Abstract:
The present invention allows a user to select a handle that is ergonomically friendly to a user&#39;s hand and replace it with the replaceable handle that is designed to fit over a soldering iron rod. There are a number of advantages to the present invention. One of the advantages is that a user can choose an individual handle with the desired shape, size, color, and material. Another advantage is that since each user has an individual handle, hygiene problems may be minimized. Still another advantage is the cost savings because as the replaceable handle wears out, only the handle needs to be replaced rather than the whole soldering iron.

Description:
CROSS-REFERENCES TO RELATED APPLICATIONS 
     This application is a continuation-in-part application of U.S. application Ser. No. 09/842,992 filed Apr. 26, 2001, which is incorporated herein by reference. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     This invention relates generally to a soldering iron and, more particularly, to a soldering iron having a releasable and replaceable cartridge and associated handle that may be replaced with a customized handle for a particular user. 
     2. General Background and State of the Art 
     Cartridge type soldering irons have been in use for a number of years. One example of a cartridge type soldering iron is disclosed in U.S. Pat. No. 4,839,501. As disclosed therein, there is a replaceable cartridge and associated rigid handle. One of the problems with a soldering iron with a replaceable cartridge as shown in the U.S. Pat. No. 4,839,501 patent is that it is not comfortable for every user. That is, if a user does not like the size or shape of the handle of a soldering iron, the user has to either find another iron that is more comfortable or continue to use the uncomfortable soldering iron. Moreover, a soldering iron may be handled by a number of users, which can cause hygiene problems. This is especially true because most germs are transmitted via human hands. 
     Therefore, there is a need for a cartridge type soldering iron having a handle that can be fitted to a particular user and, at the same time, minimize any hygiene problems being caused by a number of users handling the same soldering iron. 
     INVENTION SUMMARY 
     The present invention solves the aforementioned problems with a cartridge type soldering iron by providing a handle that is releasable from the soldering iron cartridge and replaceable with a handle that is more comfortable to the user. This allows a user to select a handle that is ergonomically friendly to his hand and replace it with the replaceable handle that is design to fit the soldering iron cartridge. There are a number of advantages to the present invention. One of the advantages is that a user can choose its own handle with the desired, shape, size, color, and material. Another advantage is that since each user has its own handle, hygiene problems may be minimized. Still another advantage is the cost savings because as the replaceable handle wares out, only the handle needs to be replaced rather than the whole soldering iron. 
     The above described and many other features and attendant advantages of the present invention will become apparent from a consideration of the following detailed description when considered in conjunction with the accompanying drawings. 
     BRIEF DESCRIPTION OF THE DRAWINGS 
     A detailed description of exemplary embodiments according to the invention will be made with reference to the accompanying drawings. 
     FIG. 1 is an exemplary view of an assembled soldering iron in accordance with one embodiment of the present invention; 
     FIG. 2 is an exemplary view of a disassembled soldering iron of FIG. 1; 
     FIG. 3 is an exemplary view of a disassembled soldering iron in accordance with an alternative embodiment of the present invention; 
     FIG. 4 is an alternative embodiment of a connector, 
     FIG. 5 is yet another alternative embodiment of a connector, 
     FIG. 6A is an exemplary view of an alternative embodiment of the present invention; 
     FIG. 6B is an exemplary cross-sectional view of the embodiment illustrated in FIG. 6A; and 
     FIG. 7 is an exemplary view of a sleeve and handle illustrated in FIG. 6A coupled to a substantially similar connector illustrated in FIG.  1 . 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     This description is not to be taken in a limiting sense, but is made merely for the purpose of illustrating the general principles of the invention. The section titles and overall organization of the present detailed description are for the purpose of convenience only and are not intended to limit the present invention. 
     FIG. 1 illustrates by way of example a soldering iron cartridge  10  (cartridge) having a sleeve  12  disposed within an insulator  14 , which is also disposed within a releasable handle  16 . This assembly is further adapted to electrically connect to a connector  18  having a cord extending to a plug  48 . 
