Not Applicable
1. Field of the invention
The present invention relates to the field of utility knives and specifically to such knives as use a segmented blade from which dull segmented can be broken off.
2. Background Information
Utility knives in their many forms are well known in the art. They are used by a wide variety of trades people, and others, on a daily basis. Utilizing disposable blades, they offer an easy method of having a sharp knife readily available without the need to stop for sharpening.
“Snap knives”, or utility knives which use a segmented blade from which segments are snapped off, and disposed of, as they become dull are also well known in the art. It is generally quicker to get a “new” cutting edge with a snap knife than a conventional utility knife as the blade does not need to be removed and replace (or reversed). Instead the blade is merely advanced beyond the end of the knife and the dull segment snapped off. The newly exposed segment is positioned for use and work continues.
Snap knives also suffer disadvantages relative to standard utility knives. These are associated with the removed segment and the method of snapping it from the blade. While considered dull by the user, these segments still retain a sharp edge and point.
The typical methods of snapping off a dull segment pose a risk to the user. This risk comes from the need to handle the bade and removed segment, both of which are sharp, and from the tendency for the snapped segment to fly away as a result of the snapping operation.
The most basic method of snapping a segment is to advance the blade until a segment line is positioned just beyond the end of the knife handle. The end of the blade is placed against a flat surface, with the scored segment line toward the surface, and pressure applied to knife handle, pressing the end of the blade against the surface, flexing the blade at the segment line, and causing the blade to snap at the segment line. As is readily apparent, when the blade snaps, it releases a significant amount of energy which typically results in the freed segment being projected away at high speed. Clearly, a flying blade segment with a sharpened edge poses a risk to both the user and those in the vicinity. There is also significant risk of damage to the surface used for the snapping operation, both from the end of the blade and from the handle of the knife after the blade snaps.
Alternate methods of snapping a segment utilize some type of tool, often having a notch which fits the end of the blade, to snap the dull segment. These reduce the likelihood of the segment flying free, but often leave the cutting edge of the segment exposed to the user's fingers during the operation. The segment must then be handled to remove it from the tool and discard it.
The removed segments still retain a relatively sharp edge and tip. As such they pose a hazard if not disposed of properly, Unfortunately it is common practice to leave them littering the floor of the work place, intentionally or unintentionally. Because of their small size, flat shape, and tendency to be projected outward, blade segments become lost easily. Even if found, they are hazardous to pick up due to their sharp edge and tip. The result is that even the best intentioned user usually leaves a few segments behind. A group of less well intentioned users can leave behind dozens, or even hundreds of segments scattered across a job site.
Alternate methods of snapping and disposing of segments are known. These typically include some type of container with a slot for the blade. The end of the blade is inserted into the slot, the segment snapped by angling the knife to one side, and the segment falls into the container. In some configurations, these devices are incorporated into a holster or other means for the user to carry them. While effective, these devices can be inconvenient to use. They are attached to a belt, or positioned nearby which means that the user must stop work, move the knife away from the work area, snap the blade, and then return the knife to the working position. In some situations, this burden may be minimal. In others, such working in physically restrictive area, such as the crawl space under a house, or on top of a ladder, this burden may be sufficiently excessive to cause the user to forego the use of the container return to simpler methods and let the segment fall.
A further problem with the slotted container approach is that the blade must be inserted into the slot. The segment to be removed is relatively small and the slot, of necessity, is a close fit to the blade. This requires a relatively high degree of precision to fit the blade into the slot. Not a significant problem if working at a bench in a well lighted shop, but a major challenge in low light situations, cramped quarters (especially where the container may not be in line of sight), or where the user is unstable or moving. Again, these difficulties may cause the user to bypass the safe method and revert to snapping and discarding segments using whatever method is available.
There is a need for an improved snap knife which allows used segments to be safely snapped off and discarded. This improved knife should incorporate a snapping mechanism as an integral part of the tool so that it does not become lost and so that it can be used with the knife in or near its working position. This mechanism should be self aligning with the blade to eliminate the difficulties encountered with inserting a blade into a separate slot. The snapping mechanism should retain the freed segment so that it can not fly free. Ideally, a container should be incorporated so that the blade segments can be stored until such time as they can be properly disposed of.
The present invention is directed to a utility knife for use with segmented, snap-off blades which incorporates an integral mechanism for snapping the blade segments. It preferably also incorporates a disposal container to retain the snapped segments for later disposal.
According to the invention there is provided a two part handle, pivotally interconnected. The blade is contained within a first part, and is extendable outward through a blade slot for normal use or for snapping. The second part has a second slot for receiving the end of the blade. This opening is automatically aligned with the blade slot when the handles are opened outward completely. The blade can be advanced so that the end enters the second slot and can be snapped by closing the handles.
According to an aspect of the invention the ends of the two handle parts are angled so that when fully opened they are parallel to each other and to the segment lines on the blade.
