Electrically-powered polisher

An electrically-powered polisher is provided which includes a central housing having a top and a bottom and a front and a back with a rotary pad mounted adjacent to the bottom of the housing. A front handle extends horizontally outwardly from the housing front substantially parallel to the top and bottom of the housing adjacent to and above the housing bottom. A rear handle extends outward from the housing rear and extends vertically between the top and bottom of the housing. A collar is defined at the top of the housing and a male receptacle, including male prongs, is mounted therein. The male receptacle is capable of being electrically connected to a female socket head of an electrical cord supplying power to the waxer. The collar is recessed in the top of the housing with the male prongs of the receptacle extending from the housing into the collar. A cord lock is provided and includes a cord receiving trough formed in the top of the housing adjacent to the collar and an overhung tab for retaining a portion of an electrical cord in the trough.

 

I claim:

1. An electrically powered polisher comprising:

a central housing having a top and a bottom and a front and a back with a rotary pad mounted adjacent no the bottom of the housing;

a front handle extending horizontally outward from the housing front substantially parallel to the top and bottom of the housing adjacent to and above the housing bottom;

a rear handle extending outwardly from the housing rear and extending vertically between the top and the bottom of the housing;

a collar defined at the top of the central housing and a male receptacle including male prongs mounted therein with the make receptacle capable of being electrically connected to a female socket head of an electrical cord supplying power to the polisher, the collar being recessed in the top of the housing with the male prongs of the receptacle extending from the housing into the collar; and

a cord lock including a cord receiving trough formed in the top of the housing adjacent to the collar and an overhung tab for retaining a portion of an electrical cord in the trough.

2. The polisher of claim 1 wherein the front handle includes a first gripping portion spaced forwardly from the housing and extending beyond the housing on either side thereof and the rear handle includes a second arcuate gripping portion extending from the top of the housing to a point spaced rearwardly of the housing substantially horizontally aligned with the bottom thereof.

3. The polisher of claim 2 wherein the first gripping portion includes a bent section and the rear handle, the cord receiving trough, the collar and the bent section are aligned with one another along a vertical reference plane extending through the housing from the front to the back thereof.

4. The polisher of claim 2 wherein the front handle includes parallel straight sections spaced from each other on either side of the housing and connected to the first gripping portion with the first gripping portion and straight sections cooperating to define a first gripping aperture forwardly of the housing.

5. The polisher of claim 1 wherein the rear handle, the cord receiving trough and the collar are aligned with one another along a vertical reference plane extending through the housing from the front to the back thereof.

6. The polisher of claim 1 wherein the trough and tab cooperate to define an entry slot through which an electrical cord can be inserted in the trough.

7. The polisher of claim 1 wherein the housing, the front and rear handles, the collar and the cord lock are formed integrally with each other.

8. An electrically powered polisher comprising:

a central housing having a top and a bottom with a rotary pad mounted below the bottom of the housing and a motor in the housing for driving the pad in an orbital path;

connecting means recessed at the top of the housing for mounting a male receptacle having male prongs to electrically connect a power supplying electrical cord to the motor;

cord locking means recessed at the top of the housing for maintaining a mating electrical connection between the power supplying electrical cord and the connector means; and

a horizontal front handle extending outwardly from the housing from adjacent the bottom thereof and a vertical rear handle extending between the top and the bottom of the housing with the front and rear handles defining respective first and second gripping apertures to allow for bi-planar two-handed operation of the polisher to guide a pad along a work surface.

9. The polisher of claim 8 wherein the connecting means comprises a collar recessed in the top of the housing and the male prongs extend from the housing into the collar so as not to be exposed from the collar above the top thereof.

10. The polisher of claim 8 wherein the cord locking means includes a cord receiving trough formed in the top of the housing and an overhung tab projecting over the trough for engaging a cord portion in the trough and frictionally locking the portion therein.

11. The polisher of claim of claim 8 wherein the horizontal front handle has a first gripping portion spaced forwardly from the housing and extending beyond either side thereof and two parallel straight sections spaced from each other on either side of the housing and connected to the first gripping portion with the first gripping portion and straight sections cooperating to define the first gripping aperture.

12. The polisher of claim 11 wherein the horizontal front handle is symmetrically arranged about a horizontal central axis extending through the housing and aligned with the vertical rear handle.

FIELD OF THE INVENTION

The present invention relates to electrically-powered polishers and, more particularly, to electrically-powered polishers having an ergonomic design which allows an operator to exert bi-planar control over the polisher during operation thereof while preventing accidental disconnection of an electrical cord that would interrupt electric power to the polisher.

BACKGROUND OF THE INVENTION

Typically, power tools, and more particularly tools which drive a working element in an orbital path for engagement with a work surface, such as an orbital polisher or waxer designed for use with car finishes, do not provide a structure for effective and precise operator control and maneuverability of the working element as it engages the work surface. It is important that an operator be able to precisely guide the pad in its orbital path along a work surface and to simultaneously control the pressure with which the pad is applied to the work surface. If an operator applies too much pressure, such as by not being able to control and prevent the entire weight of the power tool unit from being applied to the pad and, therefore, the work surface, the finish can be damaged or even ruined. In addition, too little pressure and the finish will not be buffed properly. The vibratory response associated with the orbital motion of the pad also significantly affects the operator's ability to control the polisher as such vibratory response experienced by the polisher operator is generally much greater than that associated with other non-orbital type power tools.

It is also desirable that an operator be able to reach a relatively large area on the work surface from a generally stationary position while at the same time not losing control over the pressure applied by the pad to the work surface. The increased vibration due to orbital motion as mentioned above also exacerbates the loss of control as the operator extends their arms to reach areas on the work surface, e.g., the car, remote from their body. So, for example, it is known to provide a single steering wheel type handle on a polisher for gripping with the handle extending horizontally from the middle of an upstanding housing for the motor. Such handles do not allow an operator to control accurately the polisher using one hand, particularly as the operator moves the polisher away from their body to reach relatively large areas on the surface being buffed without having to continually adjust and move their standing position.

