Patent Publication Number: US-6334233-B1

Title: Vacuum cleaner with snap-fit handle and torque-reducing support

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
     This application claims the benefit of Provisional Application Ser. No. 60/114,485, filed Dec. 31, 1998. 
    
    
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     This invention relates to a vacuum cleaner. In one of its aspects, the invention relates to a handle/support assembly for an upright vacuum cleaner with a snap-fit handle construction. In another of its aspects, the invention relates to a torque resistant handle/support assembly for an upright vacuum cleaner. 
     2. Description of the Related Art 
     Known upright vacuum cleaners include a pivotal handle assembly that is detachably secured to a base module. To alleviate packaging constraints, the handle portion is typically shipped separately from the base module such that they must be assembled together once received from the manufacturer. One known handle, as disclosed in U.S. Pat. Nos. 5,761,763 and 5,500,977, provides an upper handle portion that is telescopically mounted over attachment posts extending from an upper end of a lower body shell. The upper handle portion and the lower body shell are secured to one another by passing screws through the handle portion. 
     In another known handle construction, as disclosed in U.S. Pat. Nos. 4,648,149 and 4,621,390, an upper handle portion and a lower handle portion have attachment openings which are manipulated into alignment as the portions are assembled. The lower handle portion has attachment openings on an upper section, wherein the upper section is telescopically received within an opening in the upper handle portion that has mating attachment openings. After insertion of the lower handle portion, either the upper or lower handle portions are manipulated to insure that the attachment openings are properly aligned. Once aligned, separate snap pins are then pressed through the attachment openings to properly secure the two portions together. 
     These techniques for securing the handle are undesirable as they require separate attachment fasteners, which may become misplaced during shipping or assembly. Further, if the fastener breaks, an additional fastener must be obtained to properly secure the handle, causing inconvenience to the user at best and a permanently defective handle assembly at worse. In some instances assembly of the handle further requires a special tool to properly secure the fastener to the handle. 
     Often the handle assembly must also serve as a support for a vacuum cleaner module. In one such vacuum cleaner, as disclosed in U.S. Pat. No. 5,309,600, the handle assembly includes a unitary support member that spans substantially the width of the base module. This type of support member does not provide a means for accommodating a rearwardly extending vacuum hose from the vacuum module. 
     In another known handle assembly, as disclosed in PCT Publication No. WO 94/17716, an elongated support member is laterally offset from the center of the base module. While this arrangement overcomes the difficulties associated with positioning rearwardly extending vacuum hoses, the torque resistance of the handle during operation of the vacuum cleaner is reduced. 
     SUMMARY OF THE INVENTION 
     These and other problems of the prior art are overcome with a snap-in handle for a handle/support assembly, wherein the handle/support assembly substantially reduces torquing of the vacuum module relative to the support member. 
     According to the invention, a handle assembly for an upright vacuum cleaner comprises a primary support member having an upper handle-mounting portion, a body portion and a foot portion adapted to be mounted to a base member. A handle section is telescopingly received on the upper handle-mounting portion of the primary support member. One of the handle section and the primary support member have at least one projecting mounting tab and the other of the handle section and the primary support member have at least one slot in registry with and receiving the at least one projecting mounting tab to retain the handle section on the primary support member. In this way, the two handle sections are snap-fit together without the use of any tools. Preferably, there are two mounting tabs and two slots in registry with the mounting tabs. Further the handle section and the upper handle-mounting portions are rectangular in horizontal cross-sectional configuration for rotational rigidity. In one embodiment, the mounting tabs are mounted on the upper handle-mounting portion and the slots are provided in the handle section. Preferably, the mounting tabs are integrally formed with one of the handle section and the primary support member. In a preferred embodiment, the mounting tabs are in the form of fingers that are formed by integral U-shaped slots in the one of the handle section and the primary support member. 
     In a preferred embodiment, the primary support member is an inverted L-shape in profile. Preferably, a secondary support member is adapted to mount between the base and the overhanging portion of the primary support member. 