According to another aspect of the invention the second handle part incorporates a disposal chamber for receiving and retaining the removed segments for later disposal, This chamber may be either defined by the handle part or may be a separate removable, and optionally disposable, cartridge. Where a disposal chamber is provided, the second slot serves to feed segments into it and the slot is sealed by the opposing handle part when the handles are closed.
Further in accordance with the invention storage for additional unused blades may also be provided either in the same chamber as the removed segments, or in a separate chamber. this chamber would be closable in some manner to retain the blades and segments. The cap used to close the chamber may also comprise means to hold the spare blades, preferably positioning them to one side to reduce interference with or from the segments.
The advantages of such an apparatus are increased safety and usability. A dull segments can be quickly snapped off the blade without the user ever being required to touch the blade or to move the knife any significant distance from its working position. The process merely involves retracting the blade, opening the handles, advancing the blade into the second slot, and closing the handles. That done, the blade has been snapped and work can process.
The above and other features and advantages of the present invention will become more clear from the detailed description of a specific illustrative embodiment thereof, presented below in conjunction with the accompanying drawings.
The following discussion focuses on the preferred embodiment of the invention, a snap knife configured for use much like a conventional utility knife. However, as will be recognized by those skilled in the art, the disclosed method and apparatus are applicable to a wide variety of situations in which safe and easy snapping of segments from a cutting tool which uses a segmented blade is desired.
Glossary
The following is a brief glossary of terms used herein. The supplied definitions are applicable throughout this specification and the claims unless the term is clearly used in another manner.
Closed, Open—relative positions of the two parts of the handle. The Closed position is when the inner handle is nested within the outer handle and the knife is usable for cutting. The Open position is when the inner and outer handles are positioned opposite each other, in position for snapping a blade segment.
Inner, Outer—directions which when used relative to the two parts of the handle, are defined with the handle in its closed position. Inner is then toward the interior of the combined handle and Outer is toward the exterior. Consistent with this, Inner is toward the enclosed angle through which the two parts of the handle move when pivoting.
Segmentation Lines—scored line in blade which proved a weakened path along which the blade will snap relatively easily
Snap Knife—generally any knife which utilizes a segmented blade, allowing the end segment to be snapped off when it becomes dull, exposing a new, sharp segment.
The disclosed invention is described below with reference to the accompanying figures in which like reference numbers designate like parts. Generally, numbers in the 200's refer to prior art elements or elements in the surrounding environment while numbers in the 100's refer to elements of the invention. Note that the blade illustrated in the figures, and described below, is not a part of the invention itself.
Overview
The present invention is a snap-knife with significantly improved usability and safety. These both result primarily by the provision of a means of snapping off blade segments which eliminates all need for the user to touch the blade during or after the operation. The handle is simply opened outward to the fully extended position, the blade extended to enter the breaking slot in the opposite part of the handle, and the handles closed again, The pivoting motion of the handles as they close snaps off the blade and the removed segment is retained within the enclosed cavity of the handle. All risk of injury or damage from flying or discarded blade segments is eliminated. The risk of damage to a surface caused by pressing the blade against it to snap the blade, as is commonly done, is also eliminated.
The process of snapping a blade segment is much easier than with conventional knives because no separate tool is needed and the breaking slot incorporated into the handle automatically aligns with the blade when the handle is opened out.
Structure
The basic structure of the present invention is that of a two part handle having an inner part, 100, and an outer part, 104, pivotally connected. The two parts of the handle can pivot relative to each other between a closed and an open position. In the closed position, illustrated in
The inner part of the handle, 100, is structured much like a conventional snap knife and in cooperation with the follower, 102, and the blade, 200, functions in much the same manner. Referring to
With the blade and follower engaged as described above and both positioned within the channel, the parts function as a conventional snap knife as is well known in the industry. The follower and blade may be retracted within the handle, guarding the blade, or extended to expose a portion of the blade so that it may be used for cutting, scoring, or other operations. When the blade is extended to the point that one of the segment lines is exposed, a segment of the blade may be snapped off in a conventional manner. The blade extends through a blade slot, 124, in the end of the handle which preferably closely receives the blade, providing support for cutting and snapping operations. Preferably, at least a portion of the edge of this opening is aligned parallel to the segment lines in the blade to ease snapping off a segment.
It is when the above assembly of inner handle part, blade, and follower are combined with the outer part of the handle the benefits of the present invention are realized. The raised portion, 112, of the inner part of the handle is specifically designed to work in combination with the outer portion of the handle. Its primary purpose is to block the breaking slot (described below) in the outer part of the handle, so that blades and blade segments can not accidentally slide out of the breaking slot. This raised portion also provides increased material thickness about the pivot point and provides a smooth transition between the outer part of the handle and the inner part.
Referring to
As shown in
Ideally, the lips of the breaking slot will be arranged at a slight angle to the plane of the blade, such that the lip contacts the blade at the spine slightly before contacting the cutting edge. This has been found to provide a cleaner break of the blade than other configurations.
