The present application relates generally to an improved safety carton cutter having a retracting mechanism that automatically retracts the blade immediately after use, thereby reducing the risk of serious injury to a user and bystanders.
Carton cutters and other forms of cutting instruments are used in connection with a number of activities, including box cutting, cutting of corrugated materials and packaging and a host of other tasks. U.S. Pat. No. 2,679,100 illustrates one form of knife which incorporates a two-piece housing having a cavity in which a blade is secured. The two housing sections are releasably secured to each other using a fastening screw, and the blade remains exposed in a fixed position during use. When the blade becomes dull, the user removes the fastening screw, separates the housing sections and inserts a new blade in place of the dull one. U.S. Pat. No. 2,635,337 discloses a notched linoleum cutting knife that incorporates a one-piece handle and a fixed blade. Both of these cutting devices (as well as others not specifically described herein) have exposed blades that can be hazardous and result in injury to users who are not particularly careful. For example, an unsuspecting person can be inadvertently cut by the exposed blade upon attempting to retrieve the knife from a storage container.
In addition, there are potential hazards associated with the transport of fixed-blade utility knives. Prior to transport, a user must cover the sharp edge or remove the blade to reduce the risk of harm from the blade. This can result in delays if done properly, or injury if a user simply decides to leave the blade exposed.
The dangers associated with exposed, fixed blade knives have resulted in significant improvements in the field and, in particular, in knives with a selectively retractable blade. See e.g., U.S. Pat. No. 2,862,296, U.S. Pat. No. 2,948,961, and U.S. Pat. No. 3,107,426. In such knives, the blade is disposed within the housing and is selectively extended and retracted by engaging an external member. The external member actuates a carriage which carries the blade, allowing a user to extend and retract the blade as desired.
Despite the improvements associated with cutting devices having retractable blades, there still exist other potential hazards. For example, for a knife having a retractable blade, if that blade is left exposed in an extended position, it could still result in injury. In addition to the inadvertent injuries that can potentially result from a blade left in the exposed position, other potentially more severe injuries can occur soon after a cutting stroke as applied to a box or the like is complete, when the blade is traveling at a relatively higher speed. For example, depending on the material being cut, a high drag force on the blade is often produced, causing a user to compensate by applying greater force in order to complete the cutting stroke through the material. The forces that are applied can cause the knife and the exposed blade to leave forward, that is, to accelerate beyond control just as the cut through the material is completed. At this point, the drag force is no longer present and the user holding the knife with the exposed blade cannot manually react quickly enough to stop the acceleration of the blade. This can potentially result in injuries even more severe than those sustained by virtue of a utility knife fixed in place.
Some utility knives have incorporated automatically retractable blades, such as U.S. Pat. No. 5,813,121, wherein the blade automatically retracts once pressure on the actuating button is released and the cut is completed. At the beginning of and during the cutting process using this form of cutting device, a user's thumb must remain in place on the actuating button to prevent the blade from retracting at the initiation of the cut. However, as the cutting process comes to a conclusion, a user may not be able to react quickly enough to release the actuating button, thereby potentially resulting in a similar injury discussed above.
Attempts to produce a utility knife to mitigate the aforementioned drawbacks include U.S. Pat. No. 7,356,928 (“Votolato”). Votolato discloses a cutting device having a fixed blade with a spring loaded safety guard that covers the blade. When a cut is desired, a user depresses a trigger that allows the guard to rotate and expose the blade for a single use. After the single use, the guard rotates back to a locked position, shielding the blade, regardless of whether the trigger remains depressed.
Despite addressing some of the drawbacks associated with prior art utility knives, a number of issues persist. For example, if excessive force is applied to the guard prior to depressing the trigger, the mechanism may break, thereby undesirably exposing the blade and essentially leaving a user with utility knife having a fixed blade. The same can result if the guard is damaged from dropping the knife, or the guard is worn from corrugated friction.
Another drawback in the form of a cutting instrument disclosed in Votolato is that such instruments have an inherently reduced degree of accuracy. To begin a cut at a precise point, the tip of a blade generally needs to be at least somewhat exposed so that it can manually be placed by a user at a desired location. In a cutting instrument with a blade guard like the one disclosed in Votolato, the blade is hidden, requiring a user to approximate, that is, guess at the exact location where the blade will begin to cut. This feature prevents a user from aligning the tip of the blade at a precise location, (e.g., a reference mark), thereby possibly resulting in inaccurate cuts, damage to merchandise, waste of materials and the like. In some instances, a user would be required to reposition the utility knife several times until the desired position is found.
