PLUNGER ASSEMBLY AND PLUNGER ASSEMBLY HOUSING

Abstract

A toilet plunger assembly includes a plunger having a handle and a cup. The cup includes a continuous interface with the handle and the cup includes a suction-inducing face, wherein the cup is operatively coupled with a lower distal end of the handle at the interface by an over-molding process. A base and housing are provided, the housing having a first vertically extending side wall, a second vertically extending side wall adjacent and orthogonal to the first vertically extending side wall, an open third side, an open fourth side, and a top horizontal wall coupled with the first vertically extending side wall and the second vertically extending side wall. The first vertically extending side wall and the second vertically extending side wall are supported by the base when the housing is in a stored condition and the plunger is concealed with the housing are in their respective stored conditions.

Description

CROSS REFERENCE TO RELATED APPLICATION

Applicant hereby claims the priority benefits under the provisions of 35 U.S.C. § 119, basing said claim of priority on related U.S. Provisional Application No. 63/213,991 filed Jun. 23, 2021, which is incorporated in its entirety herein by reference.

FIELD OF THE INVENTION

The present invention concerns a toilet plunger assembly and a plunger assembly housing, and more particularly relates to a toilet plunger assembly having an injection molded handle without gaps and a housing for the plunger assembly. Also disclosed is a method for manufacturing the plunger.

BACKGROUND OF THE INVENTION

Modern toilet plungers typically comprise a plunger handle and a cup attached to a distal end of the plunger handle. The cup, typically formed separately from a molded elastomeric material, usually has a lower portion formed as a concave configuration and may be attached at its upper end to the plunger handle, which is often fabricated from wood. The cup may be designed to make a seal around a toilet drain, allowing the user to force water in the toilet up and down, by which the pressure is developed to dislodges a clog in the toilet. An undesirable feature of such toilet plungers is that the interface between the cup and the plunger handle often results in a gap, seam, or crevice in which water and contaminants may be trapped, creating a potentially unsafe condition, particularly for pets and small children. Likewise, unless precautions are taken, a recently used toilet plunger may contaminate the floor upon which it may be stored, particularly when stored openly in a bathroom. In addition, modern toilet plungers tend to be unattractive, again particularly when stored openly in a bathroom. An improved toilet plunger assembly and a plunger assembly housing is desired to overcome these deficiencies.

SUMMARY OF THE PRESENT INVENTION

An aspect of the present invention is to provide a plunger comprising an injection molded handle having an upper proximal end and a lower distal end, wherein the lower distal end comprises an outwardly extending flange disposed about an outer periphery of the lower distal end and a cup having an upper portion and a lower portion, the upper portion of the cup including an interface with the handle, the interface comprising a recess and an outwardly extending groove at a base of the recess, and the lower portion of the cup including a suction-inducing face. The cup is injection over-molded from an elastomeric material about the lower distal end of the handle, whereby the outwardly extending groove at the base of the recess is formed by the outwardly extending flange disposed about the lower distal end of the handle and the interface of the cup with the handle is continuous.

Another aspect of the present invention is to provide a toilet plunger assembly comprising a plunger having an injection molded handle having an upper proximal end and a lower distal end and a cup having an upper portion and a lower portion, the upper portion of the cup including an interface with the handle and the lower portion of the cup including a suction-inducing face, wherein the cup is operatively coupled with the lower distal end of the handle at the interface. The assembly also includes a base upon which the plunger is supported when in a stored condition and a housing having a first side comprising a first vertically extending side wall, a second side comprising a second vertically extending side wall adjacent and orthogonal to the first vertically extending side wall, an open third side, an open fourth side, and a top horizontal wall coupled with the first vertically extending side wall and the second vertically extending side wall. A lower portion of each of the first vertically extending side wall and the second vertically extending side wall are supported by or proximate with the base when the housing is in a stored condition and wherein the plunger is concealed from view with the plunger and the housing are in their respective stored conditions.

