Electrical device handle and protector therefor
United States Patent [1 1 Ehrlich ELECTRICAL DEVICE HANDLE AND PROTECTOR THEREFOR [75] Inventor: Stephen Jeffrey Ehrlich,  
 Randallstown, Md.  
 [73] Assignee: The Black &amp; Decker Manufacturing Company, Towson, Md.  
 [22] Filed: Dec. 5, I973 {21] Appl. No.: 421,983  
 [56] References Cited UNITED STATES PATENTS 1,606,833 11/1926 Grovcr 16/116 R 2,679,911 6/1954 403/292 X Apr. 22, 1975 2.965.426 12/1960 Wiedcrhold 403/377 X 3.199.398 8/1965 85/83 3,221,481 12/1965 Mattson ct al 56/169 FOREIGN PATENTS OR APPLICATIONS 688,848 6/1964 Canada 339/208 1,224,522 2/1960 France 174/92 Primary E.\&#39;uminerLaramie E. Askin Attorney, Agent, or Firm-Joseph R. Slotnik; Leonard Bloom; Edward D. Murphy [57] ABSTRACT A protective connector for an electrical device handle, and the handle formed therewith, are disclosed wherein the connector is formed of two longitudinally aligned portions of different outside diameters with a passageway extending longitudinally throughout the length of the connector to receive electrical wires, the connector being adapted to be mounted within a tubular member and also being adapted to receive a second tubular member effectively joining the tubular member with the smaller portion of the connector being spaced from the inner surface of the first tubular member and defining an annular passageway therebetween. An air inlet is provided through the first tubular member in communication with the passageway.  
 23 Claims, 7 Drawing Figures ELECTRICAL DEVICE HANDLE AND PROTECTOR THEREFOR BACKGROUND This invention relates to electrical devices and, more particularly, to handles for such devices through which electrical wires pass.  
  Many electrical devices are formed with an elongated handle having one end thereof adjacent to an electrical motor wherein the handle also serves as a conduit for electrical wires to lead the wires safely away from the motor and tool which the motor drives, for example, to lead the wires to a hand grip and adjacent control switch for the device. In many of these devices, it is desirable to form the elongated handle of a plurality of different sized members. For example, in electric powered trimmer-edgers, the elongated handle often is formed of two tubular pieces one of which is relatively large in diameter to facilitate through flow of motor cooling air, as will be described, while the other is significantly smaller in cross-section to, among other things, save in materials cost and for appearance purposes. To connect these handle members. it is generally required that the larger member be swaged to snugly fit the smaller, and this adds to the overall cost of the device. Furthermore. it has generally been necessary to deburr the connecting ends of the tubular pieces to prevent cutting of the insulation around the electric wires extending through the tubular handle.  
  Electrical motor devices of the type referred to generally include a motor cooling fan to insure adequate motor life. With certain devices, such as the power operated lawn trimmer-edger, referred to above, the motor is located adjacent the ground, and the tool, during operation, produces a substantial amount of dirt and debris in the immediate vicinity of the motor. Because of this dirt and debris and because of the moisture which often exists on the grass, it is undesirable to draw cooling air into the motor from the area immediately adjacent thereto since this would result in contamination of the motor and other parts of the appliance. Consequently, motor cooling air is generally drawn through inlets provided in the handle remote from the motor and the motor driven tool, and this air is then caused to flow downwardly through the handle, and then through the motor. with this arrangement, it is necessary to protect the wires within the tubular handle to eliminate the possibility of a probe, e.g., nails or other sharp objects, from being inserted in the air inlets and possibly puncturing or damaging the wire insula tion.  
  Accordingly, it is an objective of this invention to provide a connector for facilitating assembly of tubular handle sections whereby swagging and other previously used manufacturing steps required for facilitating assembly of the handle sections is eliminated.  
  It is another objective of this invention to provide a connector which protects the electrical wire in the vicinity of the air inlets to prevent the possibility of damage to the wire insulation and concomitant shock in the event a user inserts a probe or other device into the air inlet, wherein such protective connector also serves to define an air inlet passageway for the air entering the handle through the air inlet.  
  Additional objectives and advantages of the invention will be set forth in part in the description which fol lows, and in part will be obvious from the description,  
 or may be learned by practice of the invention. The objectives and advantages of the invention may be realized and attained by means of the instrumentalities and combinations particularly pointed out in the appended claims.  
