaction between the stator core 136 and the plurality of magnets 122 of the rotor 120 causes the rotor 120 to rotate either clockwise or counterclockwise, thereby causing the housing 106 to rotate. Thus, rotation of the rotor 120 causes the housing 106 to rotate, whereby rotation of the housing 106 results in rotation of the attached fan blades, thus supplying air.
[026] As illustrated specifically in Figure 3, the top insulator 134 and the bottom insulator 140 are provided for insulating the plurality of stator windings 138 from the stator core 136. The top insulator 134 is configured to be fit onto a top side of the stator core 136 for covering the stator core 136 from the top side and the bottom insulator 140 is configured to be fit onto a bottom side of the stator core 136 for covering the stator core 136 from the bottom side. Once the stator core 136 is covered by the top insulator 134 and the bottom insulator 140, the plurality of stator windings 138 are wound onto the plurality of stator teeth 156 of the stator core 136. Thus, the top insulator 134 and the bottom insulator 140 surrounding the stator core 136 provide electrical insulation between the stator core 136 and the plurality of stator windings 138, thereby preventing flow of current or short circuiting between the plurality of stator windings 138 and the stator core 136.
[027] Further, as illustrated in Figure 3, the bottom insulator 140 comprises a first portion 140a and a second portion 140b. The first portion 140a of the bottom insulator 140 is configured to surround the stator core 136 for insulation, and the second portion 140b extends axially from the first portion 140a. In an embodiment, the second portion 140b extends axially downward from the first portion 140a. The second portion 140b of the bottom insulator 140 includes a radial outer side 150, a radial inner side 152 and a recess 132 that is formed in a peripheral wall of the second portion 140b. In an embodiment, the bottom insulator 140 is made of a polymer. For example, polymer may be nylon. The radial outer side 150 of the second portion 140b comprises one or more fastening provisions 150a.
[028] The one or more fastening provisions 150a of the bottom insulator 140 enables coupling of a cover member 110.Herein, the fastening provisions 150a are a non screw type fastening mechanism, that is the fastening provisions 150a do not involve the usage of an external fasteners such as a screw or a rivet or the like. In an embodiment, the non-screw type fastening mechanism includes a threading mechanism in which a threading provision is provided on the second portion 140b of the bottom insulator 140, and a corresponding threading provision is provided on the cover member 110, which allows for the cover member 110 to be threaded on to the second portion 140b of the bottom insulator 140. Figure 3 specifically illustrates the embodiment in which the one or mor fastening provisions 150a include the threading mechanism wherein threading provision is provided on the second portion 140b of the bottom insulator 140.
[029] In an alternative embodiment, the non-screw type fastening mechanism includes a snap-fit mechanism provided on the second portion 140b of the bottom insulator 140 which allows for the cover member 110 to snap fit on to the second portion 140b of the bottom insulator 140. In that, the snap fit mechanism has a male part provided on the bottom insulator 140 and a female part provided on the cover member 110, or vice versa, which engage with each other in a snap fit manner to attach the cover member 110 to the bottom insulator 140. In another embodiment, the non-screw type fastening mechanism includes other fastening mechanism such as, but not limited to, press-fit fastening mechanism whereby the cover member 110 is press fit on to the second portion 140b of the bottom insulator 140.
[030] The cover member 110 is configured to cover the electrical component 108 and the housing 106 from a bottom side of the hub assembly 100. The radial inner side 152 of the second portion 140b comprises one or more protrusions 152a. In an embodiment, the one or more protrusions 152a is vertical in shape. The one or more protrusions 152a of the bottom insulator 140 enables coupling of the electrical component 108. In an embodiment, the electrical component 108 comprises a light unit assembly whereby the light unit assembly provides illumination function. In an embodiment, the cover member 110 covers and allows for diffusion of light from the light unit thereby providing improved aesthetics. In an embodiment, the cover member 110 may be translucent member. In another embodiment, the cover member 110 may include a fabric, textile, chain, or the like to enable decorative diffusion of light made up of that particular fabric, polymer or metal.
[031] Further, the recess 132 of the bottom insulator 140 is configured to accommodate a connector PCB 154 (shown in Figure 6A). The connector PCB 154 operably connects the power PCB 112 to a digital PCB 148 (shown in Figure 5), thereby operably connecting the power PCB 112 to the first electrical component 108.
[032] Figure 5 illustrates a series of figures illustrating the light unit being assembled. Referring to Figure 5 in conjunction with Figure 1, in an embodiment, the light unit comprises a light housing 144, an illumination device 146 and the digital PCB 148. In an embodiment, the light housing 144 is provided with an annular recess and the illumination device 146 is an annular ring light. The illumination device 146 is placed within the annular recess of the light housing 144 via a snap-fit mechanism. In an embodiment, the illumination device 146 is a singular annular ring light. In an alternative embodiment, the illumination device 146 has plurality of segments configured in a circular manner to form a ring like structure, and each segment has a light source. In an embodiment, the light source is a Light Emitting Diode (LED) source or any other similar light source. Each segment/light source is configured to illuminate individually or in combination depending upon the operational status of the fan.