A further aspect of the present invention is a method of manufacturing a toilet plunger comprising the steps of providing a first mold assembly adapted to receive a prefabricated plunger handle, wherein the plunger handle has an upper proximal end and a lower distal end and the lower distal end comprises an outwardly extending flange disposed about an outer periphery of the lower distal end, wherein a first exposed surface of the first mold assembly comprises a semi-spherical recess for forming an upper portion of a cup, and providing a second mold assembly, wherein a second exposed surface of the second mold assembly comprises a semi-spherical protuberance for forming an lower portion of the cup. The plunger handle is installed in the first mold assembly and the first mold assembly is closed relative the second mold assembly, wherein the first exposed surface of the first mold assembly and the second exposed surface of the second mold assembly cooperate to form a cavity corresponding to a finished shape of the cup and the lower distal end of the plunger handle extends into the cavity. The cup is injection over-molded by injecting an elastomeric material into the cavity and about the lower distal end of the plunger handle to form the cup, wherein the cup further comprises: an interface between the upper portion of the cup and plunger handle, wherein the interface comprises a recess and an outwardly extending groove at a base of the recess, such that the outwardly extending groove at the base of the recess is formed by the outwardly extending flange disposed about the lower distal end of the plunger handle and the interface between the upper portion of the cup and the plunger handle is continuous; and a suction-inducing face on the lower portion of the cup. The first mold assembly is separated relative the second mold assembly after the elastomeric material is cured and the toilet plunger is removed from the first mold assembly or the second mold assembly.

These and other aspects, objects, and features of the present invention will be understood and appreciated by those skilled in the art upon studying the following specification, claims, and appended drawings.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 is a perspective view of a toilet plunger assembly of the present invention in situ in a bathroom;

FIG. 2 is a perspective view of the toilet plunger assembly of the present invention shown in FIG. 1 in situ in a bathroom, with the housing removed;

FIG. 3 is an exploded perspective view of a toilet plunger assembly of the present invention shown in FIG. 1;

FIG. 4 is another exploded perspective view of the toilet plunger assembly of the present invention shown in FIG. 1;

FIG. 5 is an exterior perspective view of the toilet plunger assembly of the present invention shown in FIG. 1;

FIG. 6 is a side view of the plunger of the toilet plunger assembly of the present invention shown in FIG. 1;

FIG. 7 is a cross-sectional view of the plunger of the toilet plunger assembly of the present invention shown in FIG. 1;

FIG. 8 is a top view of the toilet plunger assembly of the present invention shown in FIG. 1;

FIG. 9 is a cross-sectional view of the toilet plunger assembly of the present invention shown in FIG. 1 taken along the line IX-IX in FIG. 8;

FIG. 10 is a perspective view of the distal end of the plunger and the end cap of the toilet plunger assembly of the present invention shown in FIG. 1;

FIG. 11 is a perspective view of the molding apparatus for the plunger of the toilet plunger assembly of the present invention shown in FIG. 1; and

FIG. 12 is a cross-sectional view of the molding apparatus for the plunger of the toilet plunger assembly of the present invention shown in FIG. 1 taken along the line XII-XII in FIG. 11.

DETAILED DESCRIPTION OF THE INVENTION

For purposes of description herein, the terms “upper,” “lower,” “right,” “left,” “rear,” “front,” “vertical,” “horizontal,” and derivatives thereof shall relate to the invention as orientated in FIG. 1. However, it is to be understood that the invention may assume various alternative orientations, except where expressly specified to the contrary. It is also to be understood that the specific devices and processes illustrated in the attached drawings, and described in the following specification are simply exemplary embodiments of the inventive concepts defined in the appended claims. Hence, specific dimensions and other physical characteristics relating to the embodiments disclosed herein are not to be considered as limiting, unless the claims expressly state otherwise.

Reference number 10 in the Figures generally designates the toilet plunger assembly, which includes a plunger 12, a base 14 upon which the plunger 12 is supported by or proximate to when in a stored condition, and a housing 16. The plunger 12 may include an injection molded handle 18 having an upper proximal end 20, a lower distal end 22, and a cup 24. The cup 24 has an upper portion 26 and a lower portion 28, the upper portion 26 of the cup 24 including an interface 30 with the handle 18 and the lower portion 28 of the cup 24 including a suction-inducing face 32.

The cup 24 is operatively coupled with the lower distal end 22 of the handle 18 at the interface 30. That is, the lower distal end 22 of the handle 18 may include an outwardly extending flange 34 disposed about an outer periphery 36 of the lower distal end 22 and the interface 30 of the cup 24 may include a recess 38 and an outwardly extending groove 40 at a base 42 of the recess 38. As more fully described below, the cup 24 is injection over-molded from an elastomeric material, such as rubber, about the lower distal end 22 of the handle 18, whereby the recess 38 and the outwardly extending groove 40 at the base of the recess 38 is formed by the outwardly extending flange 34 disposed about the lower distal end 22 of the handle 18 and the interface 30 of the cup 24 with the handle 18 is continuous.