 BRIEF DESCRIPTION OF THE INVENTION To achieve the foregoing objectives and in accordance with the purpose of the invention, as embodied and broadly described herein, the protective connector for an electrical device handle comprises first and second longitudinally aligned portions, the second portion having at least a longitudinal section recessed radially with respect to the other surface of the first portion, a passageway extending longitudinally through the first and second portions adapted to receive an electrical line cord therin, the first portion adapted to receive a first tubular handle member and the second portion adapted to be mounted within a second tubular handle member. Preferably the connector includes a plurality of circumferentially spaced projections extending outwardly from the second portion. It is also preferred that the connector be formed of two halves joined together along a parting line with the second portion of each half having at least one finger on the outer surface thereof extending across the parting line and overlapping the other half of the second portion.  
  The invention also comprises an electrical device handle including first tubular member having an air inlet therethrough, a second tubular member and a protective connector having first and second longitudinally aligned tubular portions, the first tubular portion having a larger outside diameter than the second tubular portion, the second tubular portion being fitted within the first tubular member and one end of the second tu bular member being fitted within the first tubular portion, the outside diameter of the second tubular portion being smaller than the inside diameter of the first tubular member defining a passageway therebetween, the passageway communicating with the air inlet, the connector being adapted to receive an electrical line cord extending throughout the length thereof.  
  Preferably, the handle also includes a plurality of projections extending from the outer surface of the second portion of the connector to position the second portion spaced from the first tubular member.  
  The invention consists in the novel parts, constructions, arrangements, combinations and improvements shown and described. The accompanying drawings, which are incorporated in and constitute a part of the disclosure, illustrate two embodiments of the invention and, together with the description, serve to explain the principles of the invention.  
 BRIEF DESCRIPTION OF THE DRAWINGS In the drawing:  
  FIG. 1 illustrates a perspective view of a typical garden tool, namely a lawn trimmer-edger, having an elongated tubular handle including a protective connector formed in accordance with this invention.  
  FIG. 2 is a perspective view ofa protective connector formed, in accordance with one embodiment of this invention, of two hingedly connected parts and shown as a blank in its open position.  
  FIG. 3 is a perspective view of the connector of FIG. 2 illustrated in a closed position.  
  FIG. 4 is a sectional view of two handle sections, one of which contains a protective connector formed in accordance with this invention and illustrating the alignment of parts prior to assembly of the handle.  
  FIG. 5 illustrates the sections of the handle of FIG. 4 after assembly.  
  FIG. 6 is a sectional view taken along line 6-6 of FIG. 4.  
  FIG. 7 is a sectional view taken along line 77 of FIG. 5.  
 DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT The handle and protective connector of this invention may be used with many different types of electrical devices. One particular type of electrical device for which it is particularly suitable is a lawn tool, such as a trimmer-edger 10, shown in FIG. 1. For purposes of describing this invention and to facilitate understanding its use and advantages, the handle of this invention is shown and described for use with the trimmer-edger 10; however, it is clear that no limitations are intended by describing the use of the handle in connection with only a single device.  
  In accordance with the invention, the handle includes a plurality of tubular members and a connector for receiving the tubular members. the connector also providing a tubular passageway through which electrical wires pass. As here embodied, a handle 12 is adapted for attachment at one end 14 to the motor housing 16 of an appliance, for example, a lawn trimmer-edger 10. The handle 12 terminates in a hand grip 17 at its upper end, the grip having a convenient on-off trigger switch 19 provided thereon. The handle 12 also serves as a conduit to contain and safely lead electrical wires 21, 23 safely away from the appliance motor housing 16 and tool which the motor drives, such as a rotary blade (not shown), thereby keeping the wire away from the working portion of the appliance l0. Wires 21, 23 form a line cord 18 which, through switch 19, is connected to a suitable electric source for powering the device 10. As here embodied, the handle 12 is formed of a plurality of tubular members 20, 22, one member 20 may have a smaller diameter than the other member 22 permitting it to be telescopically inserted therein. The handle also includes a connector 24 which is in part received within the larger tubular member 22 and which receives within it the smaller tubular member 20.  
  The connector 24, shown in a preferred form in FIGS. 2 and 3, is formed of two almost symmetrical halves 26, 28, which have projections 30, 32 respectively extending radially therefrom. The projections 30, 32 are joined together at their distal end along a hinge line 33 resulting in a one-piece integral connector 24 which may be folded upon itself, meeting on the parting surfaces 34, 35 to form a tubular connector as shown in FIG. 3.  
