Abstract:
A template cutting assembly is designed for cutting a sheet medium and includes a base and a frame connected by a hinge assembly. The base has a first end and a second end, the first end providing a hinge attachment point for the base. Likewise, the frame has a first end and a second end with the first end being the hinge end. A cutting surface is mounted on the base, and a template is removably mounted on the frame. The template has at least one guide channel for guiding a knife blade for cutting the medium.

Description:
BACKGROUND OF THE INVENTION 
       [0001]    The present invention generally relates to devices used for cutting sheet material such as photos, colored backing paper, and the like into selected shapes. More specifically, the present relates to the use of templates for cutting such shapes in conjunction with arts and crafts activities such as scrapbooking. 
         [0002]    The use of a template as a cutting guide is well known. For example, U.S. Pat. No. 6,321,457 describes a cutting template and a method for using it. The &#39;457 patent describes a translucent planar template having guide channels arranged in geometric shapes or patterns. A piece of sheet material, such as a picture or piece of paper, is placed on a planar cutting surface, such as a table, counter, piece of plastic, or the like. Next, the template is pressed onto the sheet material, trapping the sheet material between the template and the planar surface. Typically, a knife or specialized cutter is provided for use with the template. 
         [0003]    A user would place the knife against an edge of the guide channels, and then draw the knife along the edge of the guide channel, thereby cutting the sheet material into the desired shape. As different template designs would be desired, the &#39;457 patent teaches the concept of interchanging templates by lifting off the first template and trapping the sheet material with a new template having a different design. 
         [0004]    Other prior art teaches similar devices in which the template is firmly and more securely mounted onto a base, having a cutting surface. Such a mounting can be in the form of fasteners such as bolts, screws, or the like. First, the sheet material is placed on the cutting surface. Next, the template is mounted onto the base, firmly trapping the sheet material between them. Such a mounting system more firmly traps the sheet material and better prevents it from moving during cutting operations. Finally, a knife or cutter is provided and is drawn through the grooves, in a similar fashion as above. 
         [0005]    However, a perceived disadvantage of the &#39;457 patent was its failure to provide both a mechanism for anchoring the template while retaining template interchangeability. Furthermore, the prior art is somewhat deficient in allowing the template to be interchanged, without disturbing the material being cut. Any disturbance in the position of the material may result in subsequent cuts not aligning properly with older cuts. Another perceived disadvantage in the prior art is the cutting surface often becomes scratched, rough, or uneven over time. A final perceived disadvantage in the prior art is the inconsistency and nonrepeatability of cuts due to variations in the position of the knife against the edge from one cut to another. 
         [0006]    Thus a need exists for an improved template cutting assembly configured for use with an interchangeable, anchored template. Furthermore, a need exists for an improved template cutting assembly providing template interchangeability that limits disturbance to the material being cut. A need also exists for an improved template cutting assembly addressing the disadvantages discussed above. 
       SUMMARY OF THE INVENTION 
       [0007]    The above-listed needs are met or exceeded by the present template cutting assembly with a hinged frame. To allow both interchangeability and secureability of a template to a base, a frame is attached to the base, and is configured so that a user can slideably engage the template in the frame. A hinge assembly connects the base and frame, and allows the frame, with the engaged template, to be positioned substantially flush against the base, directly above a cutting surface, in a “closed” position. To more securely keep the frame in the closed position during use, the template cutting assembly has a locking mechanism. After use, the frame can be pivoted, into a more “open” position, away from the base. Then, the template can be slideably disengaged from the frame. Thus, the template cutting assembly anchors the template to the base, while providing template interchangeability. 
         [0008]    Furthermore, the template cutting assembly has a ratcheting hinge that is configured to suspend the frame at varying degrees of openness. This results in less disturbance to the sheet material on the cutting surface when the templates are slideably engaged and disengaged. The present template cutting assembly also provides a removable cutting surface. The base has a recessed center, into which the removable cutting surface is placed. As an older cutting surface becomes scratched and damaged, it may be removed and a new one inserted. Finally, to improve cutting consistency, the template cutting assembly has guide channels that are beveled, and a specially designed knife. The knife has a curved blade holder, configured such that the curvature of the blade holder corresponds to the curve of the beveling. The blade holder also rotates about a central axis of the knife. This reduces a users need to constantly realign the knife to keep the blade holder and the beveling flush. 
