Abstract:
There is disclosed herein a system, methods and device for creating three-dimensional decorations. The system, devices and methods disclosed operate to facilitate quick creation of relatively inexpensive and reproducible three-dimensional decorations from most any cuttable material. A pattern cutting system includes a two-part template and a cutter having a cutting blade. The template includes substantially planar first and second portions, each with a plurality of grooves therein, the cutting blade of the cutter fitting within the grooves to effectively cut material. The two portions are preferably hinged together, for example, by a living hinge, to be foldable such that the grooves in each portion align. A cuttable material, such as paper, is sandwiched and retained between the first portion and the second portion while the cutter cuts the material along the plurality of grooves.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application claims the benefit of U.S. patent application Ser. No. 61/391,371 filed on Oct. 8, 2010. 
     
    
     TECHNICAL FIELD OF THE INVENTION 
       [0002]    The present system and methods are related to relatively inexpensive devices for creating decorations. Particularly, the system and methods relate to templates and cutters which facilitate production of hanging three-dimensional decorations. 
       BACKGROUND OF THE INVENTION 
       [0003]    The creation of three-dimensional decorations from cutting and folding different materials, such as paper stock and the like, is well-known. Children and adults alike have taken scissors to paper to create snowflakes and various unfurling hanging designs. The difficulty in reproducing such designs led to the use of cutting templates. 
         [0004]    Templates typically operate to either mark the material for cutting or allow the user to cut the material using guide slots provided on the template. In either case, the template must be placed on top of the material to be cut, which is generally spread upon a table top or the like, and the two components—i.e., the material and template—must be held firmly by the user to effect the desired cutting pattern. This process can be difficult for many, specifically where several cuts are required. 
         [0005]    The present system, device and methods solve the numerous problems associated with creating reproducible, three-dimensional decorations from cuttable material. The system allows for quick and easy creation of inexpensive, reproducible, three-dimensional decorations from an assortment of flexible, cuttable materials. The present system accomplishes these and other goals without sacrificing creativity, aesthetics and simplicity. 
       SUMMARY OF THE INVENTION 
       [0006]    There is disclosed herein a system and methods for creating three-dimensional decorations which avoid disadvantages of prior system, devices and methods while affording structural and operating advantages. The system, devices and methods disclosed operate to facilitate quick creation of relatively inexpensive and reproducible three-dimensional decorations from most any cuttable material. 
         [0007]    In one embodiment, a pattern cutting system comprises a two-part template and a cutter having a cutting blade. The template includes substantially planar first and second portions, each with a plurality of grooves therein, the cutting blade of the cutter fitting within the grooves to effectively cut material. The two portions are preferably hinged together, for example, by a living hinge, to be foldable such that the grooves in each portion align. A cuttable material, such as paper, is sandwiched and retained between the first portion and the second portion while the cutter cuts the material along the plurality of grooves. 
         [0008]    In a preferred embodiment of the disclosed pattern cutting system, the first and second portions are identical in size and shape. The first and second portions may be most any shape, but are preferably shaped like one of either a rectangle or a triangle. 
         [0009]    In an embodiment, the cutter comprises a guide member to prevent cutting of the first and second portions by the blade as it moves through each. The guide member extends from the cutter to be proximate and parallel to the preferably retractable blade. 
         [0010]    In a preferred method for creating three-dimensional decorations, the cuttable material is first sandwiched between the first template portion and the second template portion. Then, the cutting blade is moved through each of the plurality of grooves to thereby cut the material. The cut material is then removed from between the first and second template portions and is manipulated to form a three-dimensional decoration. In an embodiment of the method, a plurality of cut material is joined together to form the desired decoration. 
         [0011]    Finally, a cutting template is also set forth. The template comprises a first portion having a plurality of cutting grooves therein, and a second portion hingeably attached to the first portion and having a plurality of cutting grooves therein, wherein the plurality of cutting grooves of the second portion align with the plurality of cutting grooves of the first portion when the two portions are overlapped. 
         [0012]    In various embodiments, the cutting grooves of the template portions are either all parallel or arranged in at least two groups of parallel grooves. Similarly, the plurality of cutting grooves may be provided in all the same lengths or in various patterned or random lengths. 
         [0013]    These and other aspects of the invention may be understood more readily from the following description and the appended drawings. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0014]    For the purpose of facilitating an understanding of the subject matter sought to be protected, there are illustrated in the accompanying drawings embodiments thereof, from an inspection of which, when considered in connection with the following description, the subject matter sought to be protected, its construction and operation, and many of its advantages should be readily understood and appreciated. 
