Abstract:
A molded heavy-duty ergonomic handle comprises: a top portion, the top portion extending in a longitudinal direction and being substantially smooth; and at least one U-shaped side channel having a plurality of ribs therein, the at least one channel having substantially smooth exterior surfaces and being located on a longitudinal side of the top portion.

Description:
FIELD OF THE INVENTION  
       [0001]     The present invention relates generally to molded handles. Specifically, it relates to an injection molded handle that efficiently uses material and is structurally sound, easier to produce, and is ergonomic, meaning it has a generally smooth lower surface, free from exposed ribs that provide discomfort to a user thereof when lifting heavier loads or any load for an extended period of time.  
       BACKGROUND  
       [0002]     Prior art injection molded handles, for example on sewing machine covers, generally contain smooth top surfaces and oversized ribs along the underside. The smooth top surfaces provide a visually pleasing design. The oversized ribs provide additional strength necessary for proper handle operation. However, locating the ribs on the underside creates discomfort for users when carrying heavier loads, or even lighter loads for an extended period of time. Further, the ribs must be oversized, because the use of ribs as strengthening members on the lower portion of the handle is inefficient under bending loads. In an attempt to maintain the molding costs, prior art designs have been unable to eliminate the use of ribs on the underside without sacrificing strength or using more complicated molds, which may use cams and slides. Still further, other design features are necessitated in part by the molding process, such as providing a smooth top surface to provide a convenient and cost-effective location for injection mold gates. Consequently, it is desirable to have a design that efficiently uses material to provide a structurally sound and ergonomic molded handle that is easy to produce.  
       SUMMARY OF THE INVENTION  
       [0003]     In one embodiment of the present invention, a molded heavy-duty ergonomic handle comprises: a top portion, the top portion extending in a longitudinal direction and being substantially smooth; and at least one U-shaped side channel having a plurality of ribs therein, the at least one channel having substantially smooth exterior surfaces and being located on a longitudinal side of the top portion.  
         [0004]     In another embodiment of the present invention, a handled cover comprises: a handle, the handle having two opposing ends and comprising: a top member, the top member extending in a longitudinal direction between the two opposing ends and having a smooth top surface; and at least one U-shaped side channel having a plurality of ribs therein, the at least one channel having substantially smooth exterior surfaces and being located on a longitudinal side of the top portion; a first and a second base, each base being adjacent to one of the opposing ends of the handle; and a cover, the cover being adjacent to the first and second bases. 
     
    
     BRIEF DESCRIPTION OF FIGURES  
       [0005]      FIG. 1  is a perspective view of an object with a molded ergonomic handle of the present invention;  
         [0006]      FIG. 2 . is a perspective view of the molded ergonomic handle of  FIG. 1 ;  
         [0007]      FIG. 3 . is a top view of the molded ergonomic handle of  FIG. 1 ;  
         [0008]      FIG. 4 . is a bottom view of the molded ergonomic handle of  FIG. 1 ;  
         [0009]      FIG. 5 . is an end view of the molded ergonomic handle of  FIG. 1 ; and  
         [0010]      FIG. 6 . is a side view of the molded ergonomic handle of  FIG. 1 .  
         [0011]      FIG. 7  is a cross-sectional view through the middle of an embodiment of a molded ergonomic handle.  
         [0012]      FIG. 8  is a cross-sectional view through the middle of an embodiment of a molded ergonomic handle having web continuous with the top portion and internal sides of the side channels. 
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0013]     Referring to  FIGS. 1-6 , a molded ergonomic handle  20  is shown, the design of which efficiently imparts needed strength while providing an ergonomic underside and facilitating simple production thereof. Handle  20  generally comprises top portion  22 , side channels  26 , and ribs  34 , which are located within channels  26 . Handle  20  ultimately attaches to or is formed integrally (where all parts are maintained in a fixed relationship as a single unit) or monolithically (as a single uniform unit) with an intended object  60 , such as a sewing machine cover (shown), a tool box lid, a bowling ball bag, a piece of luggage, a tote, a briefcase, etc. In another aspect, the invention according to the present invention may comprise an injection mold having a mold cavity that is complementary to the shape of the handle  20  or handle  20  plus object  60 . Additionally, the invention may encompass a method of molding handle  20 .  