         [0009]    More specifically, a template cutting assembly provided for cutting a medium includes a base and a frame connected by a hinge assembly for respective movement between a closed, cutting position and an open position. The base has a first end and a second end, the first end providing a hinge attachment point for the base. Likewise, the frame has a first end configured for engaging the hinge attachment point, and a second end. The template is removably mounted on the frame and has at least one guide channel for guiding a knife blade for cutting the medium. 
         [0010]    In another embodiment, a template cutting assembly includes a system for cutting a medium that includes a base and a frame connected by a hinge assembly for respective movement between a closed, cutting position and an open position. The base has a first end and a second end, the first end providing a hinge attachment point for the base. Likewise, the frame has a first end configured for engaging the hinge attachment point, and a second end. A cutting surface is mounted on the base and the template is removably mounted on the frame. The template has at least one guide channel for guiding a knife blade for cutting the medium. The system also includes a knife with a handle and a blade housing. The blade housing has a complementary contoured surface configured for engaging a corresponding edge of the template. 
         [0011]    In a further embodiment, a template cutting assembly includes a knife provided for use with a template system for cutting a medium. The system includes at least one template having at least one guide channel with a beveled edge. The knife has a handle with a first end and a second end, with a grip area disposed between the ends, and having a hollow interior. The knife also has a blade housing releasably attached to the first end. This blade housing has an edge portion contoured to be complementary to the beveled edge. Finally, the blade housing has an axial shaft projecting into the hollow interior that is configured for being rotatably engaged and secured in the interior. 
     
     
       BRIEF DECRIPTION OF THE DRAWINGS 
         [0012]      FIG. 1  is an overhead perspective of the template cutting assembly in a closed position; 
           [0013]      FIG. 2  is an overhead perspective of the template cutting assembly in an open position; 
           [0014]      FIG. 3  is an exploded view of  FIG. 2 ; 
           [0015]      FIG. 4  is a bottom plan view of the frame; 
           [0016]      FIG. 5  is a bottom plan view of the base; 
           [0017]      FIG. 6  is an exploded view of the present hinge assembly; 
           [0018]      FIG. 7  is a partial elevated cross-section of the present hinge assembly; 
           [0019]      FIG. 8  is a fragmentary vertical cross-section of the template cutting assembly in the closed position; 
           [0020]      FIG. 9  is an elevational view of a knife suitable for use with the present template cutting assembly; 
           [0021]      FIG. 10  is a cross-section taken along the line  10 - 10  of  FIG. 9  in the direction generally indicated; and 
           [0022]      FIG. 11  is an exploded view of the knife of  FIG. 9 . 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0023]    Referring to  FIGS. 1-2 , the present template cutting assembly is generally designated  10  and includes a base  12  and a frame  14  that are connected by a hinge assembly  16 . Both the base  12  and the frame  14  have corresponding hinge ends  18  and  20  and opposite respective outer ends  22  and  24 . The base  12  is typically laid flat upon a substrate such as a table, counter, or the like during use, and the frame  14  pivots along a hinge assembly axis  26 . For definitional purposes, a “closed” or “cutting position” will be defined as when the frame  14  and base  12  are substantially flush together, as shown in  FIG. 1 . Furthermore, as the frame  14  pivots away from this position, it becomes more open, such as in  FIG. 2 . Lastly, a “topside” and an “underside” of the frame  14  and the base  12  are defined relative to the depiction of  FIG. 1 , in which an underside of the frame  14  meets a topside of the base  12  in the closed position. 
         [0024]    Referring now to  FIG. 3 , the base  12  is preferably made of a single piece of molded plastic, although other materials and other plastic manufacturing techniques may be used as well. The base  12  is preferably relatively rigid, with little flexibility or compression during normal use. A recessed center  28  is defined by a raised base rim  30 , preferably in a square shape, although other shapes are contemplated. A removable cutting surface  32  has dimensions substantially the same as the recessed center  28  in length, width, and height. Thus, when the cutting surface  32  is inserted into the base  12 , a generally planar surface is created by the two components, which in turn allows the frame  14  to flushly close into the cutting position. The tight engagement of the cutting surface  32  in the recessed center  28  also prevents the cutting surface  32  from moving during use. 
         [0025]    To facilitate more precise placement of the sheet material to be cut, preferably a picture or piece of paper, a guide rail  36  rises above the base rim  30  on the hinge end  18 , and is generally parallel to the hinge axis  26 . The guide rail  36  provides a straight edge against which the edge of a piece of sheet material to be cut can be flushly placed. In the preferred embodiment, to further assist precise placement, the cutting surface  32  has a grid  37  of vertical and horizontal lines. The cutting surface  32  is preferably made out of a material with the following combination of attributes: flexibility, planar smoothness, resistance to scratching, resistance to wear, and limited tensile compressibility. 
