KNIFE BLOCK WITH INTEGRATED SHARPENER

BACKGROUND OF THE INVENTION
1. Field of the Invention

The present invention relates to knife blocks and knife sharpeners, and more particularly, to knife blocks which hold knives, flatware, and other cutlery, and electric knife sharpeners which sharpen knives.

2. Description of the Related Art

Countertop space in a kitchen is limited, constantly utilized, and integral to the kitchen's look, feel, and function. As a result, consumers often avoid large, clunky, countertop appliances, or quickly discard or relegate them to more distant locations in or outside of the kitchen where they collect dust and are often never used again. However, some kitchen items are fairly ubiquitous despite their large countertop footprints. Wooden knife blocks, for example, store and maintain high quality knives, flatware, or other cutlery consumers use to prepare meals. A knife block holds knives at an angle relative to the surface of the countertop, maintains them separate from one another and other kitchen surfaces, and generally has an aesthetically pleasing appearance. In short, knife blocks help make a kitchen look and feel like a kitchen, and contribute to the culinary experience.

High quality knives and/or other cutlery stored in knife blocks often become dull after repeated use and need to be sharpened. Many consumers, including those who regularly cook and prepare meals, have never used commercially available knife sharpeners, let alone electric knife sharpeners. While such consumers may want to sharpen their knives, many are unsure how to use a knife sharpener, may consider it too complicated or time consuming, and/or are unwilling to purchase another appliance that will take up additional space on the countertop or shelf space anywhere else. Additionally, consumers may be nervous about the knife sharpening process (i.e., figuring out how to set up and mount the knife sharpener, how to hold a knife properly against an electrically powered grinding wheel, etc.). This results in more dull knives, which can lead to more kitchen accidents as duller knives require more force to cut. In city apartments where space is often more limited, consumers may be even less likely to own this type of additional appliance that would require additional figuring out and repeated setup and storage after use. Thus, there is a need in the art for improved knife sharpener systems that are more accessible, easy to use, less intimidating to consumers, and take up less space alongside conventional knife block holders.

OBJECTS AND SUMMARY OF THE INVENTION

This summary is not intended to identify or point to essential features or limit the scope of the subject matter claimed herein. The present invention relates to systems and methods for a knife block with an integrated electronic sharpener, with at least the following objectives:

To integrate an electric knife sharpener into a knife block with minimal or no increase in the knife block's footprint on a countertop (i.e., a kitchen countertop), and while preventing built-in sharpener components from contacting the knife block's housing or the knives it stores;

To allow for proper heat ventilation of a knife block housing with an integrated electric powered sharpener;

To minimize sound and vibration during use of the integrated knife-block sharpener system;

To enable a user to easily manipulate the integrated knife-block sharpener system to a closed configuration for storing knives and an open configuration for sharpening the knives;

To ensure user safety and a wiring configuration of the integrated knife-block sharpener system which is long lasting, inconspicuous, and accommodates translatable movement of the electric knife sharpener through the knife block's housing between the open and closed configurations; and

To satisfy a user's ergonomic needs during use of the integrated knife-block sharpener while maintaining a pleasant aesthetic appearance thereof.

In accordance with one embodiment of the invention, a knife block system for holding and sharpening one or more knives includes a knife block and a knife sharpener assembly. The knife block has a housing and defines a plurality of slots for receiving the knives. The knife sharpener assembly is operatively associated with the housing, and movable relative to the housing between a closed configuration within the housing and an open configuration extending out of the housing.

In certain embodiments, in the closed configuration, the knife sharpener assembly is fully nested within the housing of the knife block and hidden from view. In the open configuration, the knife sharpener assembly is accessible by a user to sharpen the knives. In other embodiments, the knife sharpener assembly is electric, linearly translatable between the open and closed configurations, and includes a motor, an axle, and a grinding wheel mechanically coupled to one another. The knife sharper assembly is supported by a movable housing such as a carriage which is longitudinally translatable into and out of the housing of the knife block.

In accordance with another embodiment of the invention, a method of accessing a knife sharpener assembly operatively associated with a knife block includes moving the knife sharpener assembly relative to the knife block from a closed configuration within the housing to an open configuration extending out of the housing, with the knife sharpener assembly biased toward the open configuration. In certain embodiments, the knife block defines an interior region, and moving the knife sharpener assembly includes pressing an end portion of a housing supporting the knife sharpener assembly toward the interior region, and releasing (i.e., ceasing to press) the end portion of the housing. The knife sharpener assembly may be spring biased to translate out of the interior region following releasing of the end portion of the housing. In yet other embodiments, the knife sharpener assembly is electric and includes a motor, an axle, and a grinding wheel which are mechanically coupled to one another and configured to linearly translate relative to the knife block.

Other features of the knife block system and methods for use thereof are explained in greater detail below. The present invention describes numerous embodiments, features, and variations of the invention, and provides non-limiting examples of such embodiments, features and variations. Titles and headers are provided for convenience and ease of reading. In accordance with such further embodiments of the invention, the below detailed description and claims provide additional limitations, either in system or process form. It will be appreciated that for each system described and claimed, the invention also includes the methodologies corresponding thereto.

