Patent Publication Number: US-2012030899-A1

Title: Electrical connector for handle and wand of vacuum cleaner

Description:
TECHNICAL FIELD AND INDUSTRIAL APPLICABILITY OF THE INVENTION 
     The present invention relates generally to the electrical connector field and more particularly to a novel electrical connector assembly and to a floor cleaning apparatus incorporating such an assembly. 
     BACKGROUND OF THE INVENTION 
     It is well known in the art to equip a floor cleaning apparatus such as a canister vacuum cleaner, an upright vacuum cleaner and even an extractor with a cleaning wand assembly that may be connected with electrified attachments or cleaning tools. Such cleaning tools may incorporate one or more electrical operating systems including, but not limited to, an agitator drive motor, booster fans, work area lighting systems and the like. In order to power these electrical systems the floor cleaning apparatus must include an electrical power line extending from the power source, located in the main body of the floor cleaning apparatus, to the tool or attachment. 
     The present invention relates to an electrical connector assembly useful in providing power to just such electrical systems. The electrical connector assembly of the present invention includes cooperating male and female connectors that allow the various components of the floor cleaning apparatus, and more particularly the wand assembly, to be interconnected while maintaining the supply of electricity to the electrical system provided on the attachment or tool. Advantageously, the electrical connector assembly further includes a resilient shield adapted to keep dirt and debris out of the electrical contacts of the cooperating female connector when the female connector is disconnected from the cooperating male connector. This ensures that dirt and debris do not interfere with the electrical connection between the connectors when they are reconnected to utilize the floor cleaning apparatus. 
     SUMMARY OF THE INVENTION 
     In accordance with the purposes of the present invention as described herein, an electrical connector assembly is provided. The electrical connector assembly includes a male connector and a cooperating female connector. The male connector includes a first plug body and a first electrical prong. The first electrical prong has a proximal end and a distal end. The proximal end of the first electrical prong is held in the first plug body. 
     The cooperating female connector includes a second plug body having a cavity. A first electrical contact is held in that cavity. In addition a resilient shield is received in the cavity. The resilient shield is displaceable from a first position covering the first electrical contact to a second position exposing the first electrical contact. Thus, in the first position the shield seals off the first electrical contact from the environment thereby preventing dirt and debris from fouling the first electrical contact. In contrast, in the second position the first electrical contact is exposed for simple connection with the first electrical prong. 
     Further describing the invention, a spring is received in the cavity. The spring biases the resilient shield into the first position. The resilient shield includes a first cam face at a first end, a second cam face at a second end and a substantially v-shaped body section connected to the first and second cam faces. 
     In accordance with an additional aspect of the present invention a floor cleaning apparatus is provided. The floor cleaning apparatus comprises a housing including a nozzle assembly and a canister assembly. A suction generator is carried on the housing. A dirt collection vessel is also carried on the housing. In addition, the floor cleaning apparatus includes a wand assembly having a flexible hose, an operator handle and a wand. The wand assembly further includes an electrical connector assembly. 
     The electrical connector assembly is characterized by having a male connector and a cooperating female connector. The male connector includes a first plug body and a first electrical prong. The first electrical prong has a proximal end and a distal end. The proximal end of the first electrical prong is received and held in the first plug body. 
     The cooperating female connector includes a second plug body having a cavity. A first electrical contact is held in that cavity. In addition, a resilient shield is received in the cavity. The resilient shield is displaceable from a first position, covering the first electrical contact and protecting that contact from dirt intrusion, to a second position exposing the first electrical contact for connection with the first electrical prong. 
     In accordance with yet another aspect of the present invention a method of resisting dirt intrusion into a female electrical connector is provided. That method comprises the step of providing a first electrical contact of the female electrical connector in a cavity of a plug body and providing a resilient shield in that cavity. The resilient shield is displaceable from a first position covering the first electrical contact to a second position exposing the first electrical contact for connection with a first electrical prong of a male connector. 