     In another preferred embodiment, the primary support member has a pair of integrally molded projections extending downwardly from the foot portion thereof for mounting the primary support member to a base. The projections are integrally formed by vertically extending flanges. Tool-mounting projections are also preferably integrally formed with and extend from either side of the primary support member. 
     In accordance with a preferred embodiment of the invention, the body section is positioned laterally of a vacuum hose opening in the base. The secondary support leg is positioned adjacent to but spaced from the body section to provide space for a vacuum hose between the base and a vacuum module which is mounted to the handle and to the base. The secondary support member gives torsional resistance to the handle assembly. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The invention will now be described with reference to the drawings in which: 
     FIG. 1 is a partially exploded view of an upright vacuum cleaner according to the invention; 
     FIG. 2 is a perspective view of a primary support member for a handle/support assembly of a vacuum cleaner illustrated in FIG. 1; 
     FIG. 3 is a rear elevational view of the primary support member in FIG. 2 from a rearward direction; 
     FIG. 4 is a front elevational view of a handle section of the handle/support assembly; 
     FIG. 5 is a perspective view of the handle section in FIG. 4; 
     FIG. 6 is an enlarged rear elevation of the lower portion of the handle in the circle VI of FIG. 2; 
     FIG. 7 is a cross-sectional view taken along lines  7 — 7  of FIG. 2; 
     FIG. 8 is a sectional view of an assembled handle taken along lines  8 — 8  of FIG. 1; 
     FIG. 9 is a rear perspective view of a second embodiment of the invention; and 
     FIG. 10 is an exploded front perspective view of the second embodiment of the invention illustrated in FIG.  9 . 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     Referring now to the drawings and to FIG. 1 in particular, an upright vacuum cleaner comprises a handle/support assembly  10 , a vacuum module  12  (shown in phantom) and a base housing  14 . The vacuum module  12  and the base housing  14  are disclosed in more detail in PCT Publication No. WO 94/17716, which is incorporated herein by reference. The vacuum module  12  and the base housing  14  form no part of this invention except to the extent that they are used with the handle/support assembly  10  according to the invention and thus will not be described in detail in this application. In accordance with the invention, handle/support assembly  10  includes a primary support member  16 , a secondary support member  18  and a detachable handle section  20 . As seen best in FIGS. 2 and 3, primary support member  16  has a foot member  22 , a body section  24 , a handle mounting section  26  and a secondary support leg  27 . Foot member  22  is releasably securable in a first mounting tube  28  of base housing  14 . First mounting tube  28  is positioned so as to be laterally offset from a vacuum hose opening  30  disposed generally in the center of a back portion  32  of base housing  14 . In one embodiment, foot member  22  is provided with integral retainers  34  that have an inclined lower surface and a lateral shoulder that is received beneath the lower edges of mounting tubes  28  and  29 . Foot member  22  further includes a guide flange  38  to support the primary support member  16  on the base housing  14 . Guide flange  38  is receivable within a slot  40  that is positioned adjacent to first mounting tube  28  in base housing  14 . Three depending flanges  35  form a circular guide which is received in the first mounting tube  28  and two depending flanges  37  fit into a semicylindrical mounting tube  29  on the base  14 . The depending flanges  35  in the mounting tube  28  and the depending flange  37  in the semicylindrical mounting tube  29  and the guide flange  38  in the slot  40  give significant lateral support for the connection of the handle body section  24  to the base housing  14  while the retainer  34  retains the handle  10  in the base housing  14 . The foot member  22  further has a pair of rectangular openings  39  aligned with the depending flanges  35  and  37  to assist in molding the flanges. The flanges  35  and  37  are joined at the back edges thereof by integral webs  55  and  57 , respectively. The foot  22  further has a pair of upstanding X-shaped projections  41  on a lateral shelf  53 . 