         [0026]    Referring now to  FIG. 5 , an underside  38  of the base  12  of the preferred embodiment is shown in further detail. For definitional purposes, this paragraph will refer to “raised” and “lowered” sections as if the entire base  12  was inverted. An outer rim  40  is buttressed by at least one, and preferably two ribs  42  in both the horizontal and vertical directions. These ribs  42  preferably have the same height as the outer rim  40 , thus providing further support for the base  12  underlying the cutting surface  32 . Within the outer rim  40 , a gutter  43  borders a raised center area  44 . This raised center area  44  has a height, length, and width greater than the cutting surface  32 , because the raised center area  44  is actually the bottom surface of the recessed center  28  (shown hidden). By leaving portions of the base  12  hollow, weight and material are saved. However, the ribs enhance the stability and structural integrity of the base  12 . 
         [0027]    Referring now to  FIGS. 1 ,  2 ,  4 , and  8 , the frame  14  is defined by a back piece  46 , at least one, but preferably two side bars  48  extending from the back piece, and preferably a front piece  50  connecting the side bars  48  at the outer end  24 . The frame  14  is preferably manufactured out of molded plastic, and substantially forms a square, however, other materials, manufacturing methods, and shapes are contemplated. Using the reference frame of  FIGS. 1 and 2 , a backstop  54  and side edges  56  each extend downward from the underside of the back piece  46  and the side bars  48  respectively. Together the backstop  54  and the side edges  56  form a rim along the underside of the frame  14 . It can be seen that the height (“H”) of the side edges  56  is greater than the thickness (“T”) of a template  57 , ( FIG. 8 ). Likewise, a space  58  defined by the backstop  54  and the side edges  56  is dimensioned to slidingly, yet snugly, accommodate the template  57 . However, the length of the back piece  46  and side bars  48  are greater than the length of the template  57 . 
         [0028]    Referring now to  FIG. 8 , an over-rail  60  extends horizontally from the topside of the side edge  56 . A back over-rail  62  can be seen starting from the topside, hinge end of the frame  14  ( FIG. 1 ) extending horizontally beyond the backstop  54 , and topside above the space  58  for the template  57  ( FIG. 5 ). A handle  64  extends further outward from the outer end  22  of the front piece  50  to assist in opening and closing the frame  14 . In preferred embodiments, the top surface of the handle  64  is textured for ease of use. 
         [0029]    Referring now to  FIGS. 4 and 8 , an under-rail  65  extends from underside of the side edge  56  to form a sliding track  69  for the template  57  ( FIG. 8 ). The under-rail  65  preferably is formed by three separate tabs;  66 ,  68 , and  70 ; although other configurations such as a single piece are contemplated. A hinge end tab  66  and an outer end tab  68  have substantially the same dimensions. Each is preferably one inch long; and each has a width, extending towards the center, substantially the same as the width (“W”) of a template rim  72 , which will be defined and discussed in greater detail below. The common dimensions aid in providing sliding support for the template  57 . A third middle tab  70  has a longer length, but a shorter width. The side edge  56 , the over-rail  60 , and the under-rail  65  define the track  69 , into which the template rim  72  is slid. This track  69  has substantially the same thickness as the template rim  72 , as shown in  FIG. 8 . 
         [0030]    The template  57  is preferably manufactured out of a translucent plastic material, such as integrally molded plastic, however, other fabrication methods and materials are also contemplated. This material is preferably rigid during normal use, but should have some amount of flexibility. In the embodiment shown, the template  57  is generally square shaped, although other configurations are contemplated. The template rim  72  has a width (“W”) shown in  FIG. 8 , and is thinner than a center area  74 . The template rim  72  is designed to allow the edge of the template  57  to fit into the track  69 . 
         [0031]    Referring now to  FIGS. 3 and 8 , guide channels  76  are arranged in some pattern or design about the template  57 , as depicted the guide channels form concentric circles. The guide channels  76  are cut through the entire thickness of the template center area  74 , and are preferably beveled. The beveling is best illustrated in  FIG. 8 , and results in the guide channels  76  being wider on the topside than the underside. 
