A switchblade includes a casing that defines a cavity and a blade having a cutting edge. The blade has a retracted position in which the cutting edge is inside the cavity and a deployed position in which the cutting edge is outside of the cavity. A spring is operably connected to the blade to bias the blade to the deployed position. An actuator extends through at least a portion of the casing and has a hold position that engages with the blade to prevent movement of the blade with respect to the casing and a release position that permits movement of the blade with respect to the casing. A safety is operably connected to the actuator and has a lock position that prevents operation of the actuator and an unlock position that permits operation of the actuator.

FIELD OF THE INVENTION

The present invention generally involves a switchblade. In particular embodiments, the switchblade may be single or double action in either a folding or out-the-front configuration.

BACKGROUND OF THE INVENTION

Pocket knives provide a convenient tool for cutting that may be easily carried by a user for deployment when desired. For some pocket knife designs, two hands are needed to deploy and retract a blade, while other designs include a spring that assists a user to deploy or retract the blade using a single hand. Each design balances the convenience and speed of operation with increased risk associated with inadvertent operation.

A switchblade is a particular style of pocket knife that has a folding or sliding blade that automatically deploys when an actuator is operated. For a single action switchblade, a spring under compression may be engaged with the blade, and operation of the actuator releases the blade to allow the spring to automatically deploy the blade. Once deployed, the actuator is released to hold the blade in the deployed position. To retract a single action switchblade, the actuator is again operated to release the blade, and the blade must be manually retracted. For example, a single action switchblade design may include a charging handle that may be manually operated to retract the blade. For a double action switchblade, operation of the actuator compresses a spring against the blade to automatically deploy and retract the blade.

Although a switchblade provides convenient one-handed operation, the convenience of operation also increases the risk that the actuator may be inadvertently operated. For example, the actuator may be inadvertently bumped while the switchblade is in a pocket or attached to a belt, automatically deploying the blade in a manner that may cause personal injury or damage. Alternately, the actuator may be inadvertently bumped while the switchblade is deployed, releasing the blade from a fixed position. In addition, for single action switchblades that include a charging handle, the charging handle can create a pinch point during automatic deployment of the blade. As a result, the need exists for an improved actuator that reduces inadvertent operation of the actuator and an improved charging handle that reduces or eliminates the pinch point during automatic deployment of the blade.

BRIEF DESCRIPTION OF THE INVENTION

One embodiment of the present invention is a switchblade that includes a casing that defines a cavity. A blade having a cutting edge has a retracted position in which the cutting edge is inside the cavity and a deployed position in which the cutting edge is outside of the cavity. A spring is operably connected to the blade to bias the blade to the deployed position. An actuator extends through at least a portion of the casing and has a hold position that engages with the blade to prevent movement of the blade with respect to the casing and a release position that permits movement of the blade with respect to the casing. A safety is operably connected to the actuator and has a lock position that prevents operation of the actuator and an unlock position that permits operation of the actuator.

An alternate embodiment of the present invention is a switchblade that includes a casing that defines a cavity and a blade having a cutting edge. The blade has a retracted position in which the cutting edge is inside the cavity and a deployed position in which the cutting edge is outside of the cavity. A spring is operably connected to the blade to bias the blade to the deployed position. An actuator is releasably engaged with the blade and has a hold position that engages with the blade to prevent movement of the blade with respect to the casing and a release position that permits movement of the blade with respect to the casing. A safety is operably connected to the actuator and has a lock position that prevents operation of the actuator and an unlock position that permits operation of the actuator.

In yet another embodiment of the present invention, a switchblade includes a casing that defines a cavity and a blade having a cutting edge. The blade has a retracted position in which the cutting edge is inside the cavity and a deployed position in which the cutting edge is outside of the cavity. A spring is operably connected to the blade to bias the blade to the deployed position. An actuator extends through at least a portion of the casing and has a hold position that engages with the blade to prevent movement of the blade with respect to the casing and a release position that permits movement of the blade with respect to the casing. A charging handle is in sliding engagement with the casing and moves with respect to the casing to engage the blade to overcome the spring bias to move the blade to the retracted position. A releasable latch is pivotally connected to the charging handle.