     In the following description there is shown and described several different embodiments of the invention, simply by way of illustration of some of the modes best suited to carry out the invention. As it will be realized, the invention is capable of other different embodiments and its several details are capable of modification in various, obvious aspects all without departing from the invention. Accordingly, the drawings and descriptions will be regarded as illustrative in nature and not as restrictive. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The accompanying drawings incorporated herein and forming a part of the specification, illustrate several aspects of the present invention and together with the description serve to explain certain principles of the invention. In the drawings: 
         FIG. 1  is a perspective view of a floor cleaning apparatus in the form of a canister vacuum cleaner incorporating the electrical connector assembly of the present invention; 
         FIG. 2  is a detailed exploded perspective view illustrating the flexible hose and operator handle of the wand assembly of the canister vacuum cleaner illustrated in  FIG. 1 ; 
         FIG. 3  is a detailed exploded perspective view of the wand assembly of the canister vacuum cleaner illustrated in  FIG. 1 ; 
         FIG. 4   a  is a detailed cross sectional view illustrating the cooperating female connector of the electrical connector assembly of the present invention with the resilient shield in the first position covering the electrical contacts of the female connector to prevent intrusion of dirt and debris into those contacts; 
         FIG. 4   b  is a detailed cross sectional view similar to  FIG. 4   a  but illustrating the resilient shield in the second position exposing the electrical contacts of the female connector for connection with the electrical prongs of the cooperating male connector; 
         FIG. 5  is a schematical block diagram illustrating the present invention connected to a floor cleaning apparatus incorporating a telescoping wand assembly as well as a power tool attachment that may be connected to the distal end of the wand assembly or, alternatively, directly to the operator handle on the end of the flexible hose of the wand assembly; and 
         FIG. 6  is a detailed perspective view of the resilient shield and the associated spring. 
     
    
    
     Reference will now be made in detail to the present preferred embodiment of the invention, examples of which are illustrated in the accompanying drawings. 
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS OF THE INVENTION 
     Reference is now made to the drawing figures illustrating a floor care apparatus in the form of a canister vacuum cleaner  10  incorporating the electrical connector assembly  60  of the present invention. While a canister vacuum cleaner  10  is illustrated, it should be appreciated that the floor care apparatus of the present invention may comprise a different apparatus such as, for example, an upright vacuum cleaner or even an extractor. Thus, the present invention should not be interpreted as being limited to a canister vacuum cleaner  10  as illustrated. 
     As best illustrated in  FIGS. 1 and 5 , the canister vacuum cleaner  10  includes a canister assembly  12  having a housing  14  supported for movement across the floor on ground engaging wheels  15 . The housing  14  includes an internal motor compartment  16  for receiving a suction generator  18  as well as a dirt collection compartment  20  for receiving a disposable filter/cleaning bag  22 . 
     The canister vacuum cleaner  10  further includes a wand assembly, generally designated by reference numeral  24 . The wand assembly  24  includes a flexible hose  26  having a hose cuff  28  at one end and an operating handle  30  at the opposite end. The hose cuff  28  may be releasably connected to an inlet port  32  provided on the housing  14  so as to allow direct communication from the flexible hose to the cleaning bag  22  held in the dirt collection compartment  20 . The wand assembly  24  further includes a wand  34 . In the embodiment illustrated in  FIG. 1 , the wand  34  is of one piece tubular construction. In the alternative embodiment illustrated in  FIG. 5 , the wand  34  is a telescoping wand including first and second telescoping sections  36 ,  38 . 
     The canister vacuum cleaner  10  further includes a nozzle assembly generally designated by reference numeral  40 . The nozzle assembly  40  includes an outer housing  41  that forms an agitator cavity/suction inlet  42  for receiving a rotary agitator  44  of a type well known in the art. The nozzle assembly  40  further includes an agitator drive motor  46  for driving the rotary agitator  44 . The agitator cavity/suction inlet  42  is provided in fluid communication with an outlet port  50 . A first connector  52  on the distal end of the wand  34  is releasably connected to the outlet port  50  while a second connector  54  on the opposite or proximal end of the wand  34  is connected to the operator handle  30 . 