Furthermore, using the form of cutting instruments disclosed in Votolato presents another related problem when attempting to cut with the aide of a guide. For example, in order to make a straight cut through corrugated material, a straight guide is placed precisely along a line to be cut and the side of the blade is aligned with the guide during the entire cut. This cannot be accomplished using the utility knife disclosed in Votolato because the guard would at least initially obstruct the blade from starting at the desired location beside the guide.
In view of the deficiencies and drawbacks in the prior art, it is a primary object of the present invention to provide a safety carton cutter having a blade that is automatically held in a constant exposed position during the cutting process, and is retracted immediately after the cutting process is complete.
Another object of the present invention to provide a safety carton cutter having a blade that is automatically retractable to ensure that the blade is safely positioned after use.
Yet another object of the present invention is to provide a carton cutter that is safe, yet can also cut accurately.
Additional objectives will be apparent from the description of the invention that follows.
In summary, there is provided in a preferred embodiment of the present invention an improved safety carton cutter having an automatically retractable blade. In the safety carton cutter, after the blade is moved forward into an extended position by applying force with a user's finger to an actuator or latch, the blade is held in the extended position ready to cut even after the user's finger is removed from the actuator. Then, once the cutting process is complete, the blade automatically retracts as the frictional pulling force on the blade is released. Generally, after being moved into an open position, the blade of the device remains extended like that of blade in a conventional utility knife. However, when a cut is complete in connection with a frictional material, such as corrugated board, the blade automatically retracts to a safe position.
The preferred embodiment of the carton cutter comprises a housing having a first frame member and a second frame member. A blade carrier or receptacle contained in the housing carries a blade and is connected to a biasing member. The biasing member urges the blade receptacle into a retracted or closed position. On either side of the blade receptacle is an actuator or latch which allows the sliding of the blade receptacle together with the blade. Contained within the housing is a mechanism, described in more detail below, that enables the blade to remain in an extended position during the cutting process, and is configured and arranged to automatically retract the blade receptacle upon completion of a cutting motion.
The above-described and other advantages and features of the present disclosure will be appreciated and understood by those skilled in the art from the following detailed description and drawings of which
With reference to
The first frame member 20 and the second frame member 40 are pivotably secured to one another at the rear end 14 of the carton cutter 10 with a pair of frame bosses 22, 22. Each frame boss 22, 22 is aligned with a pivoting aperture 42, 42 located on either side of the second frame member 40. This connection allows the second frame member 40 to pivot with respect to first frame member 20 as illustrated in
The first frame member 20 is preferably formed of die cast zinc or aluminum. However, it should be understood that other materials are suitable for forming the first frame member 20, such as acetal, nylon, other hard plastics, steel, brass, and/or other materials that are known in the art. Second frame member 40 is preferably formed of a molded plastic material, such as acetal, nylon or polycarbonate. It should be understood that the second frame member can also be made from the same materials mentioned above in connection with the first frame member.
As shown in
As shown in
The first frame member 20 has a vertically oriented cam 26, having a slot 28 which forms a cam edge or profile 30. The cam profile 30 communicates with a rotating projection or follower 70 that is positioned on the blade receptacle 60 and secured with a fastener 72 that is configured to be press fitted into a bore 73, resulting in a loose friction fit that permits the follower 70 to rotate as needed. As shown most clearly in
The action described in connection with the safety carton cutter 10 occurs if the user's finger is released from the actuator 62, 62 after the blade is shifted to an extended position but before the cutting process commences (or even at some time during the cutting process), such that manual force from the user is not applied to keep the blade extended. In this regard, the safety carton cutter 10 is similar to a utility knife having a blade that remains extended even when a finger is removed from the button that extends the blade forward. The difference, however, is that the blade retracts as soon as the cut is complete. As discussed below in more detail, this is made possible in part by the frictional forces pulling the blade forward a fraction of an inch as the carton cutter makes a cut. In that regard, the safety carton cutter 10 is a hybrid cutting device having the best of both non-automatically and automatically retractable cutting devices.