Other objects, advantages, features, and characteristics of the present invention, as well as the methods of operation and functions of related structural elements, and the combination of parts and economies of development and manufacture, will become readily apparent to those of ordinary skill in the art upon consideration of the detailed description with reference to the accompanying drawings, all of which form a part of this specification.

BRIEF DESCRIPTION OF DRAWINGS

The drawings are not intended to limit the scope of this invention, which is set forth with particularity in the claims as appended or as subsequently amended, but merely to clarify and exemplify the invention. Accordingly, a further understanding and a more complete appreciation of the present invention and many of the attendant aspects thereof may be readily obtained as the same becomes better understood by reference to the following detailed description, when considered in conjunction with the accompanying drawings, where:

FIG. 1A is a perspective view of an integrated knife-block sharpener system shown in a closed configuration in accordance with the invention;

FIG. 1B is a perspective view of the integrated knife-block sharpener system of FIG. 1A, shown in an open configuration;

FIG. 2A is a cutaway perspective view of a casing and an electronic sharpener assembly of the knife-block sharpener system of FIG. 1A, shown in a closed configuration;

FIG. 2B is a cutaway perspective view of the casing and the electronic sharpener assembly of FIG. 2A, shown in an open configuration;

FIG. 3 is a bottom perspective view of the integrated knife-block sharpener system of FIG. 1A, shown in an open configuration;

FIG. 4 is an additional bottom perspective view of the integrated knife-block sharpener system of FIG. 1A, shown in an open configuration with a partially exploded perspective view of the electronic sharpener assembly;

FIG. 5 is an enlarged bottom perspective view of the casing and carriage supporting the sharpener assembly of FIG. 2A, shown in an open configuration;

FIG. 6 is a top cut away perspective view of the casing and sharpener assembly of FIG. 2A, shown in a closed configuration;

FIG. 7 is a top cut away perspective view of the sharpener assembly of FIG. 2A, shown in a closed configuration;

FIG. 8A is a perspective view of an alternative embodiment of an integrated knife-block sharpener system in a closed configuration, in accordance with the invention;

FIG. 8B is a bottom perspective view of the integrated knife-block sharpener system of FIG. 8A, shown in the closed configuration;

FIG. 9 is a top perspective view of the casing and sharpener assembly of FIG. 8A, shown in a closed configuration;

FIG. 10 is a top cut away perspective view of the casing and sharpener assembly of FIG. 8A, shown in a closed configuration; and

FIG. 11 is a side perspective cut away partially exploded view of the sharpener assembly and casing of the integrated knife-block sharpener system of FIG. 8A.

DETAILED DESCRIPTION OF THE INVENTION

The present disclosure is not intended to be limited to the specific terminology selected, and it will be understood that each specific element of all embodiments of the knife-block sharpener systems of the invention, illustrated in FIGS. 1A-7 and 8A-11, includes all technical equivalents which operate in a similar manner. Techniques, methods, systems, and operating structures in accordance with the invention may be embodied in a wide variety of forms and modes, some of which may be quite different from those in the disclosed embodiments. Consequently, the specific structural, functional, and step-by-step details disclosed herein are merely representative. The embodiments herein are described in sufficient detail to enable those skilled in the art to practice the embodiments, and it is to be understood that logical, mechanical, and other changes may be made without departing from the scope of the embodiments, and that the description herein is not to be taken in a limiting sense.

Each element in methodologies described herein depict a step or a group of steps for using an integrated knife-block electric sharpener assembly. Each step may contain one or more sub-steps. For purposes of illustration and explanation, these steps, as well as all other steps identified and described, are presented in a certain logical order. However, it will be appreciated that any exemplary embodiments described herein can contain an alternate order of the steps adapted to a particular application of a technique disclosed, and that any such variations and/or modifications are intended to fall within the scope of the invention. The depiction and description of steps in any particular order is not intended to exclude embodiments having the steps in a different order, unless required by a particular application, explicitly stated, or otherwise clear from the context.

It will be appreciated that the various embodiments described herein may be supplemented with and/or engaged by (e.g., communicated with and/or operated by) a wireless electronic device or an electronic interfacing mobile app on an internet enabled mobile device's operating system, such as, for example, Android, iOS, or Windows Phone OS, and in part by using a web interface. Electronic systems described herein may also include a stationary or portable computing device which can actuate electrical components, and may comprise various preprogrammed features combined and integrated with basic components, including but not limited to, one or more servers, databases, mobile end applications, web portals, network settings, etc. With the support of these components, the system may provide various services and functionalities, such as remote operation, related to the system's use and features through user interfaces such as a website or mobile applications.