The handle 18 may be formed through an injection molding process from high strength plastic resin, such as filled polypropylene, as a solid component, a composite component, or as a hollow form. A hollow form is shown in FIG. 10. The handle 18 may be formed in any cross-sectional configuration, such as circular, elliptical, square, or triangular. As shown in the Figures, the handle 18 comprises a triangular cross section and includes an upwardly tapered portion 44 and a downwardly tapered portion 46 along a longitudinal length of the handle 18 for ease in grasping and manipulation by a user. This configuration is lightweight, very strong, and easy to hold. A slip arrestor or knob 48, having an outer diameter or dimension greater than that of the longitudinal length of the handle 18, may also be added to the proximal end 20 of the handle 18 for ease in grasping and manipulation by a user.

An impermeable solid surface 50 may be disposed orthogonal to the longitudinal length of the handle 18 at the lower distal end 22 in order to block the flow of the elastomeric material during the over-molding process into an interior cavity 52 of the handle 18. In the case where the handle 18 is a solid component, the impermeable solid surface 50 may be formed integrally with the lower distal end 22 itself. In the case where the handle 18 is hollow, the impermeable solid surface 50 may be formed by an impermeable end cap 54 disposed on the lower distal end 22 of the handle 18 to block and prevent flow of the elastomeric material into the interior cavity 52 of the handle 18. As shown in FIGS. 10 and 12, the impermeable end cap 54 may be held in place when installed during the over-molding process, discussed in more detail below, by a plurality of tabs 56 extending distally from the lower distal end 22 of the handle 18 and a corresponding plurality of openings 58 arranged about the perimeter 60 of the impermeable end cap 54 that each receive one of the tabs 56. As shown in FIG. 10, three such tabs 56 and openings 58 are provided.

As noted above, the lower portion 28 of the cup 24 includes a suction-inducing face 32. As shown in FIG. 7, the suction-inducing face 32 of the lower portion 28 of the cup 24 may comprise a semicircular concave surface 62. The suction-inducing face 32 of the lower portion 28 of the cup 24 may further include a flexible flap 64 formed about an outer circumferential periphery 66 of the suction-inducing face 32. The flexible flap 64 may form an opening 68 at a lower distal end 70 of the plunger 12, wherein the flexible flap 64 is adapted to fold out from inside the semicircular concave surface 62 of the cup 24.

Such a configuration is particularly adapted for use in toilet applications. That is, an outer circumference 72 of the opening 68 is small enough to fit into an entry of a plumbing system, such as a toilet 74, so as to create a pocket of negative air pressure within the cup 24 to dislodge a clog in the toilet 74, while an inner circumference 76 of the opening 68 may be sized to fit over a raised circular protuberance 78 of the base 14, as further described below.

As more fully described below, the cup 24 is injection over-molded from an elastomeric material about the lower distal end 22 of the handle 18, which may be prefabricated, such as by injection molding, as noted above. By virtue of such an over-molding process, the elastomeric material of the cup 24 is chemically bonded to the lower distal end 22 of the handle 18, such that the outwardly extending groove 40 at the base 42 of the recess 38 is chemically bonded to the outwardly extending flange 34 disposed about the lower distal end 22 of the handle 18. Also, since the cup 24 is chemically bonded with the handle 18 about an upper opening 80 in the interface 30, the result is a continuous curvilinear transition between the outer surface 82 of the distal end 22 of the handle 18 and the upper surface 84 of the upper portion 26 of the cup 24 that promotes gravity-induced liquid flow from the handle 18 and the cup 24. Such a continuous curvilinear transition substantially promotes gravity-induced movement and shedding of any and all contaminants or debris that may remain on the plunger 12 after use. In particular, in contrast to prior plunger designs, manufactured gaps, seams, or crevices within which water and contaminants may be trapped and where water can puddle, potentially hosting bacteria colonies, are avoided.

As shown in FIGS. 2-4, radial ribs 86 may be added to the upper surface 84 of the upper portion 26 of the cup 24, each of which extends radially from the interface 30 with the distal end 22 of the handle 18 to provide rigidity to the upper portion 26 of the cup 24. The radial ribs 86 may be molded with the cup 24.

As shown in FIGS. 1-4 and 9, the plunger 12 described above is particularly adapted as part of the toilet plunger assembly 10, which also includes the base 14, upon which the plunger 12 is supported when in a stored condition, and the housing 16.