     Body section  24  has a generally upright front support section  42  that is laterally offset from vacuum hose opening  30 , to avoid interference with attachment of a rear extending vacuum hose (not shown) to base housing  14 . A flange  45  extends rearwardly from the side of the front support section  42  and a flange  49  extends forwardly of the front support section. A wall  51  extends laterally from the flange  45 . Referring to FIG. 3, one or more mounting brackets  44  on a rearward side of body section  24  are integrally formed with the primary support member  16  to selectively mount vacuum cleaner wands or the like (not shown). The wands are mounted at the lower ends on the integrally formed X-shaped protrusions  41 . An upper portion  47  of body section  24  is integrally formed with handle mounting section  26 . One wall  48  of handle mounting section  26  has U-shaped slots  50  that define integral, spaced apart resilient spring fingers  52  having rearwardly projecting mounting tabs  54  at the upper ends thereof. Mold openings  104  extend through a front wall  56  to the slots  50 . The front wall  56  of handle mounting section  26  has an integrally formed fixed tab  58  projecting forwardly. Mounting tabs  54  and fixed tab  58  will be described below in greater detail. 
     A pair of triangular openings is formed in the bottom portion of section  42  adjacent to the X-shaped projections  41  to assist in molding the projections  41 . 
     Secondary support leg  27 , which has a length that is substantially less than the length of body section  24 , comprises an upper portion of the wall  49 , a forwardly directed rim  106  and molded projections  102  which terminate in a tube supporting receiver  68 . The secondary support leg  27  is integrally formed with handle mounting section  26  and positioned adjacent to body section  24 . A latch member  74  that cooperates with a latch mechanism (not shown) disposed on vacuum module  12  is formed in the upper portion of the wall  49  to secure vacuum module  12  to primary support member  16  in a manner disclosed in the Weaver et al. U.S. Pat. No. 5,309,600 which is incorporated herein by reference. 
     Secondary support member  18  has a lower end  60 , a body section  62  and an upper end  64 , as seen in FIG.  1 . Lower end  60  is releasably securable in a telescoping manner within second mounting tube  66  of base housing  14 . Second mounting tube  66  is spaced laterally from vacuum hose opening  30 , opposite first mounting opening  28  to provide a space for the passage of the vacuum hose from the base housing  14  to the vacuum module  12  as illustrated in PCT Publication No. WO 94/17716. Upper end  64  is releasably securable to a receiver  68  to integrate primary and secondary support members  16  and  18 . Secondary support member  18  is preferably a hollow metal tube. 
     In accordance with one aspect of the present invention, primary and secondary support members  16  and  18 , respectively, cooperate to increase the structural integrity of handle/support assembly  10  by providing an integrated support structure for vacuum module  12  that extends substantially across the width of base housing  14 . Therefore, any torquing of vacuum module  12  relative to primary support member  16  during use of the vacuum cleaner assembly is substantially reduced. Further, primary and secondary support members  16  and  18  define a generally rectangular aperture  76  therebetween, which easily accommodates a rearwardly extending vacuum hose (not shown) extending from vacuum module  12 . 
     Referring to FIGS. 4 and 5, handle/support assembly  10  further includes a contoured handle section  20  that is easily and quickly securable to handle mounting section  26  of primary support member  16  through snap fasteners without the use of tools. In one embodiment, handle section  20  comprises a gripping portion  78 , a center portion  80  and a base portion  82 , all of which are integrally formed as a one-piece unit. 
     Gripping portion  78  extends upwardly at an acute angle, away from the remainder of handle section  20 . The gripping portion  78  has a generally tubular shape and can be provided with a plurality of ridges (not shown) to prevent a user&#39;s hand from slipping. 
     In accordance with another aspect of the invention, base portion  82  has an open end  84  shaped and sized to complement the external shape of handle mounting section  26  such that handle mounting section  26  is telescopically received within base portion  82 . To secure handle section  20  to primary support member, base portion  82  has spaced apart finger slots  86  disposed in a rear wall  88 , as seen in FIG. 5, and a tab slot  90  disposed in a front wall  92 , positioned opposite rear wall  88 , as seen in FIG.  4 . Finger slots  86  are adapted to receive mounting tabs  54  and tab slot  90  is adapted to receive fixed tab  58  when handle mounting section  26  is telescopically received with open end  84  base portion  82 . Thus, base portion  82  of handle section  20  snaps into position on primary support member  16  without requiring separate fasteners or the use of tools as illustrated in FIG.  8 . Whereas the invention has been described with respect to two finger slots  86  and two mounting tabs  54 , it is within the scope of the invention to use one or more finger slot and mounting tab combinations to secure the handle section  20  to the primary support member  16 . Thus, one, three or more finger slot and mounting tab combinations can be used for this purpose according to the invention. Further, the mounting tabs  54  have been described as mounted on resilient fingers. It is preferred in some applications to eliminate the U-shaped slots  50  and the resilient mounting fingers  52 , and integrally mold the mounting tabs  54  directly to the wall  48  of the handle mounting section  26 . 