Another problem in operation of these tools is the location of the means utilized in providing power to their motors as oftentimes the electrical cord supplying such power can be connected to the housing, or with pigtail cords, mounted to the tool housing so as to increase the likelihood that the power supplying cord and its associated connecting head will make contact with the working surface and finish being polished during operation of the polisher. This is undesirable due to potential marring of the finish caused by such contact. Pigtail cords also present the problem that when the work surface is close to the ground, such as the lower portions of a car's exterior surface, the mating interface between the pigtail and power supplying cords' heads can be run along the ground, potentially through any standing water accumulated thereon, which can present a hazardous situation to the operator. If the water causes a ground fault, the power to the tool will be abruptly interrupted, which can cause damage to both the power tool and the surface in engagement with the tool. Also, normally the cord is disposed undesirably near the portion of the tool used by the operator to support the tool during its operation, i.e., the handle(s), so as to require an operator to continually adjust their support of the tool and grip on the handle(s) during operation of the tool due to interference from the power supplying cord.

Where pigtail electrical cords extend from the housing, one common problem is with accidental separation between the head of the pigtail cord and the mating head of the power supplying cord connected thereto. Where a pigtail cord is not utilized and the power supplying cord is connected directly to an electrical receptacle on the housing, the problem of accidental separation also occurs thereat. This a particular problem with orbital polishers and waxers as typically they are used with car surfaces which can require an operator to move around the automobile to buff or wax the entire extent of its exterior surfaces. Such movement can cause tension to be applied to the interface between the electrical supply and tool electrical receptacle, be it on the head of a pigtail cord attached to the housing or on the housing itself. In addition, the increased levels of vibration generated through the polisher housing aggravates the accidental separation problem as the cord(s) are constantly experiencing intermittent tension forces due to the oscillations of the polisher vibrations.

Thus, there is a need for a power tools particularly one that drives its working element in an orbital path, which allows an operator to effectively and accurately control the working element and reach a relatively large area on a working surface from a generally stationary position. There is also a need for an ergonomic power tool as described above which removes the electrical connection as an impediment to control and operation of the tool and substantially limits disconnections at the interface between the power supply and power receiving receptacle of the tool.

SUMMARY OF THE INVENTION

In accordance with the present an electrically-powered polisher is provided which overcomes the aforementioned problems of the prior art.

The electrically-powered polisher includes a central housing having a top and a bottom and a front and a back with a rotary pad mounted adjacent to the bottom of the housing. A front handle extends horizontally outwardly from the housing front substantially parallel to the top and bottom of the housing adjacent to and above the housing bottom. A rear handle extends outward from the housing rear and extends vertically between the top and bottom of the housing. A collar is defined at the top of the housing and a male receptacle, including male prongs, is mounted therein. The male receptacle is capable of being electrically connected to a female socket head of an electrical cord supplying power to the waxer. The collar is recessed in the top of the housing with the male prongs of the receptacle extending from the housing into the collar. A cord lock is provided and includes a cord receiving trough formed in the top of the housing adjacent to the collar and an overhung tab for retaining a portion of an electrical cord in the trough.

The bi-planar control provided by the front and rear handles is an improvement over prior designs, such as with the previously-described single steering wheel-type handle or where two handles are provided which do not extend in respective vertical and horizontal planes. The provision of the horizontal front handle adjacent the bottom of the housing allows for improved control over the rotary pad as it is applied to a working surface, particularly as to the pressure with which the pad is applied to the surface. The vertical handle contributes to improved control, particularly where an operator is reaching with the tool from a relatively stationary position and cannot use both hands to control and grab the handle(s). In addition, with the collar and male receptacle therein and the cord lock all being disposed at the top of the housing, the cord is substantially removed from the gripping portion of the handles and the interface between the pad and the working surface and is maintained in mating connection with the male receptacle during operation of the waxer, even when tension is applied to the cord. Moreover, with the cord head mounted to the housing in the recessed receptacle at the top of the housing, there is little danger in having the cord head accidentally engaging the work surface or encountering standing water on the ground, as is possible with other polishers using pigtail cords.

In one form, the front handle includes a first gripping portion spaced forwardly from the housing and extending beyond the housing on either side thereof. The rear handle can include a second arcuate gripping portion extending from the top of the housing to a point spaced rearwardly of the housing substantially horizontally aligned with the housing bottom. Preferably, the first gripping portion includes a bent section and the rear handle, the cord receiving trough, the collar and the bent section are aligned with one another along a vertical reference plane extending from the front of the housing to the back of the housing. The front handle can include parallel straight sections spaced from each other on either side of the housing and connected to the first gripping portion with the first gripping portion and straight sections cooperating to define a first gripping aperture forwardly of the housing.

In one form, the trough and tab cooperate to define an entry slot through which an electrical cord can be inserted in the trough. Preferably, the housing, the front and rear handles, the collar and the cord lock are formed integrally with each other.

In another form of the invention, the electrically-powered waxer includes a central housing with the motor in the housing for driving the pad in an orbital path. Connecting structure is recessed at the top of the housing for mounting a male receptacle therein. Cord locking structure is recessed at the top of the housing for maintaining a mating electrical connection between the power supplying electrical cord and the connector means. A horizontal front handle extending outwardly from the housing from adjacent the bottom thereof and a vertical rear handle extending between the top and the bottom of the housing are provided. The front and rear handles define respective first and second gripping apertures to allow for bi-planar two-handed operation of the waxer to guide a pad along a work surface.

Preferably, the connecting structure is in the form of a collar recessed in the top of the housing so that the male prongs of the receptacle extend from the housing into the collar and are not exposed above the top of the collar.