The base 14 may be injection molded from high strength plastic resin, such as Acrylonitrile butadiene styrene (ABS), and provided with four vertical base side walls 88, with a support platform 90 disposed at an elevation between an upper edge 92 and lower edge 94 of each of the base side walls 88. The support platform 90 may thus be elevated relative a floor surface F, such that an air passage 96 is formed below the support platform 90 and a drip tray 98 is formed above the support platform 90. The drip tray 98 is defined by an upper portion 100 of the base side walls 88 and the raised circular protuberance 78. The raised circular protuberance 78 may be adapted to correspond with and receive the opening 68 at the lower distal end 22 of the plunger 12.

The housing 16 may also be injection molded from high strength plastic resin, such as ABS. However, it is contemplated that the housing 16 may be fabricated from other materials, such as metal, in order to provide a variety of aesthetics. The housing 16 has a first side defined by a first vertically extending side wall 106, a second side defined by a second vertically extending side wall 106 disposed adjacent and orthogonal to the first vertically extending side wall 104, and at least one of an open third side 108 or an open fourth side 110, and a top horizontal wall 112 coupled with and orthogonal to the first vertically extending side wall 104 and the second vertically extending side wall 106. As shown in the Figures, both the third side 108 and fourth side 110 are open, allowing the toilet plunger assembly 10 to be stored in a corner of a bathroom. However, it is contemplated that only the third side 108 or the fourth side 110 is open, with a third vertically extending side wall (not shown) on the other of the third side 108 or fourth side 110 and disposed adjacent and orthogonal to either the first vertically extending side wall 104 or the second vertically extending side wall 106. Such an arrangement of course would limit the storage of the toilet plunger assembly 10 to a wall in the bathroom.

A pair of ribs 114 may be disposed on an interior surface 116 of each of the first vertically extending side wall 104 and second vertically extending side wall 106, such that each of the pair of ribs 114 extend upwardly onto an interior surface 118 of the top horizontal wall 112 to provide additional structural rigidity to the housing 16. The pair of ribs 114 may be integrally molded with the housing 16. A lower portion 120 of each of the first vertically extending side wall 104 and the second vertically extending side wall 106 are supported by the base 14 or the floor F when the housing 16 is in a stored condition and wherein the plunger 12 is concealed from view when the plunger 12 and the housing 16 are in their respective stored conditions.

The lower edge 122 of at least one of the base side walls 88 and a lower edge 124 of at least one of the first vertically extending side wall 104 or the second vertically extending side wall 106 may include an air vent 126. As shown in FIGS. 1-4, the top horizontal wall 112, the raised circular protuberance 78, the lower edge 122 of at least two adjacent base side walls 88, and the lower edge 124 of each of the first vertically extending side wall 104 and the second vertically extending side wall 106 include the air vent 126. The air vent 126 through the top horizontal wall 112 may be formed as a simple circular opening. The air vent 126 through the raised circular protuberance 78 may be formed as a simple circular opening or, as shown in FIG. 3, a plurality of parallel, longitudinally extending slots 128. The air vents 126 on the lower edge 122 of the adjacent base side walls 88 and the lower edge 124 of each of the first vertically extending side wall 104 and the second vertically extending side wall 106 may be formed as simple aligned notches at the lower edges 122, 124 of each.

Each of the first vertically extending side wall 104 and the second vertically extending side wall 106 may include an inwardly and downwardly extending flange 130 on the interior surface 116 thereof. The base 14 may further include an upwardly extending flange 132 proximate a first side 134 and a second side 136 of the base 14 and proximate the first vertically extending side wall 104 and the second vertically extending side wall 106, respectively, such that the upwardly extending flange 132 extends into and is received within a gap G formed between the inwardly and downwardly extending flange 130 and the interior surface 118 of each of the first vertically extending side wall 104 and the second vertically extending side wall 106. This arrangement effectively provides an interlock that improves the stability of the toilet plunger assembly 10. To further improve stability and for ease of manufacture, each of the inwardly and downwardly extending flanges 130 on the interior surface 118 of each of the first vertically extending side wall 104 and the second vertically extending side wall 106 and each of the upwardly extending flanges 132 proximate the first side 134 and second side 136 of the base 14 and proximate the first vertically extending side wall 104 and the second vertically extending side wall 106 each comprise a continuous band, as perhaps best shown in FIGS. 3 and 4.