     As should be appreciated, it is necessary to provide power to the agitator drive motor  46  and any light source  56  as well as any other electrical system provided on the nozzle assembly  40 . This is accomplished by the electrical connector assembly  60  (see  FIGS. 3 ,  4   a ,  4   b  and  5 ) which delivers electrical power from the canister assembly  12  to the nozzle assembly  40 . 
     More specifically, as illustrated in  FIG. 2 , electrical power travels from a source in the canister assembly  12  through the hose cuff  28  and along the hose  26  to the operator handle  30  by means of a contact connection (not shown) between the cuff and the canister assembly and a series of electrical wires  58  in a manner known in the art (note wires  58  wound around hose  26 ). The electrical wires  58  are connected with the operator controls on the handle  30  such as a suction generator actuator  59  and an agitator control switch  61 . More specifically, the suction generator actuator  59  allows the operator to turn the suction generator  18  on and off. In contrast, the agitator control switch  61  allows the operator to interrupt power to the agitator drive motor  46  when the suction generator  18  is on so as to interrupt the agitator drive for bare floor cleaning. The electrical connector  60  of the present invention provides for electrical connection between the operator handle  30  and the electrical systems provided on the nozzle assembly  40 . 
     More specifically, the electrical connector  60  may be generally described as including a female connector  64  provided on the operator handle  30 , a cooperating male connector provided on the connector  54  of the wand  34 , another or second female connector  64  provided on the first connector  52  at the opposite end of the wand  34  and a second male connector  62  provided on the nozzle assembly  40  adjacent the outlet port  50  (see  FIGS. 2 ,  3 ,  4   a ,  4   b  and  5 ). Electrical lines (not shown) connect the female connector  64  on the operator handle  30  with the agitator control switch  61 . Electrical lines  63  connect the male connector  62  and second female connector  64  on the wand  34 . Additional electrical lines (not shown) connect the male connector  62  on the nozzle assembly  40  with the agitator drive motor  46 , light source  56  or other operating electrical system on the nozzle assembly (see  FIGS. 2 ,  3  and  5 ). 
     As best illustrated in  FIG. 3 , each male connector  62  includes a first plug body  66 , a first electrical prong  68  and a second electrical prong  70 . The proximal ends  72  of the prongs  68 ,  70  are held in the plug body  66  while the distal ends  74  project from the body (see also  FIGS. 4   a  and  4   b ). 
     As best illustrated in  FIGS. 2 ,  3 ,  4   a  and  4   b , each female connector  64  includes a second plug body  76  having a cavity  78 . First and second electrical contacts  80 ,  82  are received in the cavity  78 . In addition, a resilient shield  84  is also received in the cavity  78 . As illustrated and described in greater detail below, the resilient shield  84  is displaceable from a first position (shown in  FIG. 4   a ) and a second position (illustrated in  FIG. 4   b ). In the first position the shield  84  covers the electrical contacts  80 ,  82  and protects them from intrusion with dirt and debris. In the second position, the shield  84  exposes the electrical contacts  80 ,  82  for connection with the first and second electrical prongs  68 ,  70  of the cooperating male connector  62 . A spring  86  is received in the cavity and functions to bias the resilient shield  84  into the first position. 
     More specifically, the resilient shield  84  includes a first cam face  88  at a first end, a second cam face  90  at a second end and a substantially v-shaped body section  92  intermediate the two cam faces. The body section  92  includes a first bend  94  and the plug body  76  includes a boss  96 . When properly mounted in the cavity  78 , the first bend  94  of the body section  92  is received around the boss  96 . 
     As should further be appreciated, the spring  86  is also substantially v-shaped and includes a second bend  98  (see  FIG. 4   a ). The spring  86  is received against the body section  92  in a groove  100  on the body section with the second bend  98  also received around the boss  96 . The resilient shield  84  is made from a non-conducting polymer material such as, for example, polypropylene or delrin. 
     Reference is now made to  FIG. 4   a  illustrating the resilient shield  84  in the first position with the first end  102  covering the first electrical contact  80  and the second end  104  covering the second electrical contact  82 . By covering the contacts  80 ,  82  when they are disconnected from the prong  68 ,  70  of the cooperating male connector  62  intrusion of dirt and debris into the contacts is substantially prevented. This prevents fouling of those contacts  80 ,  82  and maintains the integrity of any electrical connection. 