As further described below, the knife block with integrated sharpener (also referred to herein as ‘knife block assembly’ and ‘knife-block sharpener system’) of the present invention is configurable to a closed configuration in which the sharpener is hidden from view inside the housing of the knife block, and an open configuration in which the sharpener is visible and easily accessible by the user. The footprint of the knife block assembly of the invention, when placed on a countertop while housing both the knives and the electric sharpener, is the same or substantially the same as that of a conventional knife block. As also further discussed below, the present invention accomplishes this minimization of the system's footprint by translating and retracting an electric sharpener into and out of the knife block's housing. The user is able to switch between open and closed configurations by simply pressing a side panel of the device (i.e., a portion of a housing/carriage supporting the electric sharpener assembly). This panel is flush with the housing of the knife block in the closed configuration.

A spring-loaded translatable inner housing (e.g., a carriage or cartridge) which supports the electric sharpener assembly is nested inside a casing that is permanently mounted within and/or part of the knife block housing. When the user presses the side panel, a portion of the translatable carriage is initially forced further into the knife block housing against the bias of a longitudinally extending spring attached at respective ends to the knife block housing and the translatable carriage. When the user releases (i.e., stops pressing the side panel), the compressed spring then forces a portion of the carriage and knife block assembly out of the knife block housing.

In this manner, the user is able to dislodge a carriage supporting an electric sharpener assembly from the closed configuration to the open configuration, and to lodge it from the open configuration back into place in the closed configuration by once again pushing the side panel against the bias of the longitudinally extending spring. The carriage may be held in place by any suitable interlocking stopping mechanism, such as a detent or an interfacing spring loaded latch or ratchet mechanism on or within the housing that stops the carriage from being pushed out by the spring until it is forcibly translated by the user.

In certain embodiments, a bearing wheel mechanically coupled and longitudinally fixed to the carriage supports the carriage on and translates relative to the countertop surface on which the knife block assembly is supported. In this manner, the electric sharpener is supported by the bearing wheel while being guided out of the knife block housing along the countertop surface to an extended position where it is accessible by the user, and guided back into the knife block by the user against the bias of the spring. The bearing wheel also prevents the countertop from being scratched by the sharpener carriage as the carriage translates relative thereto.

In other embodiments, the grinder wheel and/or other components of the electric sharpener assembly are replaceable by the user in the open configuration. A coupling gear transmits torque from an axle of the motor to the grinding wheel of the electronic sharpener during use, and allows for easy removal (e.g., vertically) by the user in tight spaces. In yet other embodiments, the motor axle and an axle of the electronic sharpener may be affixed with a set screw, which also allows for easy (e.g., vertical) removal of one or more sharpener assembly components from the carriage without removing the motor, and without allowing the user access to wiring and/or other sensitive parts of the device.

In yet other embodiments, an on/off switch is provided on the side panel of the carriage of the electronic sharpener. The on/off switch is easily accessible by the user in both the open and closed configurations, and is translatable with the carriage relative to the housing. Such placement of the on/off switch enhances user safety and allows a user to quickly find the on/off switch at any time and in any configuration of the device.

The specifics of these features and others of the invention are best understood with reference to the exemplary embodiments of the invention illustrated by and described with respect to FIGS. 1A-11.

Housing & Carriage Assemblies

Referring now to FIGS. 1-5, an integrated knife-block sharpener system 100 in accordance with the invention includes a housing 102 defining a plurality of front and rear slots 104, 106 configured to store a plurality of knives and/or other cutlery. Such knives may be, by way of example, an eight inch chef knife, slicer knife, and/or bread knife, a seven inch santoku knife, a five and a half inch utility knife, a four and a half inch serrated steak knife, a three and a half inch paper knife, knives with forged German steel blades, kitchen shears, and other types of knives and precision crafted stainless steel cutlery. Housing 102 also defines a triangular shaped recess 107 configured to receive a casing 113 which houses an electronic sharpener assembly 109 (FIG. 2A). Housing 102 includes a generally rectangular-shaped front panel 112 configured to be rearwardly inclined (e.g., away from a user) relative to a horizontal countertop surface 10, and a rearward block portion 116 defining the front and rear slots 104, 106. As shown, block portion 116 defines slots of different sizes and/or angles, and is forwardly inclined (e.g., toward the user), whereby handles of knives stored in slots 104, 106 extend generally parallel to a rear surface 119 (FIG. 4) of block portion 116 (i.e., the knives are forwardly inclined toward the user).

By way of example, in certain embodiments, the angle at which slots 104, 106 guide the knives into block portion 116 is approximately thirty degrees relative to countertop 10 (e.g., sixty degrees relative to a vertical orientation). It will be appreciated that this angle may vary, and represents a balance between placing the knives at an angle at which they are easy to remove and minimizing the depth of footprint on countertop 10 by block portion 116. Other angles may be utilized. Block portion 116 is also stepped into rear and forward portions 116a, 116b as shown, and accommodates longer knives inserted into slots 106 in rear portion 116a.