As shown in FIGS. 1 and 2, each of the first vertically extending side wall 104 and the second vertically extending side wall 106 may also include a relief notch 138 to provide clearance for a baseboard B of an interior room of a building. The relief notch 138 may be formed by a mechanically weakened boundary edge, such as a breakable perforation, a molded groove, or by scoring. The mechanically weakened boundary edge may be disposed proximate a lower inward edge 140 of each of the first vertically extending side wall 104 and the second vertically extending side wall 104. In order to accommodate baseboards B of different cross-sectional configurations, a plurality of mechanically weakened boundary edges may be provided (not shown), such that the end user may select a profile for the relief notch 138 and remove only those portions of the first vertically extending side wall 104 and/or the second vertically extending side wall 106 by breaking, shearing, or snapping off material to form the relief notch 138 that most closely match the baseboard B of the interior room of the building, such as a bathroom.

As perhaps best shown in FIGS. 1 and 2, the toilet plunger assembly 10 described above is particularly adapted for storage at a corner of the bathroom, which minimizes the space consumed by the toilet plunger assembly 10 and reduces clutter. When provided with the open third side 108 and open fourth side 110, coupled with the relief notch 138 described above, the toilet plunger assembly 10 may be placed in the corner directly in contact with the walls of the bathroom, without any gaps or spaces between the walls of the bathroom and either of the first vertically extending side wall 104 or the second vertically extending side wall 106. This further assures that the plunger 12 is shielded from contact by pets or small children, preventing them from touching the plunger 12 and ingesting or spreading bacteria residing on the plunger 12.

The first vertically extending side wall 104 and/or the second vertically extending side wall 106 may be inclined toward the open third side 108 and open fourth side 110, respectively. Both first vertically extending side wall 104 or second vertically extending side wall 106 may be inclined toward the open third side 108 and open fourth side 110, respectively, each at an angle of at least 5 degrees relative a vertical plane. Such geometry tends to shift the center of gravity of the housing 16 toward the corner at which the toilet plunger assembly 10 is stored and promotes stability.

The method of manufacturing the plunger 12 in accordance with the present disclosure is described by reference to FIGS. 11 and 12. A first mold assembly 150 may be adapted to receive the injection molded handle 18, previously formed separately. As noted above, once installed, the lower distal end 22 of the handle 18 is left exposed, and includes the outwardly extending flange 34 disposed about the outer periphery 36 of the lower distal end 22. A first exposed surface 152 of the first mold assembly 150 may also include a semi-spherical recess 154 for forming the upper portion 26 of the cup 24. If the handle 18 is hollow, the impermeable end cap 54 may be positioned on the lower distal end 22 of the handle 18 to block and prevent flow of the elastomeric material into the interior cavity 52 of the handle 18 prior to the step of closing the first mold assembly 150 relative a second mold assembly 156.

The second mold assembly 156 includes a second exposed surface 158, which may include a semi-spherical protuberance 160 for forming the lower portion 28 of the cup 24 and the suction-inducing face 32. The second mold assembly 156 may also include a void 162 about the semi-spherical protuberance 160 by which the flexible flap 64 may be formed.

The first mold assembly 150 is then closed relative the second mold assembly 156. The first exposed surface 152 of the first mold assembly 150 and the second exposed surface 158 of the second mold assembly 156 cooperate to form a cavity 164 corresponding to the finished shape of the cup 24. As shown in FIG. 12, the lower distal end 22 of the handle 18 extends into the cavity 164.

The cup 24 is then formed relative the handle 18 by injection over-molding an elastomeric material, such as rubber, into the cavity 164 and about the lower distal end 22 of the handle 18 to form the cup 24, which includes the interface 30 between the upper portion 26 of the cup 24 and the handle 18, wherein the interface 30 comprises the recess 38 and an outwardly extending groove 40 at a base 42 of the recess 38. The outwardly extending groove 40 at the base 42 of the recess 38 is formed by the outwardly extending flange 34 disposed about the lower distal end 22 of the handle 18, such that the interface 30 between the handle 18 and the cup 24 is continuous. The suction-inducing face 32 on the lower portion 28 of the cup 24 and the flexible flap 64 are also formed.

Once the elastomeric material of the cup 24 is cured, the first mold assembly 150 and the second mold assembly 156 are separated relative one another, and the finished plunger 12 may be removed from the first mold assembly 150 or the second mold assembly 156. By virtue of the over-molding process, the elastomeric material of the cup 24 is chemically bonded to the lower distal end 22 of the handle 18.