In one form, the horizontal front handle is symmetrically arranged about the a horizontal central axis extending through the housing and aligned with the vertical rear handle.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of an apparatus for waxing, buffing, polishing or the like according to the present invention;

FIG. 2 is a left side elevational view of the apparatus shown in FIG. 1, including a front handle and a rear handle and a paddle actuator on the rear handle;

FIG. 3 is a top plan view of the apparatus shown in FIG. 1 showing details of the engagement of a first and a second clamshell housing member which define a cord lock and a collar for a male receptacle;

FIG. 4 is a right side elevational view of the apparatus shown in FIG. 1;

FIG. 5 is a rear elevational view of the apparatus shown in FIG. 1;

FIG. 6 is a bottom plan view of the apparatus shown in FIG. 1 showing the counterweight assembly including a quick-change post for mounting a buffer pad thereon;

FIG. 7 is an enlarged top plan view of the cord lock and the collar and male receptacle assembly of the apparatus shown in FIG. 1, as seen in FIG. 3;

FIG. 8A is a side sectional view taken along lines 8A--8A of FIG. 7;

FIG. 8B is a side sectional view taken along lines 8B--8B of FIG. 7;

FIG. 9 is a rear sectional view taken along line 9--9 of FIG. 7;

FIG. 10 is an exploded perspective view of the apparatus shown in FIG. 1 showing details of the arrangement of a DC motor having a support plate and rectifier assembly, the paddle actuator with a lock-on button, and the counterweight and pad assembly;

FIG. 11 is an enlarged perspective view of the motor and support plate assembly and the paddle actuator and its lock-on button mounted in the first clamshell housing member shown in FIG. 10;

FIG. 12 is an exploded perspective view of the paddle actuator and lock-on button assembly shown in FIG. 16;

FIG. 13 is a side elevational view, partially in section, of the assembled paddle actuator and lock-on button assembly shown in FIG. 10;

FIG. 14 is a perspective view of the assembled support plate and rectifier assembly shown in FIG. 10;

FIG. 15 is an exploded view of the support plate and rectifier assembly shown in FIG. 14;

FIG. 16 is a side sectional view of the counterweight and buffer pad assembly showing a mounting plate of the pad and a mounting post and detent ball inserted through an axial lining of the buffer pad mounting plate;

FIG. 17 is an enlarged sectional view of the support post and the axial lining shown in FIG. 16 showing a circumferential groove in the axial lining with the detent ball in the groove;

FIG. 18 is an enlarged sectional view of a portion of the apparatus shown in FIG. 17, showing the post inserted through the axial lining with the detent ball abutting the bottom of the lining to removably secure the pad to the post;

FIG. 19 is a side sectional view of the post showing the detent ball attached to a plastic backing which is attached in a recess of the post;

FIG. 20 is an enlarged perspective view of the first clamshell housing member;

FIG. 21 is an enlarged perspective view of the second clamshell housing member; and

FIG. 22 is an electrical schematic diagram of the DC motor assembly according to the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

FIG. 1 illustrates an ergonomic apparatus 10 for waxing, polishing, buffing or the like, according to the present invention. The inventive apparatus 10 has a symmetrical design about a vertical reference plane, not shown, extending centrally from a forward end 12 to a rearward end 14. The apparatus 10 includes a housing 16 preferably having a clamshell design with a first clamshell housing member 18 and a second clamshell housing member 20 which, when connected to each other, define a part line 21 which extends in the vertical reference plane about which the housing 16 is symmetrical, as shown in FIG. 3. Preferably, the first and second clamshell housing members 18 and 20 are molded plastic parts with their various portions described herein being formed integrally with each other. Corresponding portions on each of the symmetrical housing members 18 and 20 are identified by the same reference numeral with the portions on the first housing member 18 additionally provided with letter "a" and portions on the second housing member provided with the letter "b".

The housing 16 includes a main central housing 22 in which the motor assembly 24 is mounted, as best seen in FIGS. 10 and 11. The main housing 22 includes a front handle 26 and a rear handle 28 extending therefrom. As illustrated in FIGS. 1-6, the main housing 22 includes a substantially flat top 30 and a bottom 32 and the front and rear handles 26 and 28 extend transversely to each other with the front handle 26 extending horizontally outwardly towards the forward end 12 from the main housing 22 between and substantially parallel to the top 30 and bottom 32 thereof while the rear handle 28 extends outwardly towards the rear end 14 from the main housing 22 and extends vertically and arcuately between the top 30 and bottom 32 of the main housing 22.

The rear handle 28 has a hollow interior 34 in which a box-shaped switch housing 36, for a switching mechanism 37 illustrated schematically in FIG. 22, and an actuator paddle 38 are mounted. The actuator paddle 38 extends from the interior 34 through a bottom slot 35 formed in handle 28 to a predetermined distance outside the rear handle interior 34 in a rear gripping aperture 39 bounded by the rear handle 28. The paddle 38 has an arcuate shape substantially matching the contour of the rear handle 28 so as to be easily and readily operable when the user grips the rear handle 28 along its arcuate portion as more fully described hereafter.

At the top 30 of the housing 16, a raised wedge-shaped collar region 40 is defined into which a male receptacle or plug plate 42 can be mounted for receiving a female socket head of an electrical cord (not shown) for electrically connecting an alternating current power source for 110 volts at 60 Hz, to the motor assembly 24. Adjacent the collar region 40 towards the rearward end 14 of the housing 16, a cord locking mechanism 44 is defined in the housing top 30, as shown in FIGS. 7-9. The cord locking mechanism 44 prevents accidental disconnection of the female socket head connected in the collar region 40 to the male receptacle 42. Thus, with the motor 24 activated to drive a working element, such as a buffer pad 46, and with the buffer pad 46 driven in an orbital path as will be described more fully herein, the above-described design of the housing 16 allows an operator to easily manipulate the apparatus 10 of the present invention with two hands to exert bi-planar control over the apparatus 10 while the buffer pad 46 is moved along the working surface in its orbital path without having to grab the main housing 22 to effectively and accurately guide and control the pad 46 along the working surface. Also, the placement of the electrical connection between the apparatus 10 and the electrical cord supplying AC power thereto in a recessed location on the housing top 30 and with the cord-locking mechanism 44 adjacent thereto maintains the cord in place remotely from the interface between the pad 46 and the surface being worked upon, such as a car finish, while at the same time limiting disconnections interrupting the waxing, buffing or polishing process for which the apparatus 10 can be used.