Front panel 112 and block portion 116 may be integrally formed or separately mounted together by set screws, brackets, adhesive, or any other suitable means. Together, front panel 112 and block portion 116 of housing 102 define the triangular shaped recess 107 which accommodates casing 113. As shown in FIG. 1A, integrated knife-block sharpener system 100 functions as a standalone device. Electronic sharpener assembly 109 may be powered by electrical power routed thereto via wire guide 115 (FIG. 2A), and/or battery powered, as further discussed below.

Housing 102 and casing 113 may be separately formed and connected to one another in any suitable manner, or integrally formed as a single housing. As best shown in FIG. 3, casing 113 has a triangular cross section and may be configured to press-fit into triangular shaped recess 107 defined by block portion 116 and front panel 112. Casing 113 may additionally or alternatively be mounted to housing 102 by screws 117. Housing 102 and/or casing 113 may be formed from any desired material, such as, for example, wood, plastic, plastic polymers, and the like, and in varying sizes and shapes to store and enclose differently shaped knives and electronic sharpener assemblies. In certain embodiments, casing 113 is made from stainless steel or other material which conducts heat generated therein, via wire guard 115, outside of housing 102.

As best shown in FIGS. 2A-2B, casing 113 is generally hollow, and includes front panel 118 mounted to an inside surface of front panel 112 of housing 102 via any suitable means (e.g., screws, brackets, adhesives, and the like), generally triangular-shaped side panels 114a, 114b detachably coupled to or integrally formed with front panel 112 of housing 102, and a rectangular bottom panel 120 equipped with feet 122 (FIGS. 3-5) configured for placement on countertop surface 10. Thus, when integrated knife-block sharpener system 100 is operatively disposed on countertop 10 as shown in FIG. 1A, feet 122 contact countertop 10, bottom panel 120 of casing 113 is elevated relative to countertop 10, and a base surface 124 of block portion 116 also contacts countertop 10. In other words, bottom surface 124 of block 116 and feet 122 of casing 113 rest on countertop 10 to support integrated knife-block sharpener system 100. Alternatively, as components described herein may vary in size and configuration, feet 122 may be formed at different heights on various bottom surfaces of components of integrated knife-block sharpener system 100 to ensure that it is level with countertop 10, and that electric sharpener assembly 109 translates level (i.e., parallel) to countertop 10.

As shown in FIGS. 1B and 2B, side panel 114b of casing 113 defines a channel 108 for receiving and allowing longitudinal translation of a portion of a carriage 110 supporting electric sharpener assembly 109 into and out of casing 113, and thus, into and out of housing 102. In this manner, integrated knife-block sharpener system 100 is configurable to an open configuration (FIG. 1B) in which carriage 110 is extended outside of housing 102, and to a closed configuration (FIG. 1A) in which carriage 110 and electric sharpener assembly 109 are fully retracted and nested inside casing 113, which is itself permanently nested within housing 102.

It will be appreciated that in the closed configuration of FIG. 1A, carriage 110 and electric sharpener assembly 109 are not visible to the user, and the integrated knife-block sharpener system 100 has the overall appearance and general footprint of a standard knife block which contains no electronic or sharpening devices. By way of example, in certain embodiments, integrated knife-block sharpener system 100 may have overall dimensions of approximately 8.0 inches in width, 9.3 inches in depth, and 8.75 inches in height in the closed configuration, and approximately 12.75 inches in width, 9.3 inches in depth, and 8.75 inches in height in the open configuration. Other dimensions may be utilized.

In addition to this benefit, the rearward tilt of front panel 112 gives a user additional working space above countertop 10. Since a conventional knife block generally has a forward tilt toward the user, its real footprint on a countertop extends beyond the footprint of its base. Front panel 112 of housing 102 also supports a name plate 105, and functions as sound barrier by blocking/muffling noise from the motor 148 of the electric sharpener assembly 109 (further discussed below), which remains within casing 113 and housing 102 in both the open and closed configurations.

It will be appreciated by those skilled in the art that by nesting the removable carriage 110 containing the electronic sharpener assembly 109 adjacent forwardly tilted block 116, a portion of already unusable countertop space (i.e., the portion of countertop 10 below edge 121 of front panel 112) is effectively and efficiently utilized to support the hidden electric sharpener assembly 109. Furthermore, by accommodating carriage 110 and electric sharpener assembly 109 within the footprint of housing 102, and allowing for easy translation of carriage 110 into and out of housing 102, any additional countertop space taken up by carriage 110 in the open configuration of FIG. 1B is only temporary during sharpening. Thus, integrated knife-block sharpener system 100 takes up the same or similar countertop footprint as a conventional knife block, provides a built-in electric sharpener which extends and retracts into an ergonomically advantageous position with the sharpener fully supported, and takes up minimal additional space in the open configuration.