In operation, the toilet plunger assembly 10 is simple to use. The user sets the toilet plunger assembly 10 next to the toilet. When a clog is encountered, the user may merely lift the housing 16 and set it on the floor out of the way, thereby exposing the plunger 12. If desired, the user may manipulate the housing 16 via the air vent 126 in the horizontal top wall of the housing 16, for example, by inserting a finger therein and lifting. The user may then use the plunger 12 to clear the clog in the toilet 74. When the clog is removed, the user need merely shake the excess water into the toilet 74 and rinse off the plunger 12. Due to the lack of any gap, seam, or crevice between the handle 18 and the cup 24, virtually all debris that may be carried by the plunger 12 is easily and readily rinsed away.

The user then may simply return the plunger 12 to the base 14 for drying and storage. Due to the support platform 90 having the raised circular protuberance 78 corresponding with and adapted to receive the opening 68 at the lower distal end 70 of the plunger 12, the base 14 thus effectively and properly locates the plunger 12 on the base 14, while preventing water from running onto the floor. The housing 16 may then be replaced back over the plunger 12 and the base 14, ready for the next use. The air vents 126 provide air circulation and thereby function to dry the plunger 12 and the drip tray 98 of the base 14.

The toilet plunger assembly 10 of the present disclosure thus presents several advantages and benefits. Prior art plungers include gaps, seams, or crevices which retain standing water and contaminants between the handle 18 and the cup 24. The toilet plunger assembly 10 disclosed herein provides a continuous interface 30 between the handle 18 and the cup 24 that effectively eliminates any such standing water or contaminants.

Prior art toilet plungers often leave puddles on the floor after use or require an unsightly pan or dish be provided upon which plunger can be stored. The toilet plunger assembly 10 disclosed herein provides a convenient drip tray 98 on the base 14 for dripping water after use.

Prior art plungers also leave portions of the handles and cup of the plunger exposed to touch. The toilet plunger assembly 10 described above shields the plunger 12 from contact by pets or small children, preventing them from touching the plunger 12 and ingesting or spreading bacteria that might reside outside of the plunger 12. That is, the housing 16 completely shields the plunger 12 from sight and touch.

The disclosed toilet plunger assembly 10 also provides a relatively attractive alternative to prior art toilet plungers. The disclosed toilet plunger assembly 10 includes a custom designed plunger 12 which is stored on a specially adapted base 14 with a corresponding housing 16 that provides a fitted contact with corner walls adjacent to the toilet 74. The disclosed toilet plunger assembly 10 can be molded in different colors of plastic resin to match a variety of bathroom decors. Alternatively, the disclosed toilet plunger assembly 10 can be decorated, such as by painting the housing 16 or covering the housing 16 in wallpaper or contact paper, to match virtually any bathroom décor.

Since the entire toilet plunger assembly 10, except the cup 24, may be fabricated from molded high strength plastic, each of its components will withstand impact and provide a long useful life.

It will be understood by one having ordinary skill in the art that construction of the present disclosure and other components is not limited to any specific material. Other exemplary embodiments of the disclosure disclosed herein may be formed from a wide variety of materials, unless described otherwise herein.

For purposes of this disclosure, the term “coupled” or “operably coupled” (in all of its forms, couple, coupling, coupled, etc.) generally means the joining of two components (electrical or mechanical) directly or indirectly to one another. Such joining may be stationary in nature or movable in nature. Such joining may be achieved with the two components (electrical or mechanical) and any additional intermediate members being integrally formed as a single unitary body with one another or with the two components. Such joining may be permanent in nature or may be removable or releasable in nature unless otherwise stated.

For purposes of this disclosure, the term “connected” or “operably connected” (in all of its forms, connect, connecting, connected, etc.) generally means that one component functions with respect to another component, even if there are other components located between the first and second component, and the term “operable” defines a functional relationship between components.

It is also important to note that the construction and arrangement of the elements of the present disclosure as shown in the exemplary embodiments is illustrative only. Although only a few embodiments of the present innovations have been described in detail in this disclosure, those skilled in the art who review this disclosure will readily appreciate that, unless otherwise described, many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter recited. For example, elements shown as integrally formed may be constructed of multiple parts or elements shown as multiple parts may be integrally formed, the operation of the interfaces may be reversed or otherwise varied, the length or width of the structures and/or members or connector or other elements of the system may be varied, the nature or number of adjustment positions provided between the elements may be varied. It should be noted that the elements and/or assemblies of the system may be constructed from any of a wide variety of materials that provide sufficient strength or durability, in any of a wide variety of colors, textures, and combinations. Accordingly, all such modifications are intended to be included within the scope of the present innovations. Other substitutions, modifications, changes, and omissions may be made in the design, operating positions, and arrangement of the desired and other exemplary embodiments without departing from the spirit of the present innovations.