[033] The Digital PCB 148 is snap-fitted within the light housing 144 such that LEDs on the digital PCB 148 are facing downwards and a heatsink (not shown) is touching the stator core 136 to dissipate heat. In an embodiment, the light housing 144 is made of polymer material and is provided with a slot to enable the light unit to receive the IR (Infrared Radiation) command.
[034] Referring to Figure 6A in conjunction with Figure 3 and 5, the light housing 144 includes one or more vertical slots 108a on a radial outer surface. Further, the radial inner side 152 of the second portion 140b of the bottom insulator 140 comprises the one or more vertical protrusions 152a that are configured to mesh with the one or more vertical slots 108a of the light housing 144 thereby coupling the light unit onto the bottom insulator 140 resulting in elimination of requirement of fasteners.
[035] Further, referring to Figure 6B in conjunction with Figure 3 and 5, the plurality of fastening provisions 150a are provided on the radial outer side 150 of the second portion 140b of the bottom insulator 140.The plurality of fastening provisions 150a enable coupling of the cover member 110 to the bottom insulator 140 without the use of fasteners thereby eliminating the requirement of fasteners in the hub assembly 100, as well as reducing the overall height of the hub assembly 100. The attachment of the cover member 110 to the bottom insulator 140 by means of the fastening provisions 150a are of non-screw type, means that some part of the cover member 110 overlaps with the bottom insulator 140, thus achieving reduction in height of hub assembly 100. With reference to Figure 6C, in an embodiment, the cover member 110 comprises a first component 110a and a second component 110b. In an embodiment, the first component 110a is ultrasonically welded to the second component 110b such that the first component 110a fits evenly on the second component 110b. In an embodiment, the first component 110a is opaque component and the second component 110b is transparent component. Thus, the first component 110a and the second component 110b are joined to form the cover member 110 without the usage of any fasteners.
[036] Further, the provision of the digital PCB 148 within the light housing 144 and the light unit within the bottom insulator 140 also leads to a reduction in the overall height of the hub assembly 100. Further, in an embodiment, the illumination device 146 is made of plurality of segments or plurality of single LED’s based on selective illumination of which, the user comprehends the fan speed, it is necessary to ensure the illumination device 146 and the cover member 110 remain stationary. This is because, if the segments of the illumination device 146 rotates along with the rotor, the selective illumination of the segments of the illumination device 146 is not comprehensible since the illumination device 146 will appear as a single illuminated ring. Thus, by mounting of the light unit with the illumination device 146 and the cover member 110 on the bottom insulator 140, and thereby the stator assembly 130, it is ensured that the illumination device 146 and the cover member 110 are stationary and do not rotate, thus easily allowing a user to comprehend the selective illumination of the segments of the illumination device 146 for understanding fan speed.
[037] Further, as illustrated in Figure 7, a bottom canopy 200 is snap fitted onto the power supply box 102 after making necessary electrical connections from the power supply box 102 to the external source. The bottom canopy 200 is positioned above the power supply box 102 such that an annular groove provided inside the bottom canopy 200 engage with an annular protrusion 102a provided on the power supply box 102, thereby enabling a secure attachment via a ring snap mechanism onto the power supply box 102, forming a single integrated component.
[038] Advantageously, the present invention reduces the height of the fan motor thereby minimizing the overall profile of the hub assembly resulting in reduced manufacturing cost. Further, the reduced height of the motor assembly results in the reduction in the dimensions of the hub assembly thereby providing a compact hub assembly allowing for more efficient utilization of internal space in the housing.
[039] In addition, the present invention enables the inclusion of additional features or enhancements without compromising on the fan's performance or functionality. Moreover, the present invention also eliminates the requirement of fasteners thereby enabling ease of assembly, reducing manufacturing cost and facilitating easy maintenance and servicing of the hub assembly leading to a cost-effective, user-friendly and aesthetically appealing hub assembly.
[040] While the present invention has been described with respect to certain embodiments, it will be apparent to those skilled in the art that various changes and modification may be made without departing from the scope of the invention as defined in the following claims.
,CLAIMS:WE CLAIM:
1. A hub assembly (100) for a fan, the hub assembly (100) comprising:
a rotor (120) being disposed in a housing (106); and
a stator assembly (130) being disposed radially inside the rotor (120) in the housing (106), the stator assembly (130) comprising a top insulator (134) and a bottom insulator (140) for insulating a plurality of stator windings (138) from a stator core (136), the bottom insulator (140) comprises one or more protrusions (152a) adapted to receive at least one electrical component (108) and one or more fastening provisions (150a) for receiving a cover member (110) being adapted to cover at least one electrical component (108).