     FIG. 2 illustrates by way of example the cartridge  10  disassembled. The sleeve  12  has a proximal end  22  and a distal end  20 . The proximal end  22  is adapted to couple to a connector end  24  having electrical contact areas  26  and  26 ′. The distal end of the sleeve  12  is adapted to couple to a tip  28  which is designed to concentrate the heat generated by the electrical heating elements  30  within the sleeve  12  (not shown). That is, the electrical energy supplied to the electrical heat element  30  via the electrical contact areas  26  and  26 ′ are converted into heat and focused along the tip  28 . Optionally, the sleeve  12  may have a notch  32  along the surface of the sleeve  12  so that it may be used to position the insulator  14  at a predetermined position relative to the sleeve  12 , as further discussed below. 
     As illustrated by way of example in FIG. 2, the insulator  14  has an opening  34  running axially therethrough. The shape of the opening  34  may be substantially similar to the outer configuration of the sleeve  12 . Once the sleeve  12  is inserted through the opening  34 , the cartridge  10  may be firmly held in place. Moreover, within the opening  34  may be a tooth  36  which is adapted to engage with the notch  32  thereby positioning the insulator  14  relative to the sleeve  12  in a predetermined position. Additionally, the sleeve  12  may be fixed or releasably held within the opening  34  of the insulator  14 . 
     Optionally, the insulator  14  may have an outer ring  38  which is made of temperature-sensitive material. That is, as the sleeve  12  near the tip  28  gets hot, the outer ring  38  may indicate such a rise in temperature by varying its color, depending on the temperature of the sleeve. This way, a user may be warned that the soldering iron is hot. Moreover, the length of the insulator  14  may be sized so that it is less than the length of the sleeve between its proximal and distal ends. 
     FIG. 2 also illustrates an exemplary handle  16  having a hole therethrough along the longitudinal axis. The configuration of the hole  40  may be substantially similar to the outer configuration of insulator  14 . Once the insulator  14  is inserted into the hole  40 , it snugly fits into the hole  40  and it is removable. The outer circumference of the handle  16  may vary in size, shape, and may be made of a variety of materials with different degrees of firmness. This allows a particular user to pick a handle that is ergonomically comfortable to grip. Because each user may have his own handle  16 , the hygiene problem is minimized. Cost-wise, when the handle  16  wears out, rather than replacing the whole soldering iron cartridge  10 , just the handle  16  may be replaced. The handle  16  may be made of foam and may be carbon impregnated to allow static discharge. Moreover, the handle  16 , may be washable. Of course, the handle  16  may be made of a variety of materials known to those skilled in the art including rubber, elastomers, and plastics. 
     FIG. 2 further illustrates by example the connector  18  having a receptacle opening  42  therein. Within the receptacle opening  32  are electrical contact fingers  44  positioned to make electrical contact with the electrical contact areas  26  and  26 ′ of the connector end  24 . That is, once the connector end  24  is inserted into the receptacle opening  42 , electrical contact fingers  44  make electrical contact with the electrical contact areas  26  and  26 ′. Connector  18  also includes a cord  46  which is coupled to a plug  48  which is adapted to insert into an electrical outlet. Note that the length of the handle  16  is designed to fit flush against the outer ring  38  and fit flush against the opposite end. This way, once the connector end  24  is inserted into the receptacle opening  42 , the connector, connector end, and the handle are flush against each other. 
     FIG. 3 illustrates by example an alternative embodiment of the present invention wherein the sleeve  12  is inserted into a hole  40 ′ of the handle  16 ′. In this embodiment, the insulator  14  is eliminated, unlike the previous embodiment in FIG.  2 . The sleeve  12  may be releasable from the handle  16 ′, and the handle  16 ′ may have a tooth  50  adapted to associate with the notch  32  of the sleeve  12  to position the handle  16 ′ relative to the sleeve  12  at a predetermined position. One of the reasons for not needing the insulator  14  is that much of the heat is focused near the distal end  20  and minimal heat is conducted back along the sleeve  12  to the location of the notch  32 , so that a handle  16 ′ made of foam would not degrade due to the heat. Of course, the hole  40 ′ is now sized to be substantially similar in dimension to the configuration of the sleeve  12 . Moreover, the handle  16 ′ may have an outer ring  38 ′ to indicate the temperature of the outer ring  38 ′. 