It will be understood that any described processes or steps within described processes may be combined with other disclosed processes or steps to form structures within the scope of the present disclosure. The exemplary structures and processes disclosed herein are for illustrative purposes and are not to be construed as limiting.

It is also to be understood that variations and modifications can be made on the aforementioned structures and methods without departing from the concepts of the present invention, and further it is to be understood that such concepts are intended to be covered by the following claims unless these claims by their language expressly state otherwise.

Claims

1. A plunger comprising:

a handle having an upper proximal end and a lower distal end, wherein the lower distal end comprises an outwardly extending flange disposed about an outer periphery of the lower distal end; and

a cup having an upper portion and a lower portion, the upper portion of the cup including an interface with the handle, the interface comprising a recess and an outwardly extending groove at a base of the recess, and the lower portion of the cup including a suction-inducing face;

wherein the cup is injection over-molded from an elastomeric material about the lower distal end of the handle; and

wherein the recess and the outwardly extending groove at the base of the recess are formed by the outwardly extending flange disposed about the lower distal end of the handle and the interface of the cup with the handle is continuous.

2. The plunger according to claim 1, wherein the elastomeric material is rubber.

3. The plunger according to claim 1, wherein the elastomeric material of the cup is chemically bonded to the lower distal end of the handle.

4. The plunger according to claim 1, wherein the handle further comprises an impermeable solid surface disposed on the lower distal end.

5. The plunger according to claim 4, wherein the handle is hollow and the impermeable solid surface comprises an end cap disposed on the lower distal end of the handle to block and prevent flow of the elastomeric material into an interior cavity of the handle.

6. The plunger according to claim 1, wherein the suction-inducing face of the lower portion of the cup comprises a semicircular concave surface.

7. The plunger according to claim 6, wherein the suction-inducing face of the lower portion of the cup further comprises a flexible flap formed about an outer circumferential periphery of the suction-inducing face and wherein the flexible flap includes an opening at a lower distal end of the plunger.

8. The plunger according to claim 7, wherein the flexible flap is adapted to fold out from inside semicircular concave surface of the cup.

9. The toilet plunger according to claim 1, wherein the handle comprises a triangular cross section and a tapered portion along a longitudinal length of the handle.

10. The toilet plunger according to claim 1, wherein the handle is injection molded from a plastic resin.

11. A toilet plunger assembly comprising:

a plunger having a handle having an upper proximal end and a lower distal end and a cup having an upper portion and a lower portion, the upper portion of the cup including an interface with the handle and the lower portion of the cup including a suction-inducing face, wherein the cup is operatively coupled with the lower distal end of the handle at the interface;

a base upon which the plunger is supported when in a stored condition; and

a housing having a first side defined by a first vertically extending side wall, a second side defined by a second vertically extending side wall adjacent and orthogonal to the first vertically extending side wall, and at least one of an open third side or an open fourth side, and a top horizontal wall coupled with the first vertically extending side wall and the second vertically extending side wall;

wherein a lower portion of each of the first vertically extending side wall and the second vertically extending side wall are supported by or proximate to the base when the housing is in a stored condition; and

wherein the plunger is concealed from view with the plunger and the housing are in their respective stored conditions.

12. The toilet plunger according to claim 11, wherein the handle and base are injection molded from a plastic resin.

13. The toilet plunger according to claim 12, wherein the housing is injection molded from a plastic resin.

14. The toilet plunger assembly of claim 11, wherein the lower distal end of the handle comprises an outwardly extending flange disposed about an outer periphery of the lower distal end and the interface comprises a recess and an outwardly extending groove at a base of the recess;

wherein the cup is injection over-molded from an elastomeric material about the lower distal end of the handle, whereby the recess and the outwardly extending groove at the base of the recess is formed by the outwardly extending flange disposed about the lower distal end of the handle and the interface of the cup with the handle is continuous.

15. The toilet plunger assembly of claim 11, wherein:

the suction-inducing face of the lower portion of the cup further comprises a flexible flap formed about an outer circumferential periphery of the suction-inducing face and wherein the flexible flap includes an opening at a lower distal end of the plunger; and

the base comprises a support platform elevated relative a floor surface, wherein the support platform includes a raised circular protuberance corresponding with and adapted to receive the opening at the lower distal end of the plunger.