Referring now more specifically to the configuration of the housing 16, it will be noted that the symmetrical clamshell housing members 18 and 20 cooperate to form the front and rear handles 26 and 28, the collar region 40 and the cord-locking mechanism 44 described above. More specifically and referencing FIG. 3, the clamshell housing member 18 includes main housing portion half 22a, front handle half 26a, rear handle half 28a, collar region half 40a and cord locking mechanism half 44a. Likewise, second clamshell housing member 20 includes main housing portion half 22b, front handle half 26b, rear handle half 28b, collar region half 40b and cord locking mechanism half 44b. The first clamshell housing member 18 is provided with threaded bosses 48 and the second clamshell housing member 20 has countersunk recesses 50 formed therein with each of the recesses 50 leading to a threaded boss 52, as seen in FIGS. 10, 20 and 21.

To assemble the apparatus 10, the internal components including the motor assembly 24, the switch housing 36, the actuator paddle 38 and the male receptacle 42 are mounted to the first clamshell housing member 18, as seen in FIG. 11, with the second clamshell housing member 20 then being arranged against the first clamshell housing member 18 so as to align the threaded bosses 52 of the housing member 20 with the corresponding threaded bosses 48 of the first clamshell housing member 18. With the housing members 18 and 20 so aligned, screws 54 received in threaded bosses 52 can be, in turn, received in corresponding bosses 48 to clamp the clamshell housing members 18 and 20 to each other with the heads of the screws 54 seated within the countersunk recesses 50 of the second housing member 20 so as not to protrude therefrom.

With the first and second clamshell housing members 18 and 20 attached to each other, the main housing portions 22a and 22b cooperate to define an interior space 56 in which the motor assembly 24 is mounted. As best seen in FIG. 3, the main housing portion 22 so formed has a pear-shaped cross-sectional configuration. The raised collar region 40 has a triangular shape in cross-section and, as previously mentioned, projects from the substantially flat top 30 of the housing 16. The wedge-shaped collar region 40 has an oblong central recessed area 58 into which the male receptacle 42 is placed.

Turning to the configuration of the front handle 26, each of the main housing portions 22a and 22b includes a triangular attached portion 60a and 60b, respectively, which extends horizontally outward and forward from the respective main housing portions 22a and 22b between and substantially parallel to the top 30 and the bottom 32 of the housing. From the outermost forward corner of the triangular portions 60a and 60b extend respective outer channel-shaped straight sections 62a and 62b such that with the clamshell housing members 18 and 20 attached to each others the outer straight sections 62a and 62b extend substantially parallel to one another and the channels open towards each other. The straight sections 62a and 62b extend forwardly to angled channel-shaped gripping portions 64a and 64b, respectively, which extend at an angle from their respective straight sections 62a and 62b forwardly towards each other to distal ends 66a and 66b which abut one another along the part line 21 and define a bent section of the front handle 26 where the channels open rearwardly towards the main housing 22 with the clamshell housing members 18 and 20 attached.

Intermediate horizontal supporting members 67a and 67b extend within the channels of the respective straight sections 62a and 62b and angled gripping portions 64a and 64b, as best seen in FIGS. 20 and 21. Corresponding bosses 48 and 52 are formed on the intermediate supporting members 67a and 67b at the distal ends 66a and 66b and can be aligned with each other when the housing members 18 and 20 are brought together such that one of the screws 54 received in the aligned front handle threaded bosses will provide an attachment between the housing members 18 and 20 at the front handle distal ends 66a and 66b. In this manner, the front handle 26 is formed defining a forward gripping aperture 69 by the above-described connection between the angled portions 64a and 64b.

The clamshell housing members 18 and 20 also include rear handle arcuate gripping portions 68a and 68b which extend integrally from near the rear end of the top 30 of the main housing 22 and, more specifically, from the rear of the cord locking mechanism 44. The arcuate gripping portions 68a and 68b continue rearward and vertically downward to a point aligned with the bottom 32 of the main housing portion 22 so as to extend substantially through a quarter-circle arc. At this point, the rear handle 28 includes straight joining sections 70a and 70b, respectively, which extend from their respective arcuate gripping portions 68a and 68b back to the main housing portions 22a and 22b at the bottom 32 thereof. To loin the rear handle portions 28a and 28b, one of the threaded bosses 48 is formed in the arcuate gripping portions 68a and one is formed in the straight joining section 70a along with corresponding threaded bosses 52 in the arcuate gripping portion 68b and straight joining section 70b such that with screws 54 received in the rear handle aligned bosses 48 and 52, the rear handle portions 28a and 28b are secured to each other to form the rear handle 28 and define the rearward gripping aperture

As shown in FIGS. 20 and 21, the rear handle portions 28a and 28b are formed as channel-like members having opposing sidewalls with each including a smaller inner sidewall 72a and 72b and a larger outer sidewall 74a and 74b and a connecting web wall 76a and 76b spanning their respective inner and outer sidewalls 72 and 74 such that when the rear handle portions 28a and 28b are connected, they define a hollow rear handle 28 with the rear handle interior space 34 in which the switch housing 36 is mounted. Further, the inner sidewalls 72a and 72b each include respective cut-out sections 80a and 80b along the arcuate gripping portions 68a and 68b such that, with the rear handle portions 28a and 28b connected, the cut-out sections 80a and 80b cooperate to define the bottom slot 35 for the actuator paddle 38. With the actuator paddle 38 mounted in the rear handle interior space 34, the actuator paddle 38 includes a portion which extends through the bottom slot 35 into the rearward gripping aperture 39 spring biased to a predetermined distance beyond the inner sidewall 72.