     Handle section  20  can further include an integrally molded cord mount  94 , shown formed on center portion  80 , for conveniently storing an electrical cord. One or more C-shaped mounts  96  can also be integrally molded to the handle section  20  and or the primary support member for selectively mounting vacuum cleaner attachment accessories (not shown) such as upholstery brushes and the like. 
     Referring now to FIGS. 9 and 10, a stick vacuum cleaner  110  has an upper handle section  112 , a body section  114  and a suction foot section  116 , all connected together. The foot section  116  comprises a suction nozzle  118  and wheels  120 . A hose  122  connects the suction nozzle  118  with a filter housing  126  on the body section  114 . The hose is supported by a hook  124 . The body section  114  further comprises a motor housing  128  which houses a motor which draws air passing through the hose  122  through a filter (not shown) in the filter housing  122 . The motor is powered by electricity which is supplied through an electrical cord  130 , shown coiled on supports on the body section  114 . The body section  114  further has a hollow handle mounting section  132  at an upper portion thereof. A resilient finger  134  having a projection  136  is integrally formed in the handle-mounting section in the same manner as the resilient fingers  52  are formed in the handle-mounting section  26  of the first embodiment. Preferably, the resilient fingers  114 , including the projections  136 , are formed both on the front and rear portions of the handle-mounting section  132  in an identical fashion. The body section  114  further includes a carry handle  142  and a switch  144 . 
     The handle section  112  is hollow and has a lower opening  138  at a bottom portion thereof. The lower opening  138  is sized to telescopically slide onto the handle-mounting section  132  of the body section  114 . Openings  140  are formed in both the front and rear side of the handle section  112  at a lower portion thereof and in registry with the projections  136  of the resilient fingers  134  when the handle section  112  is firmly seated on the handle-mounting section  132  of the body section  114 . 
     The handle section  112  is assembled to the body section  114  by simply sliding the lower opening  138  of the handle section  112  onto the handle-mounting section  132 . The resilient fingers  134  are resiliently depressed during the movement of the handle section  112  onto the handle-mounting section  132  until the projections  136  are aligned with the openings  140 . The projections  136  then snap into the openings  140 . The openings  140  are sized to snugly receive the projections  136  so that the handle section  112  is firmly retained on the body section  114  through the projections  136  on the resilient fingers  132 . The handle section  112  can be easily removed from the body section  114  by simply pushing the projections  136  inwardly and pulling the handle section  112  away from the body section  114 . 
     The stick vacuum cleaner  112  illustrated in FIGS. 9 and 10 is conventional in the suction foot section  116  and the body section  114 . The handle section  112  is also conventional with the exception of the snap-fit fingers in the handle-mounting section  132  and the openings in the handle section  112 . The suction and filtration system of the stick vacuum cleaner  110  forms no part of this invention and, accordingly, will not be more specifically described. 
     Whereas the invention has been described with reference to vacuum cleaners, the term “vacuum cleaner” is used in a generic sense to include both dry vacuum cleaners and wet vacuum cleaners, including extraction vacuum cleaners. Examples of extraction vacuum cleaners are disclosed, for example, in the McAllise et al. U.S. Pat. No. 5,500,977, issued Mar. 26, 1996, and in the U.S. patent to Kasen et al., U.S. Pat. No. 5,937,475, issued Aug. 17, 1999, both of which patents are incorporated herein by reference. 
     Preferred embodiments of the present invention have been disclosed. Reasonable variation and modification are possible within the scope of the forgoing disclosure and drawings without departing from the scope of the invention which is defined in the appended claims.