         [0032]    Referring back to  FIG. 3 , the guide channels  76  are interrupted by at least one, and preferably three, sets of supporting connectors  78 . The connectors  78  are necessary to support interior material  80  within the circumference of any concentric circle. However, the supporting connectors necessarily interrupt the continuity of the guide channels  76 , and therefore can interfere with a cut. To allow for more precise cuts, the connectors  78  are preferably arranged at intervals of 120 degrees. This allows the template  57  to be removed from the frame  14 , rotated ninety degrees, and placed back in the frame  14  presenting open guide channels  76  in the areas previously obscured by the connectors  78 . 
         [0033]    Referring now to  FIGS. 6 and 7 , the hinge assembly  16  of a preferred embodiment is shown in more detail. The base  12  has two hinge barrels (“base barrels”)  82  associated with both corners of its hinge end  18 , likewise the frame  14  has two hinge barrels (“frame barrels”)  84  associated with either end of its hinge end  20 . In the base barrels  82 , a central bore  86  has at least one, but preferably two, radially extending diametrically opposed cavities  88  in communication with the central bore  86 , to form a keyway. In the frame barrel  84 , a frame bore  90  is counterbored, and a counterbore  92  has a ridged, or ratchet-like, inner peripheral edge  94 . A hinge pin  96  has a shaft  98  with at least one flange  100  extending radially to form a key that generally corresponds to the dimensions of the lateral cavities or keyway  88 . Preferably, the number of flanges  100  will equal the number of lateral cavities  88 . Thus, upon insertion of the pin  96  into the base barrel  82 , the engagement of the flanges  100  in the lateral cavities  88  prevents relative rotation of the pin and the barrel. 
         [0034]    A washer  102  has an inner washer bore  104  whose dimensions slidingly match the dimensions of the shaft  98 , including space for the flanges  100 . At least one, and preferably two gear teeth  106  extend outward from an outer circumference  108  of the washer  102 . The dimensions of the circumference  108  and the gear teeth  106  are generally complementary to the dimensions of the ridged inner periphery  94  of the counterbore  92 , such that the gear teeth  106  partially extend into spaces  110  defined by the ridges of the inner periphery  94 . 
         [0035]    When assembled, the washer  102  is placed within the counterbore  92  and the hinge pin  96  is inserted into the base bore  86  from the outside of the base barrel  82 . The shaft  98  extends all the way through the base barrel  82 , the washer  102 , and the frame barrel  84 . When the frame  14  is pivoted, the pin  96  is prevented from rotating because the lateral cavities  88  prevent the rotation of the flanges  100 . This in turn prevents the washer  102  from rotating. Thus, as the frame barrel  84  rotates, the ridges of the counterbore  92  are partially impinged by the gear teeth  106 . Rotation is thus retarded in the absence of outside force provided by the user. In this way, a plurality of interim open positions are achievable with the present frame  14 . The pin  96  is preferably manufactured out of molded plastic, although other materials and manufacturing techniques will suffice. Furthermore, the pin  96  also has a cap  112  and at least one, preferably two, lips  114  to retard pin  96  slippage out of the hinge assembly  16 . Such a hinge assembly is referred to here as a ratcheting hinge. 
         [0036]    Referring now to  FIGS. 1 and 6 , another feature of the present template cutting assembly  10  is that the base barrel  82  has a slanted cut  116  in its outer surface. The frame  14  has a substantially complementary slanted cut  118  in either hinge end  20  corner. Thus, when in the closed position the two slanted cuts  116 ,  118  meet in a generally flush manner. Because the cuts are slanted, lateral movement of the frame  14  in the closed position is thus significantly retarded. 
         [0037]    Referring now to  FIG. 2 , when in the cutting position, the frame  14  and the base  12  are preferably maintained in a locking relationship by a locking mechanism made up of at least one, and preferably two pairs of matched magnets  120 ,  122 . The magnets  120 ,  122  are arranged in the corners of the outer ends  22 ,  24  of the base and frame respectively and are aligned such that when the frame  14  is closed they lie substantially flush and attract each other, thus more firmly holding the frame  14  in the closed or cutting position. Other types and locations of non-magnetic locking mechanisms are also contemplated. 
         [0038]    Referring now to  FIGS. 9-11 , the template cutting assembly  10  utilizes a specialized knife generally designated  130 . This knife  130  has a handle  132  and a blade housing  134 . The handle  132  is made up sequentially of a removable insertion dome  136  that is preferably threaded, a grip area  138  and a main body  140  adjacent to the grip area. A removable tip  142  is opposite the insertion dome, is also preferably threaded and provides access to a hollow interior  144 . At least one extra blade housing  146  (shown hidden) is accommodated in this hollow interior  144 . A knife axis  147  ( FIG. 11 ) is defined along the axis formed from the tip  142  to the dome  136 . 