     With regard to the cross-section of the sleeve  12 , it may have a variety of cross-sectional shapes such as circular, oval, square, or rectangular. The hole  40 ′ however need not be similar to the cross-sectional area of the sleeve  12 , although at least a portion of the hole  40 ′ is used to engage the outer surface of the sleeve  12  to somewhat firmly hold the sleeve  12  in its predetermined position. As such, air passageways may be formed between the handle  16 ′ and the sleeve  12  to radiate the heat away from the handle  16 ′. Of course, the cross-section of the hole  40 ′ may correspond to the cross-section of the sleeve  12  to make continuous contact between the handle  16 ′ and the surface of the sleeve  12 . 
     FIG. 4 illustrates by way of example an alternative way of coupling the cord  46  to the connector  18 . In this embodiment, the cord  46  is coupled to the connector  18  at about a 45° angle so that it may be more comfortable for a user to hold the cartridge  10 . Still further, as illustrated by way of example in FIG. 5, the core  46  may be coupled to the connector  18  at about a 90° angle to each other for application in which such relationship would aid the user in using the cartridge  10  more comfortably. 
     FIGS. 6A and 6B illustrate still another alternative embodiment of the present invention wherein the sleeve  12 ′ is inserted into a hole  40 ″ of a handle  16 ″. In this embodiment, the sleeve  12 ′ has a ring  38 ″ at a predetermined position to act as a stopper along a longitudinal axis of the sleeve  12 ′. Moreover, the handle  16 ″ is divided into two portions, a distal portion  52  and a proximal portion  54 . The distal portion  52  has a bore  50  adapted to receive the ring  38 ″. As such, as the distal end  22 ′ of the sleeve  12 ′ is inserted through the bore  50  of the distal portion  52 , the ring  38 ″acts as a stopper to prevent the handle  16 ″ from moving further toward the distal end  20 ′ of the sleeve  12 ′. This ensures that the handle  16 ″ is correctly positioned relative to the sleeve  12 ′. Moreover, the outer configuration of the proximal portion  54  may be sized for a particular user, as such, the outer configuration of the proximal portion  54  may be smaller than the outer configuration of the distal portion  52 . Conversely, the outer configuration of the distal portion  52  may be greater than the proximal portion  54 . 
     To assemble the cartridge illustrated in FIGS. 6A and 6B, a user first selects from a variety of handles which are most comfortable for the user. In other words, a user selects from a variety of handles having a different outer configuration along the proximal portion  54  designed for a particular user. Once a handle  16 ″ has been selected, the proximal end  22 ′ of the sleeve  12 ′ is inserted through the bore  50  until the ring  38 ″ stops the handle  16 ″ in its predetermined position. Then, the proximal portion  22 ′ is inserted into connector  18  until an electrical contact is made. This way, the cartridge illustrated in FIGS. 6A and 6B may be customized for a particular user. Moreover, in this embodiment, the sleeve  12 ′ is coupled to the connector  18  having a core that is at about a 45° angle relative to the longitudinal axis of the sleeve  12 ′. Alternatively, as illustrated in FIG. 7, a connector  18  having a core that is substantially in line with the longitudinal axis of the sleeve  12 ′ may be used as well. 
     In closing, it is noted that specific illustrative embodiments of the invention have been disclosed hereinabove. With respect to the claims, it is applicant&#39;s intention that the claims not be interpreted in accordance with the sixth paragraph of 35 U.S.C. § 112 unless the term “means” is used following by a functional statement.