DETAILED DESCRIPTION OF THE INVENTION

Embodiments of the present invention include a switchblade with an actuator and safety that provides enhanced protection against inadvertent deployment of the switchblade. Alternately or in addition, the switchblade may include a charging handle and one or more latches that engage the charging handle to a casing to reduce or eliminate a pinch point between the charging handle and the casing. Although various embodiments are illustrated as an out-the-front (OTF), single action switchblade, one of ordinary skill in the art will readily appreciate that embodiments of the present invention may include a folding switchblade and/or a double action switchblade, and the present invention is not limited to a particular configuration or action unless specifically recited in the claims.

FIG. 1provides a plan view of a switchblade10according to one embodiment of the present invention, andFIG. 2provides an exploded view of the switchblade10shown inFIG. 1. As shown inFIGS. 1 and 2, the switchblade10generally includes a casing12that houses and supports a blade14. The casing12typically includes a pair of complementary scales16connected together by screws18to define a cavity20between the scales16. The cavity20generally extends along a longitudinal axis22between the scales16. The blade12typically includes a cutting edge24on one or both sides of the blade12. In particular embodiments, the cutting edge24may be curved, straight, and/or serrated. The blade12has a retracted position (shown inFIGS. 8 and 9) in which the cutting edge24is housed inside the cavity20and a deployed position (shown inFIG. 1) in which the cutting edge24is supported outside of the cavity20by the casing12.

The switchblade10includes various components housed inside the cavity20that enable the switchblade10to transition between the retracted and deployed positions. The particular components and their operation depend on the design and desired functionality of the switchblade10, and an exemplary illustration of one such design is provided inFIG. 2. As shown inFIG. 2, the switchblade10may include a charging spring26operably connected to the blade14to bias the blade14to the deployed position. A pair of charging spring caps28may be fixedly connected to an insert30of the blade14at one end and the casing12at the other end. A charging spring guide32may facilitate collapse of the spring26under pressure in the retracted position. A charging handle34may be in sliding engagement with the casing12between the complimentary scales16so that the charging handle34may move with respect to the casing12. As will be described with respect to operation of the switchblade10, the charging handle34may move between a home position (shown inFIG. 11) in which it is fully inserted in the casing12and a withdrawn position in which it is pulled from the casing12to compress the charging spring26and move the blade14to the retracted position.

An actuator36may extend through at least a portion of the casing12to releasably engage or disengage with a detent38defined by the blade14. For example, the actuator36may have a hold position (shown inFIGS. 3-6) in which the actuator36engages with the detent38defined by the blade14to prevent movement of the blade14with respect to the casing12. Alternately or in addition, the actuator36may have a release position (shown inFIG. 7) in which the actuator36disengages from the detent38and permits movement of the blade14with respect to the casing12.

FIGS. 3 and 4provide cross-section views of the switchblade10shown inFIG. 1taken along line A-A with the actuator36in the hold position. As shown inFIGS. 3 and 4, the actuator36may extend through one of the scales16in a direction generally perpendicular to the longitudinal axis22of the casing12and cavity20. The outer portion of the actuator36may have a surface and shape suitable for thumb or finger manipulation, and the inner portion of the actuator36extending into the cavity20may have a shape that generally matches the shape of the detent38in the blade14. For example, as shown most clearly inFIG. 2, the inner portion of the actuator36may be cylindrical to closely fit in the semi-circular detent38defined by the blade14. As shown most clearly inFIG. 4, the inner portion of the actuator36may include a relief slot40having a width approximately equal to the width of the blade14. An actuator spring42between the actuator36and the opposing scale16may bias the actuator36outward, and a projection44of the actuator36may engage with a flange46in the scale16to prevent ejection of the actuator36from the casing12. In this manner, the actuator spring42biases the actuator36to the hold position in which the cylindrical portion of the actuator36fits in the detent38to engage with the blade14to prevent movement of the blade14with respect to the casing12.

A safety48may be operably connected to actuator36to provide enhanced protection against inadvertent operation of the actuator36. The safety48has a lock position (shown inFIG. 5) that prevents operation of actuator36and an unlock position (shown inFIG. 6) that permits operation of the actuator36.