The breaking slot preferably communicates with the disposal cavity. This cavity fully encloses the end segment(s) of the blade throughout the snapping operation and afterward. This eliminates any risk of the snapped segment(s) from being thrown outward, or falling free, significantly reducing risk of injury or damage. It should be noted that while only a single segment is typically snapped off, the present invention as also adapted to remove multiple segments safely, with a single operation. This might be necessary where the blade has been used to cut thick materials, dulling more than one segment. In a conventional snap knife, this would require multiple snapping operations, removing each segment individually. With the present invention, the blade is simply extended until the desired segment line is properly aligned, and all segments are removed with a single snap.
In the preferred embodiment, the butt end of the disposal cavity opposite the breaking slot is also open to allow removal of segments which have been snapped off and to allow insertion of spare blades. This opening is blocked by an end cap, 108, to retain the segments and blades while the knife is in use. Preferably this cap is retained by an integral plug which fits into the end of the cavity. Optionally, it could be hinged or pivotally attached to the outer handle. An advantage to the plug retention method is that the end cap can also grip the spare blades, such as by inserting the blades into slot 130
In the generally illustrated embodiment of the present invention, the disposal cavity within the outer handle is shown as having a constant cross section along its length, with the breaking slot having the same profile. This offers the simplest manufacture, as the part can be formed by continuous extrusion, but also provides minimal capacity for blade segments. In the alternate embodiment of
Further improved functionality is provided if the chamber tapers continually to its widest point at the capped end. This reduces the chances of segments jamming within the chamber. It is also preferred that the width of the disposal chamber be greater that the largest dimension of a blade segment. Generally, this dimension is the longest of the two diagonals across the face. With the disposal chamber wider than this, a single segment can not become jammed within the chamber.
Clearly, the disposal cavity could be eliminated altogether, or left open so that the segments fall free. This would be applicable where a separate container, specific to the purpose or for general rubbish, is provided nearby into which the segments can be allowed to fall. One example of such a situation is where the knife is to be used at a fixed workstation having a disposal slot or container. If large numbers of segments are removed during a work shift, they may exceed the capacity of the disposal cavity. It may be more efficient to then discard the segments immediately after removal. Either an open ended cavity, where the segments fall through, or a closed cavity, where they are dumped back out through the breaking slot would be effective. The preferred configuration with the end cap removed or eliminated would suffice.
The grip, 106, is optional. While improving the comfort and usability of the knife, it does not effect the functionality in any significant manner and is not essential to the present invention. In the preferred embodiment, the grip is formed by over-molding a polymer material on the exterior of the outer handle. It could also be made as a press-on part and could be made from a variety of materials as is known in the art.
Operation
For cutting, a knife according to the present invention is used much like a conventional snap knife. The handle is placed in its closed position and the blade extended out through the blade slot to the extent necessary for the cutting task, see
To snap a blade, the handle should be closed as in
Materials
A variety of materials are suitable for a snap knife made according to the present invention. Both metals and plastics are suitable for most of the parts, with plastics such as glass filled nylon offering light weight, durability, and simple manufacturing.
The most highly stressed portion of the knife will likely be the lips of the breaking slot and possibly those of the blade slot. For durability and wear, these parts should probably be made of metal. This can be accomplished in a variety of well known ways including making the entire inner and outer handle parts of metal; making separate end pieces of metal, attached to plastic bodies; inserting metal lips into a plastics body; etc.
The following discussion presents alternative embodiments which offer various advantages in structure or functions without departing from the principles of the invention.
If desired, a detent mechanism can be added to hold the handle parts in their closed position. An option to hold them in the open position is also anticipated. A clear candidate for the detent mechanism is a spring loaded ball in one part of the handle which engages a recess in the other part. Other approaches could also be used as is well known in the art.
While the preferred embodiment utilizes a one piece outer handle, this is not a requirement. An alternative is to form the nose of the handle, including the breaking slot, and the main body of the outer handle as separate pieces and then join them together. This has the advantage of allowing different materials, such as a hardened metal for the nose, which would provide long-wearing lips for the breaking slot, and injection molded or extruded plastic for the main body. A similar approach could also be taken for the inner part of the handle.
The preferred embodiment utilizes a single compartment to hold both the blade segments which have been snapped off, and the new blades. If desired, two separate cavities could be used. This would offer the advantage of protecting the cutting edges of the new blades from being nicked by the blade segments.
For additional safety, the snap knife can be fitted with a disposable cartridge to hold the removed blade segments. See
While the preferred embodiment comprises nesting inner and outer handle parts which nest when the handle is closed, this is not necessary. Two parallel handle parts pivotally connected at one end, see
While the preferred form of the invention has been disclosed above, alternative methods of practicing the invention are readily apparent to the skilled practitioner. The above description of the preferred embodiment is intended to be illustrative only and not to limit the scope of the invention.
This application claims the benefit of U.S. Provisional Application No. 60/501,204 filed Sep. 8, 2003 and of provisional application 60/579,865 filed Jun. 15, 2004.
Number | Date | Country | |
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60501204 | Sep 2003 | US | |
60579865 | Jun 2004 | US |