  The tubular connector 24 has a first channel or tubular portion 36 and a second channel or tubular portion 38 of smaller diameter than the first portion 36. The first and second tubular portions are joined together by a wall 39 which can be radial or inclined with respect to the connector axis. The length of the projections 30,  
 32 is equal and is substantially equal in length to the 65 projecting spacers 40, 42 on diametrically opposed sides thereof and circumferentially spaced from the projections 30, 32. The length of the spacers is substantially equal to the length of the projections 30, 32.  
  The end 44 of the larger tubular portion 36 remote from the smaller tubular portion 38 is formed with an outwardly extending shoulder 46. The larger tubular portion 36 is also provided with a pair of diametrically opposed elongated apertures or slots 48, 50 to serve as bolt holes for fixedly connecting the handle tubular members 20, 22 together.  
  As is best illustrated in FIGS. 4-6, the connector 24 is inserted within the larger tubular member 22 so that the shoulder 46 abuts against the end 52 of the tubular member 22 thereby controlling the depth to which the connector 24 is inserted and also capping the end 52 of the tubular member 22 to provide protection against any burrs that might exist on the end 52. The slots 48, 50 are aligned with bolt holes 54, 56 provided through the larger tubular member 22. The outer diameter of the larger tubular portion 36 is slightly less than or preferably substantially equal to the internal diameter of the larger tubular member 22. Because the length of the spacers 40, 42 and the projections 30, 32 is substantially equal to the difference in radius between the smaller tubular portion 38 and the larger tubular portion 36, the spacers and extensions contact the interior surface of the tubular member 22 and retain the connector 24 in place preventing radial movement thereof. (See FIG. 6).  
  The internal surface of the tubular member 22 and the external surface of the tubular portion 38 of the connector 24 define an annular air passageway 60 which is terminated by the radial wall 39 between the smaller tubular portion 38 and the larger tubular portion 36. Air inlets 64 are provideed through the tubular member 22 at a location aligned with the smaller tubular portion 38 of the connector 24. Air entering the inlets 64 passes downwardly through the tubular member 22 toward the housing 16 of the appliance. This air flow is effected by suitable means such as by a motor driven fan within the housing 16 and is discharged from the motor housing after passing through the motor. Such means for producing air flow is conventional, does not form a part of this invention and is not shown.  
  As described above, the handle member 22 has a relatively large I. D. to accommodate line cord 18 and permit adequate flow of motor cooling air therethrough. However, handle member 20 desirably is somewhat smaller since it need only accommodate the line cord 18. Thus, connector 24 serves as a transitional member between members 20, 22 and eliminates the costly swage. Furthermore, connector 24 caps the end of member 22 to prevent damaging abrasion to line cord 18 during shipping when handle members 20, 22 are customarily disassembled for compact packaging.  
  The electrical line cord 18 passes from the housing 16, through the larger tubular member 22, through the connector 24 and then through the smaller tubular member 20, as can be seen in FIG. 4. The smaller tubular portion 38 of the connector 24 completely encloses the line cord 18 circumferentially preventing any foreign object, such as a nail or probe being inserted through the air inlets 64 from contacting the line cord 18. The connector 24 is also provided with a plurality of fingers 66, some of which are mounted on the first member 26 and some of which are mounted on the second member 28 in such a fashion that the fingers extend forwardly from the edge of each of these members and overlap the other corresponding member when the connector 24 is folded together as shown in FIG. 3. The fingers 66 serve to prevent the tubular portion 38 from collapsing in the event a probe or other element is forcibly inserted in air inlet 64 and against the connector 24.  
  In order to assemble the handle 12, the second or smaller tubular member is inserted within the larger tubular portion 36 of the connector 24 so that bolt holes 68, 70 provided therethrough are aligned with the bolt holes 54, 56 respectively in the first tubular member 22 and the slots 48, 50 in the connector. Bolts 72 are then inserted through the bolt holes and slots to fixedly interconnect the tubular members 20, 22 and connector 24. The line cord 18 extends from the housing 16 through the tubular members 20, 22 and out through the hand grip 17 as can be seen in FIG. 1.  
  The connector 24 has been designed so that it may be easily and inexpensively manufactured, for example it may be molded from a suitable plastic such as polypropylene. However, other methods of manufacturing the connector and other materials are also contemplated including stamping it out of sheet metal. It is also contemplated that the connector 24 could be formed as an integral sleeve without hinged portions or, in other words, it could be formed in the shape illustrated in FIG. 3.  
  As can be seen from the above description and the drawing, the protective connector and the handle incorporating the connector, formed in accordance with this invention, facilitate the assembly of handle sections and eliminate the need to swage and deburr the ends of the handle sections as well as eliminating the use of a throwaway protective grommet formerly mounted over the ends of the handle sections to prevent cutting the wire. Furthermore, the electrical wire is protected in the vicinity of the air inlets against being contacted by probes or other objects inserted in the air inlet.  