16. The toilet plunger assembly of claim 15, wherein the base comprises four vertical base side walls and the support platform is disposed at an elevation between an upper edge and a lower edge of each of the base side walls such that an air passage is formed below the support platform and drip tray is formed above the support platform and defined by an upper portion of the base side walls and the raised circular protuberance.

17. The toilet plunger assembly of claim 16, wherein the lower edge of at least one of the base side walls and a lower edge of at least one of the first vertically extending side wall or the second vertically extending side wall include an air vent.

18. The toilet plunger assembly of claim 17, wherein the top horizontal wall, the raised circular protuberance, the lower edge of at least two adjacent base side walls, and the lower edge of each of the first vertically extending side wall and the second vertically extending side wall include an air vent.

19. The toilet plunger assembly of claim 11, wherein each of the first vertically extending side wall and the second vertically extending side wall comprise an inwardly and downwardly extending flange on an interior surface thereof and the base comprises an upwardly extending flange proximate a first side and a second side of the base and proximate the first vertically extending side wall and the second vertically extending side wall, wherein the upwardly extending flange extends into and is received within a gap formed between inwardly and downwardly extending flange and the interior surface of each of the first vertically extending side wall and the second vertically extending side wall.

20. The toilet plunger assembly of claim 19, wherein each of the inwardly and downwardly extending flange on the interior surface of each of the first vertically extending side wall and the second vertically extending side wall and each of the upwardly extending flange proximate the first side and second side of the base and proximate the first vertically extending side wall and the second vertically extending side wall each comprise a continuous band.

21. The toilet plunger assembly of claim 11, wherein at least one of the first vertically extending side wall and the second vertically extending side wall comprise a relief notch at a lower inward edge thereof to provide clearance for a baseboard of an interior room of a building.

22. The toilet plunger assembly of claim 21, wherein the relief notch is formed by a mechanically weakened boundary edge proximate the lower inward edge of each of the first vertically extending side wall and the second vertically extending side wall.

23. The toilet plunger assembly of claim 11, wherein the first vertically extending side wall or second vertically extending side wall are inclined toward the open third side and open fourth side, respectively.

24. The toilet plunger assembly of claim 23, wherein the first vertically extending side wall or second vertically extending side wall are inclined toward the open third side and open fourth side, respectively, at an angle of at least 5 degrees.

25. The toilet plunger assembly of claim 23, wherein both the third side and the fourth side are open.

26. A method of manufacturing a toilet plunger comprising the steps of:

providing a first mold assembly adapted to receive a prefabricated plunger handle, wherein the plunger handle has an upper proximal end and a lower distal end and the lower distal end comprises an outwardly extending flange disposed about an outer periphery of the lower distal end, wherein a first exposed surface of the first mold assembly comprises a semi-spherical recess for forming an upper portion of a cup;

providing a second mold assembly, wherein a second exposed surface of the second mold assembly comprises a semi-spherical protuberance for forming an lower portion of the cup;

installing the plunger handle in the first mold assembly;

closing the first mold assembly relative the second mold assembly, wherein the first exposed surface of the first mold assembly and the second exposed surface of the second mold assembly cooperate to form a cavity corresponding to a finished shape of the cup and the lower distal end of the plunger handle extends into the cavity;

injection over-molding the cup by injecting an elastomeric material into the cavity and about the lower distal end of the plunger handle to form the cup, wherein the cup further comprises: an interface between the upper portion of the cup and plunger handle, wherein the interface comprises a recess and an outwardly extending groove at a base of the recess, such that the outwardly extending groove at the base of the recess is formed by the outwardly extending flange disposed about the lower distal end of the handle and the interface between the upper portion of the cup and the plunger handle is continuous; and a suction-inducing face on the lower portion of the cup;

separating the first mold assembly relative the second mold assembly after the elastomeric material is cured; and

removing the toilet plunger from the first mold assembly or the second mold assembly.

27. The method of claim 26, further comprising the step of positioning an impermeable end cap on the lower distal end of the plunger handle to block and prevent flow of the elastomeric material into an interior cavity of the plunger handle prior to the step of closing the first mold assembly relative the second mold assembly.

28. The method of claim 26, wherein the elastomeric material of the cup is chemically bonded to the lower distal end of the plunger handle.