The configuration of the cord locking mechanism 44 adjacent the collar region 40 will next be described with reference to FIGS. 7-9, 20 and 21. As previously mentioned, the cord locking mechanism 44 is disposed rearwardly of the raised wedge-shaped collar region 40 and includes a trough or well surface 82 defined by recessed U-shaped surfaces 82a and 82b in the respective main housing top portions 30a and 30b, as best seen in FIGS. 8A and 8B. An upstanding flange 84 extends from the bottom of the trough portion 82b to the top of the projecting wedge collar region 40 with a tab 86 formed thereat at right angles to the flange 84 and projecting over the trough 82 so that the top of the tab 86 is flush with the top of the wedge collar 40. Trough portion 82a has upstanding parallel side flanges 88 and 90 spaced from each other along either side of the trough portion 82a and having respective overhung lip portions 92 and 94 which project towards each other over the trough portion 82a.

Thus, when the housing members 18 and 20 are aligned and clamped together, the cord locking mechanism 44 is formed. With the female socket head on an electrical cord attached in the collar region 40 to the prongs 43 of the plug plate 42, the portion of the cord adjacent the female head can be inserted through the zig-zag entry slot 96 defined between the overhung lip portions 92 and 94 and the tab 86. The section of the cord adjacent the female head inserted through the entry slot 96 can be positioned so that it is clamped between the trough surface 82 and the overhung tab 86 positioned thereabove with the ends of the cord section extending around the upstanding flange 84 and through access openings 98 and 100 formed in the sidewall portion 102 of the trough surface 82b on either side of the flange 84. In practice, when the apparatus 10 is being used and the slack in the cord is taken up, as when the apparatus 10 is moved further away from the electrical outlet, tension created by tightening of the slack in the cords will be substantially taken up by the frictional engagement of the cord between the well surface 82 and the overhung tab 86 and lip portions 92 and 94 such that the interface of the female head with the male prongs 43 will experience little or no tension during normal usage of the appliance, thereby significantly reducing the potential occurrences of accidental disconnection at the interface.

Turning to FIGS. 12 and 13, the construction and operation of the actuator paddle 38 including a lock-on mechanism 104 which is mounted in nested relation therewith is illustrated. The actuator paddle 38 has an arcuate elongate channel-shape with a bottom surface 106 having an arcuate portion 107 provided with a radius of curvature substantially the same as the rear handle arcuate gripping portion 68 and being adapted to be gripped by an operator. Two upstanding parallel sidewalls 108 and 110 extend along either side of the bottom wall 106 such that the channel of the elongate arcuate-shaped actuator paddle 38 opens towards the rear handle interior space 34.

The elongate actuator paddle 38 has a forward end 112 and a rearward end 114 and includes a pair of trunnion pivots 116 and 118 extending laterally each from one of the sidewalls 108 and 110 at the forward end 112 of the paddle 38. The paddle 38 is mounted in the rear handle interior space 34 by a pair of corresponding trunnion mounts 120 and 122 in respective housing members 18 and 20. The trunnion mounts 120 and 122 are disposed adjacent the well 82 rearwardly thereof such that with the housing members 18 and 20 connected, the actuator paddle 38 will extend from the base of the well 82 along the curve of the arcuate rear handle gripping portion 68 to the rear end of the cut-out 80 therein. At the rearward end 114 of the paddle 38, a support 124 for the lock-on mechanism 104 is formed. With the trunnions 116 and 118 mounted in their respective trunnion mounts 120 and 122, the support 124 extends substantially horizontally and is normally biased into engagement with a transverse portion 126 of the inner sidewall 172 at the rear of the cut-out 80. A pair of spring pedestals 128 and 130 are formed on the bottom wall 106 with the forward pedestal 128 located on the arcuate portion 107 of the bottom wall 106 and the rear pedestal 130 located on the horizontal support portion 124 of the bottom wall 106.

The paddle 38 is further provided with an aperture 132 formed along its arcuate portion 107 in the bottom wall 106 and sidewalls 108 and 110 for receipt of the lock-on mechanism 104 therethrough. More specifically, the lock-on mechanism 104 includes a button 134 and a substantially flat base member 136 extending rearwardly therefrom. With the lock-on mechanism 104 assembled in nested relation to the actuator paddle 38 and the button 134 projecting through the paddle aperture 132, the base 136 extends from a support portion 137 formed on the backside of the arcuate portion 107 adjacent the rear of the button aperture 132 in the channel of the actuator paddle 38 and into the channel of the support portion 124 where the base 136 has a curved end 138 which is adapted to engage a pivot rod 140 fixed to the paddle 38 extending across the sidewalls 108 and 110 in the support portion 124. Partition wall 141 extends along the back of the button 134 and the flat portion of the base 136 and upwardly beyond the channel formed by the paddle 38 where it ends at a transverse wall 142 upstanding from the base 136 with the transverse wall 142 similarly extending upwardly beyond the channel of the paddle 38. At the top of the transverse wall 132, a curved cam surface 144 is formed for locking the paddle 138 in a closed position, as will be more fully described hereafter.

Above the curved end 138 and below the curved cam surface 144, an intermediate spring engaging member 146 extends rearwardly from the transverse wall 142. A small spring 148 is mounted in compression between the intermediate spring engaging member 146 and the bottom wall 106 in the support 124 encircling the spring pedestal 130. In this manner, the lock.-on mechanism 104 is normally biased about pivot rod 140 so that the button member 134 extends through the paddle aperture 132. The rear handle portion 28a includes a spring-engaging flange 150 formed in the rear handle interior space 34 disposed along the cut-out 80 of the rear handle 28. A large spring 152 is mounted in compression between the spring-engaging flange 150 and the base 136 and encircling the spring pedestal 128 to normally bias the actuator paddle 38 to an open position where the paddle 38 projects from the slot 80 in the rear handle inner sidewall 82 into the rear gripping aperture 39.