     When an operator wishes to connect a male connector  62  to a female connector  64 , the operator aligns the first and second electrical prongs  68 ,  70  of the male connector  62  with the first and second electrical contacts  80 ,  82  of the female connector  64  (see  FIG. 4   a ) which are accessible through openings in the plug body  76 . Next, the operator pushes the prongs  68 ,  70  of the male connector  62  into the female connector  64  (note action arrow A). When this is done, the distal end of the first prong  68  initially engages the first cam face  88  while the distal end of the second prong  70  initially engages the second cam face  90 . As the operator continues to push the male connector  62  and the female connector  64  together, engagement between the distal ends of the prongs  68 ,  70  and the cam faces  88 ,  90  cause the ends  102 ,  104  of the resilient shield  84  to be displaced inwardly in the direction of action arrows B. As illustrated in  FIG. 4   b , eventually the ends  102 ,  104  are displaced into the second position so that the contacts  80 ,  82  are completely uncovered and are open to receive the prongs  68 ,  70  and complete the electrical connection. 
     As should be appreciated from viewing  FIG. 5 , the vacuum cleaner  10  may include an attachment or tool  200  with a male connector  62  that may be connected to the cooperating female connector  64  on the end of the wand  34  or alternatively, directly to the female connector  64  on the operator handle  30  at the end of the flexible hose  28 . When the operator wants to connect a tool  200  directly to the handle  30 , the wand  34  is removed from the handle  30 . As the prongs  68 ,  70  of the male connector  62  are removed from the contacts  80 ,  82  of the cooperating female connector  64 , the spring  86  biases the resilient shield  84  back into the first position illustrated in  FIG. 4   a  where the ends  102 ,  104  of the resilient shield  84  prevent dirt intrusion. When the tool  200  is then connected to the handle  30 , the distal end of the prongs  68 ,  70  engage the cam faces  88 ,  90  of the resilient shield  84  which is then moved out of the way in the manner described above until it reaches the second position uncovering the contacts  80 ,  82  for complete interconnection with the prong  68 ,  70  (see  FIG. 4   b ). In this way it is possible to disconnect and reconnect the various components of the vacuum cleaner  10  in the manner described while at the same time always preventing intrusion of dust and dirt into the electrical contacts  80 ,  82  of the female connector  64 . 
     In summary, numerous benefits result from employing the concepts of the present invention. Specifically, an electrical connector assembly  60  is provided for a floor care apparatus  10  or other device. That electrical connector assembly  60  includes a female connector  64  with a resilient shield  84  that effectively prevents intrusion of dirt and debris into the electrical contacts  80 ,  82  of the female connector  64  when that female connector is disconnected from a cooperating male connector  62 . Thus, dirt and debris does not enter those contacts to degrade or interrupt electrical connection when that female connector  64  is properly connected to a cooperating male connector  62 . Accordingly, the present invention represents a significant advance in the art. 
     The foregoing description of the preferred embodiments of the present invention have been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed. Obvious modifications or variations are possible in light of the above teachings. For example, while the illustrated floor care apparatus  10  of the present invention incorporates a disposable filter/cleaning bag  22 , it should be appreciated that alternatively, it could include a dirt cup. That dirt cup may include a simple filter over an outlet. Alternatively, the dirt cup may include tangential sidewalls allowing for cyclonic cleaning function in a manner known in the art. Accordingly, the terminology “dirt collection vessel” should be broadly interpreted to cover any form of disposable cleaning bag or dirt cup. 
     The embodiments were chosen and described to provide the best illustration of the principles of the invention and its practical application to thereby enable one of ordinary skill in the art to utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated. All such modifications and variations are within the scope of the invention as determined by the appended claims when interpreted in accordance with the breadth to which they are fairly, legally and equitably entitled. The drawings and preferred embodiments do not and are not intended to limit the ordinary meaning of the claims in their fair and broad interpretation in any way.