Power Switch & Wire Guide

As further shown in FIGS. 1A-2B, an on/off switch 126 used to turn on and off electric sharpener assembly 109 is mounted to a proximal end 128 of carriage 110. On/off switch 126 is visible and easily accessible in both the open and closed configurations. As shown, in the closed configuration of FIG. 1A, proximal end 128 of carriage 110 is flush with side panel 114b of casing 113, and effectively becomes part of the side panel of the outer housing of the integrated knife-block sharpener system 100. More particularly, in the closed configuration, proximal end 128 of carriage 110, side panel 114b of casing 113, and a side surface 130 of block portion 116 are preferably flush with one another.

In certain embodiments, inner brackets 129a, 129b (FIG. 2A) within casing 113 may be used to guide mounting of casing 113 to a front section of block portion 116 (e.g., via internal sidewalls of block portion 116 received within or mounted to brackets 129a, 129b). In the open configuration of FIG. 1B, on/off switch 126 has translated with carriage 110, and is operatively disposed adjacent slots 132, 134 of electric sharpener assembly 109 (further discussed below) where knives are inserted for sharpening.

In this manner, on/off switch 126 is always readily accessible by the user, easy to find, and located very close to where a user's hands will be when using integrated knife-block sharpener system 100 in either the open or closed configurations. In particular, on/off switch 126 is always operatively disposed at or adjacent where the user's hand will be when operating the carriage 110 in the extended or retracted position, and/or when using the electric sharpener assembly 109 in the open configuration.

On/off switch 126 is electrically coupled to a power supply routed to electric sharpener assembly 109 via wires in wire guide 115 (FIGS. 2A-4). Wire guide 115 extends rearwardly from bottom panel 120 of casing 113, and has a hollow rectangular tube structure 136 which is open at the top and defines a channel 138 therethrough (FIGS. 2A, 2B) for receiving wiring and other circuitry (not shown). Wire guide 115 also includes a laterally extending member 140 oriented perpendicular to rectangular tube structure 136. Rectangular tube structure 136 and laterally extending member 140 of wire guide 115 are received by grooves 142 defined in base surface 124 of block portion 116 (FIG. 3). Lateral member 140 is also equipped with feet 122 to further support integrated knife-block sharpener system 100.

It will be appreciated that this elegant wiring design routes wires/cords rearwardly from electric sharpener assembly 109, under the base of housing 102 of knife block 116, to an exit point 144 at a rearmost location of housing 102 (FIG. 3), at which housing 102 may include a port where the wires/chords within wire guard 115 can be electrically coupled to a power source such as a wall socket or countertop outlet, or to one or more batteries or to a power supply device powered by one or more batteries. Wire guide 115 may be configured with a cover to protect the wiring and other electrical components therein. Connection of a power source such as an outlet to the wiring in wire guide 115 may be facilitated by, for example, a power chord which plugs into a port at exit point 144. The power chord may thus be removable for separate storage if desired.

Conventional knife blocks do not connect to electrical cords or have wiring passing through and exiting them because they do not incorporate or provide electronic appliance functionality. Wire guide 115 of the present invention and its mounting within the base of block portion 116 prevents tangling of electrical wires on countertop 10, and improves visibility by maintaining a clean wireless countertop in front of and on the sides of knife-block sharpener system 100 in both the open and closed configurations. In other embodiments, electric sharpener assembly 109 may be configured with one or more batteries operatively disposed inside casing 113 or carriage 110, and configured to electrically power motor 148. Alternatively, as noted above, one or more batteries or a power supply powered by one or more batteries may located outside of housing 102, and be configured to electrically couple to wiring in wire guide 115 to power motor 148.

Housing the wiring/cord in tube structure 136, recessed within and at the bottom of knife block 116, also prevents it from interfering with or being cut by the plurality of knives received within housing 102 in slots 104, 106, and thus helps prevent electrical hazards. Rectangular tube structure 136 also thermally and electrically isolates the wiring/cord routed through channel 138, hold the wires in place, and protects them from entanglement and puncture. Wire guide 115 may also be formed of any suitable material, but if made from metal, may additionally function as a thermal conduit through which heat generated by electric sharpener assembly 109 within casing 113 is conducted out of housing 102. As noted above, casing 113 may also be made from metal, such as stainless steel, and thus conduct heat to wire guide 115 and out of housing 102.

As shown in FIGS. 2A-2B, wire guide 115 has a forward end 146 where it attaches to bottom panel 120 of casing 113, and at which a wiring/cord/plug may exit and directly couple to electrical components within electric sharpener assembly 109, such as motor 148 via slot 149 in carriage 110. Corners 146a, 146b of forward end 146 of wire guide 115 may be rounded to reduce friction against wires/chords exiting wire guide 115 at end 146, particularly when the wiring at this location is moved when carriage 110 is moved between the open and closed configurations. It will be appreciated that wiring entering slot 149 may also translate with carriage 110.