The rear handle portion 28 has switch supporting bracket ribs 154 and 156 formed in the rear handle interior space 34 along the cut-out slot 80 with the ribs 154 and 156 framing and supporting either side of the box switch housing 36. The switch housing 36 includes an activation plunger 158 (see FIG. 11) extending therefrom and the actuator paddle 38 includes an upstanding trapezoidal flange or actuating member 160 forwardly of the aperture 32 and the pedestal 128 adapted to engage the activation plunger 158 when the paddle 38 is depressed.

In practice, an operator can readily use one hand wrapped about the rear handle 28 to properly orient the buffer pad 46 over the surface on which work, e.g., buffing, polishing or the like, is to be performed. As the rear handle 28 extends back from the main housing 22, below which is mounted the pad 46, the operator can use the rear handle 28 to reach a large region of a work surface from a relatively stationary position. Once the pad 46 is properly oriented above the work surface, the actuator paddle 38 can be depressed against the spring bias to a closed position with the paddle 38 pivoting about its forward trunnions 116 and 118 and carrying the lock-on mechanism 104 therewith as by engagement of the support portion 137 with the base 136 of the lock-on mechanism 104. With the paddle 38 so depressed, the flange 160 engages and likewise depresses the activation plunger 158 closing the switch circuit (see FIG. 22) to activate the motor assembly 24 and drive the pad 46 in its orbital path.

By providing an elongate, arcuate paddle 38 which follows the contour of the arcuate rear handle gripping portion 68 an operator can grab the rear handle 28 at various positions along the gripping portion 68, while still being able to depress the paddle 38 to its operative position without requiring an independent operation with their other hand and/or before the operator is ready to support and maneuver the apparatus 10 by the rear handle 28 during operation thereof. To deactivate the motor assembly 24, and therefore the apparatus 10, an operator need merely release the actuator paddle 38 which, by virtue of being spring loaded to its extended open position, will deactivate the motor assembly 24 by disengagement of the flange 160 from the activation plunger 158 to open the switch circuit.

In addition, if an operator does not wish to continually depress the paddle 38 during operation of the apparatus 10, the lock-on mechanism 104 can be readily accessed and utilized in an easy manner without interrupting operation of the apparatus 10 and/or requiring use of the operator's other hand. As previously mentioned, the lock-on mechanism 104 includes the transverse wall 142 extending into the rear handle interior space 34. In the interior space 34, a locking flange 162 is connected to the outer sidewall 74a disposed over the inner sidewall transverse portion 126 and includes a horizontal portion 164 and a connected vertical portion 166. Cooperating with the lock flange 162 is a guide flange 168 connected to the outer sidewall 74a and spaced forwardly from the vertical portion 166.

The paddle 38 and lock-on mechanism 104 are arranged so that with the paddle 38 depressed to its operative position, the cam end 144 will be positioned near the top of the vertical portion 166 between it and the guide flange 168. To continuously use the apparatus 10 without having to correspondingly continuously depress the paddle 38 to its operative position, the button member 134 can be depressed towards the rear handle interior space 34, i.e., in the same direction in which the actuator paddle 38 is being depressed, against the bias of spring 148, causing the outside of the curved cam surface 144 to cammingly engage the guide flange 168 and be directed over the top of the vertical portion 166 of the lock flange 162 and latch onto the lock flange vertical portion 166 under the influence of large spring 152 with the actuator 38 being maintained in its closed operative position by the lifting force applied by the curved end 138 on the pivot rod 140. To effect release of the actuator paddle 38 from the locked position, the operator merely depresses the paddle 38 slightly further to reduce the influence of large spring 152 sufficiently so as to allow the spring 148 to urge the curved cam end 144 over the top of the lock flange vertical portion 166 and against the guide flange 168 as by the pivoting action of the curved end 138 about the pivot rod 140. Thereafter, the paddle 38 is released with the spring 150 biasing the paddle 38 to the open position to deactivate the motor assembly 24.

To provide electrical power from the plug plate 42 to the motor assembly 24, the switching mechanism 37 includes an input terminal 170 and an output terminal 172 extending through sides of the switch housing 36. As best seen in FIG. 10, a lead 174 is electrically connected to the plug plate 42 and extends to the switching mechanism input terminal 170 while another lead 176 extends from the output terminal 172 to a fullwave rectifier 178 for the DC motor assembly 24. A lead 181 is electrically connected to the plug plate 42 and extends directly to the rectifier 178. As is conventional, the rectifier 178 converts AC power received at the plug plate 42 to DC power for application to the DC motor assembly 24. Thus, with the switching circuit closed as caused by depressing the paddle 38 to its operative position, DC electrical power will be provided to the armature coils, as more fully discussed herein.

The various motor assembly components are supported and oriented directly by the clamshell housing members 18 and 20 which, when connected, cooperate to clamp the motor in place in the main housing 22 without employing an extended yoke as a container to support and position the various motor components and/or a separate base or frame member to support the yoke in the housing. Referring to FIGS. 10 and 11, the motor assembly 24 consists of an armature 180 which can be of standard construction, including a core and windings 182 aligned around a shaft 184 on which is also mounted the commutator 186. A steel stator yoke 188 of open cylindrical shape is provided and can have a pair of large semi-circular permanent magnets 190 and 192 pressed therein with the magnets 190 and 192 having a half-inch gap between each other in the yoke 188 at their ends.

A support plate 194 mounts the brushes 196 and 198 in respective brush housings 200 and 202 thereon and the rectifier 178 in a rectifier well 204 formed therein, as illustrated in FIGS. 14 and 15. Referring to FIGS. 10 and 11, the armature shaft 184 includes top and bottom ends 206 and 208 with a spherical bushing 210 being mounted about the top end 206 of the shaft 184 and a ring ball bearing 212 being mounted about the shaft 184 near its bottom end 208.