           [0015]      FIG. 1  is a perspective view of an embodiment of a template for the present pattern cutting system; 
           [0016]      FIG. 2  is a perspective view of the template of  FIG. 1  in an open position; 
           [0017]      FIG. 3  is a perspective view of another embodiment of a template for the present pattern cutting system; 
           [0018]      FIG. 4  is another perspective view of the template of  FIG. 3  in the process of opening; 
           [0019]      FIG. 5  is still another perspective view of the template of  FIG. 3  in an open position; 
           [0020]      FIG. 6  is a perspective view of an embodiment of a cutter made in accordance with the present pattern cutting system; 
           [0021]      FIG. 7  is a side view of the cutter of  FIG. 6 ; 
           [0022]      FIG. 8  is a rear perspective view of another embodiment of a template for the present pattern cutting system; 
           [0023]      FIG. 9  is a front perspective view of the template of  FIG. 8 ; 
           [0024]      FIG. 10  is a perspective view of the template of  FIG. 8  in an open position; 
           [0025]      FIG. 11  is a perspective view of another embodiment of a cutter for use in the present pattern cutting system; 
           [0026]      FIG. 12  is a side view of the cutter of  FIG. 11 ; and 
           [0027]      FIGS. 13 ,  14  and  15  illustrate possible decorative ornaments which can be crafted using the embodiments of the present pattern cutting system. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0028]    While this invention is susceptible of embodiments in many different forms, there is shown in the drawings and will herein be described in detail a preferred embodiment of the invention with the understanding that the present disclosure is to be considered as an exemplification of the principles of the invention and is not intended to limit the broad aspect of the invention to embodiments illustrated. It should be noted that the features illustrated in the drawings may not necessarily reflect the proper scale, and, unless mutually exclusive or specifically stated otherwise, features of one embodiment may be employed with other embodiments as the skilled artisan would recognize. Descriptions of well-known components and processes may be omitted as to not unnecessarily obscure the embodiments of the invention. The examples used herein are intended merely to facilitate an understanding of ways in which the invention may be practiced and to further enable those of skill in the art to practice embodiments of the invention. Finally, it is noted that like reference numbers represent similar parts throughout the specification and the various views of the drawings. 
         [0029]    Referring now to  FIGS. 1-12 , there are illustrated various aspects and embodiments of a pattern cutting system, generally identified by the number  10  throughout the appended drawing figures. The cutting system  10  comprises a template  12  having a substantially planar first portion  14  with a plurality of grooves  15  therein and a substantially planar second portion  16  with a plurality of grooves  17  therein, and a cutter  30  having a blade  32  extending there from and capable of fitting within the grooves  15  and  17  of the template portions,  14  and  16 . 
         [0030]    In the embodiments of  FIGS. 1-5 , two embodiments of the template  12  are illustrated. In each, the first portion  14  and the second portion  16  are preferably identical in size and shape with aligned peripheries. Rectangular and triangular shapes are shown and provide the most common three-dimensional decoration. However, circular, oval and most any polygonal shape may also be used for the template  12 . Further, the size and shape of the two portions  14  and  16  could conceivably be different from one another for certain applications. The possibilities are innumerable and are limited only by the imagination and creativity of a manufacturing entity. 
         [0031]    For ease of use, the two portions  14  and  16  are preferably connected to one another along aligned edges  19 . A hinge  20  is used to allow the two portions to pivot apart in order to accept cuttable material there between. The hinge  20  may be most any type of hinge, including a simple living hinge and a more complex slot-and-pin type hinge. 
         [0032]    As shown, the first portion  14  and the second portion  16  together sandwich and retain a cuttable material, while the blade  32  of the cutter  30  is used to cut the material along the plurality of grooves  15  and  17 . 
         [0033]    Turning to the two individual portions,  14  and  16 , an embodiment of the system  10  can be more readily understood. In the embodiment of  FIG. 1 , the first portion  14  has the shape of a triangle, while the first portion  14  of the embodiment of  FIG. 3  is in the shape of a rectangle. Similarly, the second portion  16  in  FIGS. 1 and 3  are identical in size and shape to the respective first portions  14 . The grooves  15  and  17  of the embodiment of  FIG. 1  are shown to be arranged in two groups, each group of grooves spaced from and running parallel to an edge of the triangle. As can be seen, the grooves are of varying lengths, decreasing in length as the distance from the parallel edge increases. The grooves  15  and  17  of the embodiment of  FIG. 3 , are arranged in a single group of uniform size. Numerous other variations and combinations are possible. 
         [0034]    In the illustrated embodiment of  FIGS. 8-10  (only the rectangular embodiment is illustrated), the template  12  is configured somewhat differently to accomplish a similar result. That is, the grooves  15  pass completely through the first portion  14  and the thickness of the first portion  14  is less than the length of the cutter blade  32 . Further, an upper surface opening  22  of each groove  15  of the first portion has a beveled entry. The inward sloped edges of the upper surface opening  22  help guide the cutter  30  into and along each groove. While the grooves  15  do not extend the full length of the first portion surface, the opening  22  does extend between two sides to continue guiding the cutter  30 , as will be explained in further detail below. 