         [0039]    The handle  132  is preferably manufactured out of a rigid plastic, with the exception being the grip area  138 . A pliable, tacky material is preferred for the grip area  138 , which is made of a sleeve of material slid over a generally hourglass shaped portion of the handle  132 . In the preferred embodiment, the grip area  138  is textured, supplementing the effect of the tacky material and the hourglass shape, all of which prevent a user&#39;s fingers from slipping during use. 
         [0040]    The blade housing  134  includes a blade  148  at its very tip, the blade housing having a beveled section  150 . A radially extending spheroidal stopper  152  is located vertically adjacent the blade  148 , followed by a radially narrowed top shaft bushing  154 , and a bottom shaft bushing  156 . Projected vertically from the bottom shaft bushing  156  is an elongated shaft  158  having a ball  160  at the terminus of the shaft  158 , and a radially narrowed neck shaft section  162  connecting the ball  160  to the main shaft  158 . The blade  148  is preferably made of steel, and the beveled section  150  which houses it is preferably manufactured by molding the beveled section around the blade  148 . In fact, in the illustrated embodiment the beveled section  150 , stopper  152 , and both shaft bushings  154 ,  156  are all an integral piece of molded plastic. While molded plastic is the preferred material for these sections, other materials or manufacturing techniques are contemplated. The blade housing  134  is attached to the handle  132  using the ball  160  which engages a slot  164  ( FIG. 10 ) defined in the hollow interior  144  at the grip area  138 . 
         [0041]    Referring now to  FIG. 10 , a plastic disc  166  is attached to the inner walls of the handle  132 . This disc  166  divides the hollow interior  144  into two portions; a rear portion  167  that houses the extra blade housing  146  and a front portion  168  that mounts the blade housing  134  in use. In the center of the disc  166  is the slot  164 . The ball  160  passes through the slot  164  and the neck section  162  engages the slot in a friction fit that retards axial movement of the blade housing  134 , while allowing rotation about the knife axis  147 . Vertical movement is also prevented by the stopper  152 , which rests on an annular bore  170  of the insertion dome  136 . The bottom shaft bushing  156  is rotationally engaged in the annular bore  170 . Also, the stopper  152  forms a spherical surface against an end of the annular bore  170  to facilitate and support rotation about the knife axis  147 . In preferred embodiments, a blade cap  172  is placed over the blade housing  134  and secured by a friction fit over the dome  136  to protect the knife blade  148  when not in use. 
         [0042]    When in use, and referring to  FIG. 8 , the beveling of the beveled section  150  is preferably designed to inversely correspond to or complement the beveling of the guide channels  76 . Preferably, the knife  130  is held substantially vertically and the blade housing  134  is pressed into the guide channels  76 . Then the knife  130  is drawn along the guide channel  76 . As curves in the guide channels  76  are encountered, the blade housing  134  rotates along the knife axis  147 , and the substantially flush fit between the beveling of the guide channel and the beveled section  150  of the knife  130  is maintained. 
         [0043]    To use the template cutting assembly  10 , the material to be cut is placed on the cutting surface  32 . The material may be aligned using the guide rail  36  or the gridlines  37 . The frame  14  is then closed into the cutting position, locking the sheet material firmly in place under the template  57  of choice. The user then runs the knife  130  through the guide channels  76 , thus cutting the material into the desired shape. When the user desires a new template  57  shape or design, the template is slidingly disengaged from the frame  14 . A new template  57  is then selected and inserted such that the template rim  72  slidingly engages the track  69  until the template  57  encounters the backstop  54 . The template cutting assembly  10  is then ready for use again with the new template  57 . 
         [0044]    As can be seen the present template cutting assembly  10  addresses and remedies the perceived problems in the prior art. The template cutting assembly  10  provides for interchangeable, anchored templates  57 , and the template cutting assembly also limits disturbance to the sheet material being cut through its ratcheting hinge assembly  16 . By providing the removable cutting surface  32 , scratched, rough, or uneven cutting surfaces can be replaced. Finally, the complimentary beveling of the knife  130  and the guide channels  76  provides greater cutting consistency. 
         [0045]    While a particular embodiment of the present template cutting assembly has been described herein, it will be appreciated by those skilled in the art that changes and modifications may be made thereto without departing from the invention in its broader aspects and as set forth in the following claims.