The first and second housing members 18 and 20 each include a plurality of alignment and support members generally designated 214 which are symmetrically arranged about a longitudinal axis 216 extending centrally through the main housing 22. The alignment and support members 214 clampingly engage the outer surface 218 of the yoke 188 and tightly capture the top and bottom bearings 210 and 212 when the housing members 18 and 20 are secured to each other so that the yoke 188 and the armature 180 are in alignment along the longitudinal axis 216 with the armature shaft 184 extending therealong and the cylindrical yoke 188 encircling the armature 180. In this manner, the motor assembly 24 and the housing 16 are assembled together in one manufacturing operation without requiring a separate assembly operation for the motor before it is mounted in the housing. In addition, the motor circuitry including the switch housing 36, the plug plate 42 and the support plate 194, including the brushes 196 and 198 and the rectifier 178 can be assembled as a sub-assembly before the they are mounted to the housing 16.

More specifically and referring to FIGS. 14 and 15, the support plate 194 preferably has a U-shape having opposed leg portions 220 and 222 and a transverse foot portion 224 which extends between and cooperates with the leg portions 220 and 222 to define a central commutator space 226. The support plate 194 is mounted in the housing 16 such that the leg portions 220 and 222 are spaced on either side of the commutator 186 with the commutator 186 positioned in the central space 226. The brush housing 200 is mounted on leg portion 220 and the brush housing 202 is mounted on leg portion 222 spaced 180.degree. from each other around the commutator 186. The brush housings 200 and 202 each include a main body 228 and 230, respectively, having respective brush-receiving bores 232 and 234 extending therethrough. Central guide slots 236 and 238 are formed in the top of the main bodies 228 and 230, respectively, with the guide slots 236 and 238 communicating with respective bores 232 and 234. The brushes 196 and 198 are received in their respective brush-receiving bores 232 and 234 and include attached leads 240 and 242, respectively, each having respective flag terminals 244 and 246 for electrically connecting the brushes 196 and 198 to the rectifier 178.

With the brushes 196 and 198 placed in their bores 232 and 234, and the support plate 194 mounted in the housing 16 about the commutator 186, the brushes 196 and 198 are biased so that at least a portion thereof extend into the central space 226 into contact with the outer surface 218 of the commutator 186. In this manner the brushes 196 and 198 slidingly ride along the commutator outer surface 218 as it rotates on the armature shaft 184 to thereby electrically connect the power source to the armature coils. To urge the brushes 196 and 198 into contact with the commutator 186, each of the housings 200 and 202 include respective caps 248 and 250 and springs 252 and 254. The main body 228 and the main body 230 include enlarged outer ends 256 and 258, respectively. The enlarged outer end 256 includes oppositely-facing ramp surfaces 260 and 262 extending inwardly to respective straight shoulder surfaces 264 and 266. Likewise, enlarged end 258 includes oppositely-facing ramp surfaces 268 and 270 extending inwardly to respective straight shoulder surfaces 272 and 274.

For capturing and locking the cap 248 on the main body 228, the cap 248 includes a pair of ramp surfaces 276 and 278 extending from either side thereof to respective inner shoulder surfaces 280 and 282. Likewise, cap 250 is provided with ramp surfaces 284 and 286 extending from either side thereof to respective shoulder surfaces 288 and 290. The inner rear surfaces of each of the caps 248 and 250 is provided with a slightly raised spring locating boss 292 and 294, respectively.

To assemble the brushes 196 and 198 in their respective housings 200 and 202, the brushes 196 and 198 are inserted into their respective bores 232 and 234 with their lead wires 240 and 242 extending from the bores 232 and 234 through the slots 236 and 238 thereof with the flag terminals 244 and 246 then being connected to appropriate output terminals on the rectifier 178, as will be described herein. To urge the brush 196 through the bore 232 of the housing 228 and into the central space 226, the spring 252 is placed in the bore 232 with one end in contact with the brush 196 and its other end located on the boss 292 with the cap 248 then being press fit onto the enlarged end 256 of the main body 228 of the housing 200. The cap 248 is press fit onto the main body 228 by moving the ramp surfaces 276 and 278 against and along the ramp surfaces 260 and 262 so as to urge the cap sides outwardly as the cap 248 is pushed onto the main body 228. Once the ramp surfaces are pushed past each other, the sides of the cap 248 will rebound to their original, straight configuration with the cap shoulder surfaces 280 and 282 confronting respective shoulder surfaces 264 and 266 on the main body so as to lock the cap 248 thereon. With the cap 248 locked in place, the spring 252 will act to bias the brush 196 so that it extends out from the central bore 232 into the central space 226, limited by the engagement of the lead 240 with the inner end of the guide slot 236, as best seen in FIG. 13. The cap 250 is similarly press-fit and locked onto the main body 230 so as to bias the brush 198 through the bore 234 into the central space 226.

In the foot portion 224 of the support plate 194, the recessed rectifier well 204 is formed. The rectifier well 204 includes a pair of resilient upstanding locking members 296 and 298 therein, with the locking members 296 and 298 each having an enlarged locking portion 300 and 302 at their respective upper ends. The rectifier 178 includes a body portion 304 with a pair of input terminals 306 and 308 and a pair of output terminals 310 and 312 extending from the body portion 304. The rectifier 178 is assembled in the rectifier well 204 by pushing the rectifier body portion 304 against the enlarged ends 300 and 302 of the resilient locking members 296 and 298. This causes the locking members 296 and 298 to be urged outwardly thereby allowing the rectifier body portion 304 to be pushed past the enlarged ends 300 and 302 to seat in the well 204 with the resilient locking members 296 and 298 then snapping back to a locking position with the enlarged ends 300 and 302 abutting against the upper face of the body portion 304 to tightly capture the rectifier 178 in the recessed well 204.