The first frame member 20 has a number of additional features that contribute to the smooth and efficient operation of the carton cutter 10. For example, the first frame member 20 has a pair of guides 32, 32 that each provide support to finger latches 62, 62 located on either side of the blade receptacle 60. The first frame member 20 also has blade guide 34 which provides vertical support to the blade receptacle 60 and also serves to impede forward movement of the blade receptacle 60 when the finger latches 62, 62 come in contact with the rear of the guide 34. Preferably, the blade guide 34 incorporates a horizontal slot 36 which provides additional support to the blade receptacle 60 and helps ensure that the blade receptacle 60 proceeds in a straight line as forward pressure is applied to either one of the latches 62, 62. Additional support at the bottom surface of the blade receptacle 60 is provided internally by a track 37 at the bottom of the first frame member 20. At the front end 16 of the carton cutter 10 are two dimples 39,39 located on either side of the first frame member 20. The dimples 39, 39 give users who desire to access the interior of the housing a place to grip the first frame member 20 so that it can be rotated relative to the second frame member 40. A retention ear 38 provided on the first frame member 20 ensures that blade receptacle 60 remains slidably engaged to and does not significantly shift laterally, away from the cam 26. The retention ear 38 can be made of a resilient material and partially deform during assembly of blade receptacle 60 resulting in an assembly that stays fixed as needed. One of ordinary skill can appreciate that retention ear 38 can be substituted by an alternate mechanical fastener such as a shoulder screw or spring clip. One of ordinary skill can also appreciate that retention ear can be bonded or welded onto a first frame member after the attaching of a blade receptacle.
As shown most clearly in
Some physical principles involving utility knives and their use are of particular interest here prior to discussing the internal workings of the carton cutter 10 in more detail. When materials are cut using a sharp blade, the edge of the blade is generally forced into the work piece, forcing the material that is being cut away from the cutting edge. When this occurs, the material from the work piece is pressed on both sides of the blade and remains in the compressed state against either side of the blade. Using basic equations, the frictional force between the sides of the blade and the work piece can be determined using the equation Ff=μN, where Ff is the frictional force, μ is the coefficient of friction between the work piece and the sides of the blade, and N is the normal force against the sides of the blade from the work piece. Due to the frictional force between the sides of the blade and the work piece, there exists a force on the blade that the user must overcome to withdraw the blade from the work piece. It is this force that is of particular interest in that when the user applies a removing force, another force pulls on the blade, urging it forward in the general direction that the blade proceeds as it is extended into an exposed position.
With the foregoing physical principles in mind, it is helpful to describe the carton cutter 10 being operated in accordance with phases that make up a cycle.
With continued forward force applied by a user to a latch 62, the follower 70 beings to rotate clockwise approximately 35-45 degrees, and stops as shown in
When the user removes the forward sliding force, blade receptacle 60 and biasing member 66 retract rearward. With no additional forward force applied by a user to a latch 62, the follower 70 continues to rotate clockwise and stops as shown in
At the start of phase four, carton cutter 10 is in a cutting position and remains in such a position until the user retracts knife 10 from the work piece following a cutting process. When the carton cutter 10 is retracted from the work piece, the frictional force (second external force) acting on the blade overcomes the opposite urging force of biasing member 66, pulling the blade (and the blade receptacle 60) forward. The blade assumes an extended position having dimension C shown in
At phase two, the carton cutter 10 assumes a first open position, and at phase four, the carton cutter 10 assumes a second open position. Except for the internal orientation of the follower 70, the first open position and the second open position are substantially identical. Thus, as explained above, dimension C is often equal to dimension A. As the user continues applying force and completes a cutting process, the blade of the carton cutter detaches from the cardboard. Upon release, the blade automatically retracts and places utility knife 10 into a closed position. Overall, the extension and retraction mechanism of the utility knife 10 composed of the rotatable follower 70 and cam profile 30 and their respective surfaces produces movement of the blade receptacle 60 that is somewhat like the movement produced by a ballpoint click pen.
The accompanying drawings only illustrate a carton cutter and its constituent parts, however, other types and styles are possible, and the drawings are not intended to be limiting in that regard. Thus, although the description above and accompanying drawings contains much specificity, the details provided should not be construed as limiting the scope of the embodiment(s) but merely as providing illustrations of some of the presently preferred embodiment(s). The drawings and the description are not to be taken as restrictive on the scope of the embodiment(s) and are understood as broad and general teachings in accordance with the present invention. While the present embodiment(s) of the invention have been described using specific terms, such description is for present illustrative purposes only, and it is to be understood that modifications and variations to such embodiments, including but not limited to the substitutions of equivalent features, materials, or parts, and the reversal of various features thereof, may be practiced by those of ordinary skill in the art without departing from the spirit and scope of the invention. It should also be noted that the terms “first,” “second,” “upper,” “lower” and similar terms may be used herein to modify various elements. These modifiers do not imply a spatial, sequential, or hierarchical order to the modified elements unless specifically stated.
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