For example, as shown, motor 148 translates with carriage 110 between the open configuration (FIGS. 1B, 2B) and the closed configuration (FIGS. 1A, 2A), but always remains within casing 113. In other embodiments, motor 148 and wiring which exits wire guide 115 may be fixed to bottom panel 120 of casing 113, and motor 148 may be rotatably coupled to a longitudinally translating shaft which moves with carriage 110 within casing 113 for powering electric sharpener assembly 109. In other words, carriage 110 may be configured such that it slides out of casing 113 and housing 102 without moving motor 148 or wiring thereof, which remain static within housing 102. Electric sharpener assembly 109 is preferably configured within carriage 110 such that motor 148 remains fully within casing 113 and housing 102 in both the closed configuration and the open configuration when carriage 110 extends out of housing 102.

Spring & Roller Assembly

Continuing with respect to FIGS. 2B, 4, and 5, in certain embodiments, bottom panel 120 of casing 113 and a bottom panel 123 (FIG. 4) of carriage 110 define respective longitudinal slots 150, 160 configured to receive a longitudinally extending spring 170 (FIG. 4). Slot 150 also functions to vent heat generated by motor 148 and other sharpener assembly components 109 within casing 113. Spring 170 extends from a proximal end 170a attached to bottom panel 123 of carriage 110, preferably within slot 160, to a distal end 170b attached to bottom panel 120, preferably within slot 170. Spring 170 may alternatively be attached to different portions of bottom panel 123 or of carriage 110 generally at its respective proximal and distal ends 170a, 170b. Distal end 170b of spring is thus longitudinally fixed to casing 113 and housing 102, and proximal end 170a of spring moves longitudinally with carriage 110.

In certain embodiments, spring 170 is in compression when knife-block sharpener system 100 is in the closed configuration of FIGS. 1A, 2A. Spring 170 is also preferably in a relaxed state in the open configuration of FIGS. 1B, 2B, and when in the closed configuration, is spring biased toward the open configuration of FIGS. 1A, 2A. A detent in bottom panel 120 or a side panel of casing 113 may be configured to interface with a protrusion from carriage 110 to hold carriage 110 in place when in the closed configuration. Other conventional fixing mechanism may be utilized in casing 113 to longitudinally fix carriage 110 in the closed position of FIGS. 1A and 2A.

Spring 170 thus functions to push a portion of carriage 110 through channel 108 and out of casing 113 and housing 102 to the open configuration of FIG. 1B when a user dislodges carriage 110 (e.g., removes it from a detent or other conventional fixing and release mechanism, such as, for example, a stopper) by distally pressing proximal end 128 of carriage 110. The further compressed spring then pushes carriage 110 out of housing 102 when the user stops pushing proximal end 128 of carriage. Once system 100 is in the open configuration, spring 170 is then preferably in a fully relaxed state so that it does not pull, retract, or otherwise move carriage 110 when electric sharpener assembly 109 is being utilized, but is placed in compression when carriage 110 is pushed by the user back into casing 113. In other embodiments, electric sharpener assembly 109 may be configured without spring 170 or any bias toward the open configuration. In such embodiments, carriage 110 may be formed with a small handle or other gripping feature which the user can grasp to slide carriage 110 in and out of housing 102. In yet other embodiments, multiple springs may be utilized, housed within compartments, and/or connect to the distal end of carriage 110 inside casing 113, and to an interior surface of side panel 114a.

Referring to FIG. 5, carriage 110 is also equipped with a roller or bearing wheel 152 and a stopper 154 for guiding, supporting, and limiting translation of carriage 110 between the open and closed configurations. Bearing wheel 152 is longitudinally fixed to carriage 110 and configured to roll on countertop 10 and support proximal end 128 of carriage 110. When carriage 110 is retracted into casing 113, stopper 154 is received within a groove or notch 158 defined by a sidewall of bottom panel 120 of casing 113 to limit longitudinal translation of carriage 110 into housing 102. It will be appreciated that this stopping mechanism will prevent a user from pressing carriage 110 into housing 102 too forcefully, and help protect motor 148 and the rest of electric sharpener assembly 109 from being damaged. Bearing wheel 152 may be configured in a number of different shapes and sizes, and adjusted in size or height so that it contacts and rolls on countertop 10 when carriage 110 is longitudinally translated out of housing 102.

Spring 170 may be mounted such that proximal end 170a thereof is attached to bottom panel 123 of carriage 110 as described above, a middle section 170c thereof passes under notch 158, and distal end 170b attaches to bottom panel 120 of casing 113 at a height closer to countertop 10 than proximal end 170a, but still within groove 150 to avoid contact with countertop 10. It will be appreciated that this positioning of spring 170 in slots 150, 160 of casing 113 and carriage 110 will also facilitate easy assembly.

When a user pushes proximal end 128 of carriage 110 in the closed configuration, carriage 110 slides distally within housing 102, over the detent or other stopping mechanism (if provided), thus further compressing spring 170. By way of example, a detent 147a may be provided on carriage 110 configured to receive a metal spring loaded ball bearing 147b (FIG. 2B). In certain embodiments, spring loaded ball bearing 147b may be mounted to a wall in support bracket 129b, extend through and protrude from the opposite side of the wall (hidden), and be received by detent 147a in carriage 110. When the user pushes proximal end 128 of carriage 110 in the closed configuration of FIGS. 1A, 2A, carriage 110 may move slightly (i.e., an eighth of an inch or more) distally, popping spring loaded ball bearing 147b out of detent 147a, further compressing spring 170.