2. The hub assembly (100) as claimed in claim 1, comprising:
a power supply box (102) configured to house a power Printed Circuit Board (PCB) (112), wherein the power PCB (112) being configured to regulate and control the operation of the fan, and wherein the housing (106) has a motor section (106a) and a bearing section (106b), the motor section (106a) houses the rotor (120) and the stator assembly (130), and the housing (106) being attached to a shaft (114) at the bearing section (106b), the bearing section (106b) extending upwardly from the motor section (106a), the bearing section (106b) of the housing (106) being disposed at least partially enclosed by the power supply box (102).

3. The hub assembly (100) as claimed in claim 1, wherein the bottom insulator (140) comprises a first portion (140a) and a second portion (140b), the first portion (140a) being configured to surround the stator core (136), and the second portion (140b) extending axially from the first portion (140a).

4. The hub assembly (100) as claimed in claim 3, wherein the second portion (140b) of the bottom insulator (140) comprises a radial outer side (150), a radial inner side (152) and a recess (132) formed in a peripheral wall of the second portion (140b).

5. The hub assembly (100) as claimed in claim 4, wherein the radial outer side (150) of the second portion (140b) comprises one or more fastening provisions (150a), the one or more fastening provisions (150a) being configured to enable coupling of the cover member (110) to the bottom insulator (140).

6. The hub assembly (100) as claimed in claim 5, wherein the one or more fastening provisions (150a) for coupling the cover member (110) to the bottom insulator (140) include one or more of a threading mechanism, or a snap fit mechanism, or a press fit mechanism.

7. The hub assembly (100) as claimed in claim 4, wherein the radial inner side (152) of the second portion (140b) comprises one or more protrusions (152a), the one or more protrusions (152a) being configured to receive at least one of the one or more electrical components (108).

8. The hub assembly (100) as claimed in claim 7, wherein the recess (132) of the bottom insulator (140) being configured to accommodate a connector PCB (154), the connector PCB (154) being configured to operably connect the power PCB (112) to at least one of the one or more electrical components (108).

9. The hub assembly (100) as claimed in claim 7, wherein the electrical component (108) comprises a light unit having a light housing (144), an illumination device (146), and a digital PCB (148), the digital PCB (148) being housed within the light housing (144), and the light housing (144) having one or more vertical slots (108a) configured to mesh with the one or more protrusions (152a) on the bottom insulator (140).

10. The hub assembly (100) as claimed in claim 2, comprising a bottom canopy (200), the bottom canopy (200) being positioned above the power supply box (102), the bottom canopy (200) being snap fitted to the power supply box (102).

11. The hub assembly (100) as claimed in claim 1, wherein the housing (106) comprises a plurality of mounting flanges (126), the plurality of mounting flanges (126) extending radially outwardly from the housing (106) and being configured to receive a plurality of blades.