A pair of lead guiding stakes 314 and 316 extend from the support plate 194 substantially at the junctures of the support plate foot portion 224 with the leg portions 220 and 222. The sub-assembly of the plug plate 42, the switch housing 36, and the rectifier 178 and brushes 196 and 198 on the support plate 194 includes lead electrical connections as described below. As one skilled in the art will appreciate, various arrangements of lead wires can be utilized with the motor assembly 24 to transmit electrical power thereto. Preferably, the lead 174 is electrically connected at one end to the plug plate 42 and at its other end it has a flag terminal 174a which is electrically connected to the input terminal 170 of the switching mechanism 37. The lead 176 has a flag terminal 176a attached to the output terminal 172 of the switching mechanism 27 with its other flag terminal 176b at the other end of the lead 17 attached to one of the input terminals 306 and 308 of the rectifier 178. The lead 181 is electrically connected at one end to the plug plate 42 and at its other end it has a flag terminal 181a which is attached to the other one of the rectifier input terminals 306 and 308. The brush leads 240 and 242 are each electrically connected to one of the output terminals 310 and 312 preferably with flag terminal 244 connected to output terminal 310 and flag terminal 246 connected to output terminal 312, as seen in FIG. 14. To ensure that the non-insulated braided lead wire 242 is isolated from the other similarly non-insulated braided wires, the lead wire 242 extends from the guide slot 238 around the lead guiding stake 316 and to the output terminal 312. As is apparent, the lead guiding stakes 314 and 316 can be used to guide the lead wires connecting to the rectifier terminals in various arrangements so as to prevent the non-insulated lead wires from contacting each other.

For mounting of the rectifier and brush support plate 194 in the housing interior space 56, cut-outs defining shoulders 318 and 320 are formed along the outer edges of the support plate leg portions 220 and 222, respectively. Referring to FIGS. 11 and 20, the alignment and support members 214 of the housing member 18 include a pair of notched vertical ribs 322a and 324a with each of the vertical ribs including a horizontal abutment member 326a and 328a extending laterally from the notched area to the housing member 18. The vertical ribs 322a and 324a are laterally spaced from each other in the housing internal space portion 56a with the spacing corresponding to the distance between the support plate shoulders 318 and 320 so as to snugly receive the support plate shoulders 318 and 320 in the vertical rib notches against the abutments 326a and 328a when the plate 194 is mounted to the housing member 18. With the support plate 194 so mounted, the longitudinal axis 216 extends through the support plate central space 226.

To clamp the support plate 194 in the housing interior space 56, corresponding notched vertical ribs 322b and 324b are formed in housing member 20 (see FIG. 21) with their notches being vertically aligned with the notches in the vertical ribs 322a and 324a when the housing members 18 and 20 are connected. The notched vertical ribs 322b and 324b engage the ends 334 and 336 of the support plate leg portions 220 and 222 projecting beyond the respective brush housing 228 and 230 so as to clamp the support plate 194 against movement in the housing interior space 56.

To mount the armature 180 in the housing interior space 56 with the armature shaft 184 aligned along the longitudinal axis 216, the alignment and support members 214 include upper and lower bearing engaging members 338a and 340a in housing member 18 and corresponding upper and lower bearing engaging members 338b and 340b in housing member 20 which cooperate to form top and bottom pockets in the housing interior space 56 with the longitudinal axis 216 extending through these pockets. The pockets formed by the bearing engaging members 338 and 340 are configured so as to securely capture the respective top and bottom bearings 210 and 212 against movement in the housing interior space 56.

More specifically, since the top bearing 210 is preferably a spherical bearing, the top bearing engaging member 338 is formed with a pair of curved sidewalls 342 and 344 with the radius of curvature of the sidewalls 342 and 344 substantially matching that of the spherical bearing 210. In this manner, the spherical bearing 210 is prevented from moving axially along the longitudinal axis 216 when captured by the upper bearing engaging member 338 in the housing interior space 56. In addition, the curved sidewalls 342 and 344 are connected by horizontal top and bottom members 346 and 348 with the top and bottom members 346 and 348 being curved at their ends adjacent the longitudinal axis 216. Extending between the curved sidewalls 342 and 344 intermediate the top and bottom members 346 and 348 is a horizontal support rib 349 having a curved end which does not extend as far towards the axis 216 as the ends of the top and bottom members 346 and 348 to accommodate and match the shape of the spherical bearing 210. Thus, the diameter across the curved ends of the intermediate support ribs 349a and 349b in each of the housing members 18 and 20 when attached is substantially the same as the largest diameter extending across the middle of the spherical bearing 210. Similarly, the diameter across the curved ends of the horizontal top and bottom members 346 and 348 substantially matches the smaller diameter across the top and bottom of the spherical bearing 210 so as to prevent the same from moving in a lateral direction when clamped and captured in the housing interior space 56.

The lower bearing engaging member 340 is constructed similarly to the top bearing engaging member 338 except that it is configured so as to capture the lower bearing 212 which is preferably in the form of a ring ball bearing. Thus, the lower bearing engaging member 340 has a pair of spaced straight sidewalls 350 and 352. The sidewalls 350 and 352 are interconnected by horizontal top and bottom members 354 and 356 with the top and bottom members 354 and 356 having curved ends which terminate in straight end portions extending to the respective tops and bottoms of sidewalls 350 and 352. With the housing members 18 and 20 attached, the curved ends of the top and bottom members 354a and 354b and 356a and 356b define a diameter slightly smaller than the outer diameter of the ring bearing 212. Thus, with the ring bearing 212 secured and mounted in the lower bearing engaging member 340, the top and bottom members 354 and 356 prevent the bottom ring bearing 212 from moving axially along the longitudinal axis 216.

Extending between the sidewalls 350 and 352 intermediate the top and bottom members 354 and 356 is a horizontal support rib 358 having a curved end terminating at the sidewalls 350 and 352 such that with the housing members 18 and 20 connected together, the intermediate horizontal support rib portions 358a and 358b of each of the housing members define a diameter across their curved ends substantially corresponding to the outer diameter of the ring bearing 212 so as to capture the same against mo