Spring 170 is further compressed, and thus pushes with greater force, and when the user releases (i.e., stops pressing proximal end 128 of carriage 110), spring 170 and the momentum of carriage 110 forces now proximally moving carriage 110 to overcome resistance from potential reengagement of detent and ball bearing (147a, 147b) and out of the housing 102 to the open configuration of FIGS. 1B, 2B. Carriage 110 may then be slowly pushed back inside casing 133 by the user. Stopper 154 prevents the user from pushing carriage 110 back into housing 102 too firmly, thereby protecting motor 148 and other components of sharpener assembly 109. Once in housing 102, detent and ball bearing 147a, 147b reengage and hold carriage 110 in housing despite the distal force of compressed spring 170. Other stopping mechanisms, interference fit engagements, latches, etc. may be utilized. In this manner, the user can simply push on proximal end 128 side of carriage 110 when it is flush with housing 102 to pop out carriage 110 with electric sharpener assembly 109, and then press on/off switch 126 (further discussed below) to turn on electric sharpener assembly 109.

Modular Electric Sharpener Assembly

Referring now to FIGS. 6-7, electronic sharpener assembly 109 is housed within casing 113, and includes motor 148 mechanically coupled, via coupling gears 162a, 162b and bearings 168, to a first pair of grinding/cutting wheels 164a, 164b and a second pair of grinding/cutting wheels 166a, 166b. Each respective pair of cutting/grinding wheels (164a, 164b), (166a, 166b) is used to sharpen respective left and right sides of a knife at a different cutting/abrasion levels (e.g., gradations) depending on the blade type of the knife and/or level of sharpening needed. Diamond grinding wheels may be utilized.

As shown in FIGS. 2A, 2B, rounded sharpener sections 171, 173 respectively cover each pair of cutting wheels (164a, 164b), (166a, 166b). Sharpener sections 171, 173 may be formed from any suitable material, such as plastic with a stainless-steel outer facia. Sharpener sections 171, 173 define slots (171a, 171b), (173a, 173b) on opposite sides thereof for receiving a knife and guiding it to cutting wheels (164a, 164b), (166a, 166b) at a proper angle. A user can simply pull the blade of a knife through one of the guided slots (171a, 171b), (173a, 173b) to sharpen the blade. In certain embodiments, the angle at which slots (171a, 171b), (173a, 173b) guide the knives for sharpening is approximately 20 degrees. Other angles may be utilized.

Thus, electronic sharpener assembly 109 provides a four-slot design which gives a user two different options for a sharpening level at which he or she may sharpen both sides of a knife. For example, one pair of the slots (i.e., 171a, 171b) may sharpen opposite sides of a knife to one sharpening level, and slots 173a, 173b may be configured to sharpen opposite sides of a knife to another level. One of the pair of slots may be configured to more fine-tuning of the sharpening than the other pair (i.e., to take off less material). For example, one pair of the slots may be for sharpening and the other for honing. By aligning motor 148 and sharpener axle 172 in carriage 110 and moving/translating them in the same direction as the axis of the sharpener, motor 148 is able to run more efficiently while producing less noise. Bearings 169 further help minimize sound and vibration. A thermoplastic rubber pad/gasket may also be provided for additional noise reduction.

Coupling gears 162a, 162b interface axially to one another along a male/female connective interface 163 which axially transfers torque from motor 148 to the axle upon which the cutting wheels (164a, 164b), (166a, 166b) are mounted. Coupling gears 162a, 162b also allow the various components of electronic sharpener assembly 109 to be more easily decoupled from motor 148. By way of example, if the cover of carriage 110 is removed, coupling gear 162b can simply be lifted vertically along with other components without axially separating them from motor 148. In other words, while electronic sharpener assembly 109 is axially translatable, the components thereof may be axially fixed relative to one another in carriage 110 by virtue of being axially adjacent one another, but separable from motor 148 by lifting them vertically (i.e., in a direction perpendicular to the axle) since rotational coupling is achieved by rotative interference of coupling gears 162a, 162b during rotation thereof, not by axially fixing them to one another.

In certain embodiments, a cover of electronic sharpener assembly 109 may be divided into two parts, with one side covering motor 148 and permanently fixed in place such that it cannot be removed by a user, and a separate removable covering which exposes a sharpening region 176. If a consumer desires to replace sharpening/cutting wheels 164a, 164b, 166a, 166b once they become dull, he or she can simply pop out carriage 110 in the manner described above, remove the removable portion of the cover from casing 113, and remove/install various bearings, axles, sharpening wheels, hubs, etc.