 What is claimed is:  
 1. An electrical device handle comprising:  
 a. a first tubular member having an air inlet therethrough:  
 b. a second tubular member; and  
 c. a protective connector having first and second longitudinally aligned tubular portions, said first portion having larger outside diameter than said second portion, said second tubular portion being fitted within said first tubular member and one end of said second tubular member being fitted within said first tubular portion, the outside diameter of said second tubular portion being smaller than the inside diameter of said first tubular member defining a passageway therebetween, said passageway communicating with said air inlet, said connector being adapted to receive an electrical wire extending throughout the length thereof.  
  2. An electrical device handle defined in claim 1 including a plurality of projections extending from the outer surface of said second portion positioning said second portion spaced from said first tubular member.  
  3. An electrical device handle as defined in claim 1 wherein said first and said second tubular members include aligned apertures extending therethrough for receiving attachment means.  
 4. An electrical device handle comprising:  
 a. a first tubular member having an air inlet therethrough;  
 b. a second tubular member;  
 c. a protective connector having first and second longitudinally aligned tubular portions, said first tubular portion having a larger outside diameter than said second tubular portion, said first and second portions of said connector mounted within said first tubular member and one end of said second tubular member being mounted within said first tubular portion, the outside diameter of said second tubular portion being smaller than the inside diameter of said first tubular member defining a passageway therebetween in communication with said air inlet, a plurality of circumferentially spaced projections extending from the outer surface of said second tubular portion maintaining said second tubular portion spaced from said first tubular member, and  
 d. an electrical wire extending through said connector.  
  5. An electrical device handle as defined in claim 4 including a shoulder extending outwardly from said first tubular portion against which one end of said first tubular member abuts.  
  6. An electrical device handle as defined in claim 4 including first diametrically opposed holes through said first tubular member, second diametrically opposed holes through said second tubular member and third diametrically opposed holes through said connector, and joining means extending through said first, second and third holes.  
 7. An electrical device handle comprising:  
 a. a first elongated tubular member having an air inlet therethrough;  
 b. a second elongated tubular member;  
 c. a protective connector having first and second longitudinally aligned tubular portions, at least a section of said second tubular portion being radially recessed with respect to the outer surface of said first tubular portion and at least a part of said first tubular portion being mounted within said first tubular member with said section aligned with said air inlet, one end of said second tubular member mounted within said first tubular portion; and  
 d. an electrical wire extending through said first tubular member, said connector and said second tubular member.  
 8. A handle for use with an electrically powered garden tool comprising:  
 a. a first elongated tubular member adapted for attachment at one end to said tool, an air inlet through said first member spaced substantially from said one end;  
 b. a second elongated tubular member;  
 c. a protective connector having a first portion and a second portion axially aligned with and having a smaller outside diameter than said first portion, said first and second portions being mounted within said first member, a shoulder extending outwardly from said first portion against which the other end of said first tubular member abuts, one end of said second tubular member being received within said first portion, and  
 d. an electrical wire for connection to the tool extending through said first member, said connector, and said second member.  
  9. A handle as defined in claim 8 including a plurality of projections extending outwardly from said second portion maintaining said second portion spaced from said first member.  
  10. A handle as defined in claim 9 including aligned holes through said first member, said first portion and said second member and attachment means extending through said holes fixedly interconnecting said first member, connector and said second member.  
  ll. In an electrical device comprising a housing for an electric motor and driven output means, a hand grip portion including an electric switch, a multisection tubular handle extending between and connected to said housing and said hand grip, and a plurality of electric wires extending within said handle, the improvement comprising a protective connector joining consecutive sections of said multi-section tubular handle, said connector comprising first and second longitudinally aligned portions, said second portion having at least a longitudinal section recessed radially with respect to the outer surface of said first portion, a passageway extending longitudinally through said first and second portions receiving said electrical wires therein, said first portion receiving a first section of said tubular handle and said second portion being mounted within a second section of said tubular handle.  
  12. In an electrical device comprising a housing for an electric motor and driven output means, a hand grip portion including an electric switch, a multi-section tubular handle extending between and connected to said housing and said hand grip, and a plurality of electric wires extending within said handle, the improvement comprising a protective connector joining adjacent sections of said tubular handle, said connector comprising first and second longitudinally aligned portions, said first portion having a larger outside diameter than said second portion, a plurality of circumferentially spaced projections extending outwardly from said second portion, said first and second portions including a passageway therethrough which receives said electrical wires therein.  