         [0014]     Top portion  22  extends lengthwise (longitudinally) along the top of elongated handle  20  from either end  23  thereof. Generally, the lengthwise extension of portion  22  is smooth, or, in other words, devoid of any abrupt directional changes along the lengthwise extension that may significantly harm material flow during the molding process. Top portion  22  may be arc-like. Consequently, this top portion  22  provides a convenient and efficient location to place adjacently thereto within the mold a gate, which allows material to be injected into the mold cavity and is evidenced by surface irregularity  24 , since the smooth contour of the extension promotes material flow into the mold cavity.  
         [0015]     Side channels  26  may be located on either side of top portion  22 , and may be generally U-shaped, comprising side walls  28 ,  30  and bottom  32 . Side wall  28  extends down from top member  22  to bottom  32 , while side wall  30  extends up from bottom  32 . The U-shape efficiently provides strength, by having the bottom  32  extend laterally in a plane furthest from the neutral axis, to resist any bending moment generated from loads acting on ends  23 . Also, the U-shape is ergonomically pleasing, as side wall  28  and bottom  32  have substantially smooth exterior surfaces, thereby providing ample surface area to comfortably support a user&#39;s hand when under load. This is contrary to prior art injection molded handles (not hollow or solid) that include ribs along the bottom surface, which provide limited and discontinuous surface area and cause the user discomfort as the ribs provide local areas of high pressure upon the user&#39;s hand. Ribs  34  may be included within channels  26 , generally extending between walls  28 ,  30  as strengthening members. Finally, channels  26  may include an expanded portion  36  at either end  23  to provide added strength and reduce concentrated stresses at the junction between ends  28 ,  30  and bases  40  or an intended object  60 .  
         [0016]     Handle  20  may also optionally include web  38 , located below top portion  22  and between side walls  28 . The web  38  may be a series of discrete ribs or the like, as seen in  FIG. 7 . Alternatively, the web  38  may simply form a continuous longitudinally-extending main member with both side walls  28 , top portion  22 , and web  38 , as illustrated in  FIG. 8 . Alternatively, the main member may encompass only a portion of both side walls  28 , such that the web  38  does not extend completely to bottom  32 .  
         [0017]     Handle  20  may be attached to any intended object  60  directly or indirectly, for example through the use of bases  40 . Bases  40  allow handle  20  to mount away from object  60  to provide clearance for a user&#39;s fingers, thereby allowing the user to properly grasp handle  20 . Base  40  may comprise a raised area  42  and a mounting surface  46 . A contour may extend from raised area  42 , which allows for a larger mounting surface  46  without requiring a larger raised area  42 .  
         [0018]     Handle  20  may exist independently, or may be integral or monolithic with base  40  and/or object  60 . If handle exists independently, handle  20 , base  40 , and/or object  60  may be joined by any commercially known means, such as by welds, fasteners, or mechanical interference. If handle  20  does not exist independently, handle  20 , base  40 , and/or object  60  may be formed as a unitary piece by any commercially known method, such as by injection molding. Generally, handle  20 , and base  40  and object  60 , if integral or monolithic with handle  20 , may be made form any commercially known moldable material, such as thermoplastics and metals.  
         [0019]     The present invention allows molding of the entire handle  20  and any associated monolithic objects  60  via a single gate. As best seen in  FIG. 7 , the cross-sectional area of handle  20 , including top portion  22 , left side walls  28 ,  30 , and bottom  32 , and right side walls  28 ,  30  and bottom  32  all provide increased volume for the molten plastic to traverse over conventional handles and mold designs. Additionally, the handle  20  provides the necessary strength due to the inclusion of ribs  34 . Finally, the handle  20  enables efficient molding, as no slides and/or complex molding equipment and procedures are needed.  
         [0020]     Although the invention has been described herein with reference to the present embodiments, it will become apparent to those skilled in the art that various modifications of the present embodiments of the invention as described herein can be made without departing from the spirit or scope of the invention as defined by the appended claims.