As shown in FIG. 7, one or more magnets 174 may be provided inside carriage 110 for attracting/collecting metal burs, shavings, and the like inside carriage 109 when knives are sharpened. When the user removes the removable portion of the cover, any metal dust that has accumulated in carriage 110 during sharpening may be wiped off of magnet 174 and removed. The electronic sharpener assembly 109 of knife-block sharpener system 100 may additionally or alternatively utilize various components, knife guides, angular ranges, motorized components, and the like of conventional electronic knife sharpeners in conjunction with the various system embodiments and methodologies described herein. Examples of such conventional electronic knife sharpeners are disclosed in, for example, U.S. Pat. No. 10,814,451, filed Mar. 13, 2018 and titled ‘Powered sharpener with controlled deflection of flexible abrasive member’; U.S. Pat. No. 9,656,372, filed Jan. 11, 2016 and titled ‘Sharpener for thick knives’; U.S. Pat. No. 9,168,627, filed Mar. 11, 2011 and titled ‘Knife sharpener for Asian and European/American knives’; U.S. Pat. No. 7,854,650, filed Jan. 24, 2007 and titled ‘Knife Sharpener’; U.S. Patent Pub. No. 2010/0099338, filed Dec. 25, 2009 and titled ‘Knife Sharpener’; and U.S. Patent Pub. No. 2009/0209177, filed Jul. 9, 2007 and titled ‘Knife Sharpener’, which patents and patent publications are hereby incorporated by reference herein in their entireties.

Referring now to FIGS. 8A-11, an alternative integrated knife-block sharpener system 200 in accordance with the invention is similar to integrated knife-block sharpener system 100, except that system 200 provides a two-slot design which utilizes a single pair of cutting/grinding wheels, and is thus more simplified. All components and functionalities described above with respect to system 100 may be applied to system 200.

By way of example, system 200 includes a housing 202 defining a plurality of front and rear slots 204, 206 configured to store a plurality of knives 203, and a triangular shaped recess 207 configured to receive a casing 213 which houses an electronic sharpener assembly 209 (FIG. 10). Knives 203 may similarly be placed in slots 104, 106 of system 100. Housing 202 similarly includes a generally rectangular-shaped front panel 212 configured to be rearwardly inclined (e.g., away from a user) relative to a horizontal countertop surface 210, and a rearward block portion 216 defining the front and rear slots 204, 206. Casing 213 houses an electronic sharpener assembly 209 (FIG. 10) in a carriage 210 which is similarly longitudinally translatable out of housing 202 through channel 208 via a spring and roller/bearing wheel 252 assembly as described above. An on/off switch 226 is also provided which is accessible in open and closed configurations.

As shown in FIGS. 9-10, casing 213 similarly includes wire guard 215, but is smaller than casing 113 because electronic sharpener assembly 209 contains a single pair of grinding/cutting wheels 264a, 264b. More particularly, electronic sharpener assembly 209 is housed within casing 213, and includes a 264248 mechanically coupled, via coupling gears 262a, 262b to grinding/cutting wheels 264a, 264b, which are used to sharpen respective left and right sides of a knife at a particular cutting/abrasion level/gradation. A single rounded sharpener section 271 (FIG. 9) is provided which covers cutting wheels 264a, 264b. Sharpener section 271 defines slots 271a, 271b on opposite sides thereof for receiving a knife and guiding it to cutting wheels 264a, 264b at a proper angle. Thus, electronic sharpener assembly 209 provides a two-slot design for sharpening a knife. In certain embodiments, alternative integrated knife-block sharpener system 200 may have overall dimensions of approximately 6.5 inches in width, 9.3 inches in depth, and 8.75 inches in height in the closed configuration, and 9.375″ in width, 9.3″ in depth, and 8.75 inches in height in the open configuration.

Referring to FIG. 11, in certain embodiments, electronic sharpener assembly 209 may further comprise a detachable center piece 273 with sharpener section 271 for allowing cleaning and/or access to various sharpener components for servicing. In certain embodiments, electronic sharpener assembly 209 may further include a set screw 275 for holding coupling gears 262a, 262b together. These components may alternatively or additionally applied to integrated knife-block sharpener system 100.

The present disclosure is not intended to be limited to the specific terminology selected, and it will be understood that each specific element referenced includes all technical equivalents which operate in a similar manner. However, techniques, methods, systems, and operating structures in accordance with the invention may be embodied in a wide variety of forms and modes, some of which may be quite different from those in the disclosed embodiments. Consequently, the specific structural, functional and step-by-step details disclosed herein are merely representative. The embodiments herein are described in sufficient detail to enable those skilled in the art to practice the embodiments, and it is to be understood that logical, mechanical, and other changes may be made without departing from the scope of the embodiments. The detailed description disclosed herein is therefore not to be taken in a limiting sense.

It will be understood that the above-described embodiments and arrangements are merely illustrative of the many possible specific embodiments which represent applications of the present invention, and that numerous and varied other arrangements and configurations can be readily devised without departing from the spirit and scope of the invention and equivalents thereof.

KNIFE BLOCK WITH INTEGRATED SHARPENER

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