         [0035]    The second portion  16  of pattern cutting template  12  of this embodiment is similar, if not identical to the first portion  14  in size and shape. However, in a preferred embodiment the second portion  16  has a plurality of grooves  17  each comprised of a walled-channel  24  extending from an inner surface  26  of the second portion  16  and aligning with a groove in the first portion  14 . The walled-channels  24  provide depth to the grooves  17  to prevent the cutter blade  32  from passing entirely through the template  12 . In fact, the walled-channels  24  are closed at the inner surface  26 , thereby preventing a longer blade, for example, from passing entirely through the template  12 . This feature allows the system  10  to be used without the need of a cutting surface on which to place the template  12 . 
         [0036]    Conversely, in the first alternate embodiments shown in  FIGS. 1-2  (triangular template) and  FIGS. 3-5  (rectangular template), the overall thickness of the template  12  prevents the cutting blade  32  from extending out the opposing side. That is, while the cutting grooves  15  are present on both the first portion  14  and the second portion  16 , the blade is prevented from cutting any surface placed under the template because it is too short to extend there through. An advantage of this embodiment is that the template  12  is reversible and either portion,  14  or  16 , may be used as the upward or cutting side. 
         [0037]    As to the cutter  30 , numerous embodiments are possible. The basic components of the cutter  30  include a body or housing  36  and a blade  32 . Two distinct embodiments of the cutter  30  are illustrated in the accompanying drawings. In a first embodiment, the blade  32  is retractable, as shown in  FIGS. 6-7  and as is well-known by those skilled in the art. This allows the blade  32  to be extended to a preferred cutting depth and to be retracted for safety after use. Alternatively, a second embodiment, shown in  FIGS. 11 and 12 , illustrates an cutter  30  having a movable shroud  34  which covers the extended blade  32 . 
         [0038]    With further reference to the embodiment of  FIG. 11 , the housing  36  is an ergonomic shape which fits readily within the hand of a user. At a bottom edge of the housing  36  is an opening  38  from which a movable shroud  34  extends. The blade  32  also extends from the opening  38  but less than the extent of the shroud  34 . The shroud  34  is preferably pivotable within the opening  38  and includes a slit  35  within an end to allow protrusion of the blade  32 . While the shroud  34  is biased outward by a spring or other member (not shown), it may be forced upward into the housing  36  to expose the blade  32  from the slit  35 . Further, the downward surface  39  of the shroud is preferably configured to conform to the upper surface opening  22  of the first portion  14 . This feature allows the cutter  30  to accurately track within the grooves  15 . Of course, other indexing mechanisms may be employed to achieve the same or similar result. 
         [0039]    With the broad features of the system  10 , including the template  12  and the cutter  30  described, the operation of the system  10  may be more readily understood. 
         [0040]    The method for creating three-dimensional decorations begins by sandwiching a piece of cuttable material, such as colored construction paper, between the first template portion  14  and the second template portion  16 . The material may be folded before placing between the template portions,  14  and  16 , if desired. Once the template portions are closed about the material, the cutter  30 , via the shroud  34 , is placed within one of the plurality of grooves  15  on the first portion  14  at an edge of the template  12 . The cutter  30  is pushed downward, thereby forcing the shroud  34  into the cutter housing  36  and extending the blade  32 , until the blade passes through the sandwiched material. Then, by moving the cutting blade  32  along the length of the groove  15 , the sandwiched material is cut in the exact length and shape of the template groove. The cutter  30  is then lifted and moved to the next groove and the process repeated until the material has been cut along all desired grooves—note, for some applications, not all grooves need be used for every design. 
         [0041]    Finally, by removing the cut material from between the first and second template portions,  14  and  16 , the material may be manipulated in a known manner to form the desired three-dimensional decoration. By joining a plurality of these cut material pieces together, an almost unlimited number of decorative ornamentations may be created.  FIGS. 13 ,  14  and  15  illustrate just some of the possible decorative ornaments which may be quickly and easily crafted. The triangle template of  FIG. 1  can be used to craft the ornament of  FIG. 13(   a ) which is used to construct the ornaments of  FIG. 13(   b )-(d) by connecting multiple parts together, as well as the star ornaments of  FIG. 14(   a ) and ( b ) made from six (6) individual parts. Likewise, the rectangular template of  FIGS. 3 and 8  can be used to craft the individual ornaments of  FIG. 15(   a )-( c ), which can be connected together to form the ornaments of  FIG. 15(   d ) and ( e ). 
         [0042]    The matter set forth in the foregoing description and accompanying drawings is offered by way of illustration only and not as a limitation. While particular embodiments have been shown and described, it will be apparent to those skilled in the art that changes and modifications may be made without departing from the broader aspects of applicants&#39; contribution. The actual scope of the protection sought is intended to be defined in the following claims when viewed in their proper perspective based on the prior art.