  13. The combination as defined in claim 12 including a shoulder projecting outwardly from adjacent one end of said first portion.  
  14. The combination as defined in claim 12 including a pair of diametrically opposed apertures through said first portion adapted to receive attachment means therethrough.  
  15. A protective connector for an electrical device handle comprising first and second axially aligned portions, said first portion having a larger outside diameter than said second portion, a plurality of circumferentially spaced projections extending outwardly from said second portion, the outer edge of said projections being substantially coplanar with the outer surface of said first portion, said first and second portions each being formed of two halves joined together along a parting line, said second portion of each half having at least one finger on the outer surface thereof extending tangentially across said parting line and overlapping the other half of said second portion, said first and second portions having a central opening therethrough adapted to receive an electrical wire extending throughout the length thereof.  
  16. In an electrical device comprising a housing for an electric motor and driven output means, a hand grip portion including an electric switch, a multi-section tubular handle extending between and connected to said housing and said hand grip, and a plurality of electric wires extending within said handle, the improvement comprising a protective connectorjoining adjacent sections of said multi-section tubular handle, said connector comprising a first half and a second half, each of said halves having first and second longitudinally aligned channel portions, the outside transverse dimension of said first portion being larger than the corresponding dimension of said second portion, said first and second halves being joined together by hinge means, closure of said first and second halves together forming two longitudinally aligned tubular members having a longitudinal passageway therethrough receiving said wires.  
  17. In an electrical device comprising a housing for an electric motor and driven output means, a hand grip portion including an electric switch, a multi-section tubular handle extending between and connected to said housing and said hand grip, and a plurality of electric wires extending within said handle, the improvement comprising a protective connector joining adjacent sections of said multi-section tubular handle, said connector comprising a first half and a second half, each of said halves having first and second longitudinally aligned channel portions, the outside transverse dimension of said first portion being larger than the corresponding dimension of said second portion, said first and second halves each having a projection extending transversely from the second portion thereof, the distal end of the first half projection being joined to the distal end of the second half projection along a hinge line, closure of said first and second halves together along said hinge line forming two longitudinally aligned tubular members having a longitudinal passageway therethrough receiving said wires throughout the length thereof, said first and second channel portions of said connector being respectively joined with said adjacent sections of said tubular handle.  
  18. The combination as defined in claim 17 including second and third projections extending outwardly from the second portion of said first and second half respectively, the distal edge of said second and third projections being substantially coplanar with the outer surface of its corresponding first portion.  
  19. A blank for forming a protective connector for an electrical device handle having two parallel, spaced apart halves, each of said halves having first and second longitudinally aligned channel portions, the outside transverse dimension of the first portion being larger than the corresponding dimension of the second portion, said first and second halves each having a first projection extending transversely from the second portion thereof, the distal end of the first half first projection being joined to the distal end of the second half first projection along a hinge line, folding said blank along said hinge line effects closing said first half onto said second half, said halves meeting along matching parting surfaces and forming two longitudinally aligned tubular members having a longitudinal passageway therethrough for receipt of an electrical wire throughout the length thereof, each of said halves having at least one finger attached to the second portion thereof adjacent the parting surface and projecting outwardly to overlap the other half.  
  20. A blank as defined in claim 19 wherein each second portion has a second projection extending therefrom spaced from said parting surface.  
  21. A blank as defined in claim 20 wherein the distal end of said second projection is spaced from said second portion substantially equally to the distance between the distal end of said first projection and said second portion.  
  22. A blank as defined in claim 21 wherein each of said first portions has an aperture therethrough, each of said apertures being spaced equally from its corresponding parting surface.  
  23. A blank for forming a protective connector for an electrical device handle having two parallel spaced apart halves, each of said halves having first and second longitudinally aligned semi-cylindrical portions, the outside diameter of the first portion being larger than the outside diameter of the second portion, said first and second halves each having a first projection extending transversely from the second portion thereof,  
 the distal end of the first half first projection being joined to the distal end of the second half first projection along a hinge line, said first and second halves each having a second projection extending from the second portion spaced from said first projection the distal end of said second projections being substantially coplanar with the outer surface of said first portion, folding said blank along said hinge line effects closing said first half onto said second half, said halves meeting along matching parting surfaces and forming two longitudinally aligned tubular members having a longitudinal passageway therethrough for receipt of an electrical wire throughout the length thereof, each of said halves having at least one finger attached to the second portion thereof adjacent the parting surface and projecting tangentially outwardly to overlap the other half, each of said first portions having an annular shoulder extending from the outer surface thereof.