FIG. 5provides a cross-section view of the switchblade10shown inFIG. 1taken along line B-B with the actuator36in the hold position and the safety48in the lock position. As shown inFIG. 5, the safety48may define a projection50that fits in and engages with a complementary recess52defined by the casing12when the safety48is in the lock position. A first spring54between the safety48and the actuator36may bias the safety48outward and away from the actuator36to reduce vibration or rattling between the safety48and the actuator36. A second spring56between the safety48and the actuator36and generally perpendicular to the first spring54may bias the safety48away from the actuator36toward the front of the casing12. In this manner, the second spring56biases the safety48to the lock position in which the projection50of the safety48engages with the recess52of the casing12to prevent operation of the actuator36.

FIG. 6provides is a cross-section view of the switchblade10shown inFIG. 1taken along line B-B with the actuator36in the hold position and the safety48in the unlock position. As shown inFIG. 6, the safety48has been moved to the right or rear of the switchblade10and held in place to overcome the bias provided by the second spring56. This movement of the safety48from the lock position to the unlock position is generally perpendicular to the movement of the actuator36from the hold position to the release position. As a result of this movement of the safety48, the projection50of the safety48is no longer engaged with the recess52in the casing12, and the safety48is in the unlock position that enables operation of the actuator36.

FIG. 7provides a cross-section view of the switchblade10shown inFIG. 1taken along line C-C with the actuator36in the release position. As shown inFIG. 7, the actuator36has been depressed into the cavity20to align the relief slot40with the blade14. In this alignment, the actuator36is in the release position that permits movement of the blade14with respect to casing12to allow the blade to be retracted or deployed.

FIG. 8provides a back plan view of the switchblade10shown inFIG. 1with the blade14in the retracted position, andFIG. 9provides a cross-section view of the front of the switchblade10shown inFIG. 8taken along line D-D. As shown inFIG. 9, the actuator36is in the hold position so the inner portion of the actuator36engages with the detent38defined by the blade14to prevent movement of the blade14with respect to the casing12.

FIG. 10provides an end plan view of the switchblade10shown inFIG. 1, andFIG. 11provides a cross-section view of the front of the switchblade10shown inFIG. 10taken along line E-E showing the charging handle34in the home position. As shown inFIG. 11, the charging handle34is in the home position fully inserted into the casing12, and the actuator36may engage a surface of the charging handle34to reduce vibration and rattling. In addition, as shown inFIG. 2, the forward portion of the charging handle may include an extension72that interferes with the inner portion of the actuator36unless the charging handle34is in the home position. In this manner, the extension72of the charging handle34may prevent operation of the actuator36unless the charging handle34is fully inserted in the home position to reduce or eliminate the presence of a pinch point between the charging handle34and the casing12.

FIG. 12provides a cross-section view of the rear of the switchblade10shown inFIG. 10taken along line F-F with the charging handle34in the home position. As shown inFIGS. 2 and 12, the switchblade10may further include one or more releasable latches58between the charging handle34and the casing12. Each latch58may be pivotally connected to either the casing12or the charging handle34for releasable engagement with the other to secure the charging handle34to the casing12in the home position. For example, as shown inFIGS. 2 and 12, each latch58may be pivotally connected to the charging handle34using a pivot pin60. In particular embodiments, each latch58may further include a latch spring62between the latch58and the charging handle34to pivotally bias the latch58to engage with the casing12. In this manner, the latch springs62bias the latches58to engage with the screws18in the casing12. To release the latches58, a user may pinch the ends of the latches58together to overcome the latch spring62bias to pivotally disengage the latches58from the casing12.

Operation of the switchblade10will now be described with respect toFIGS. 1-12. Starting with the blade12in the retracted position (FIGS. 8 and 9), the actuator36is in the hold position (FIGS. 3-5), and the safety48is in the lock position (FIG. 5). In this initial retracted position, the charging spring26is under compression with the blade14inside the cavity20. The actuator spring42biases the actuator36outward, and the inner portion of the actuator36engages with the detent38in the blade14to hold the blade14inside the cavity30to prevent movement of the blade14with respect to the casing12(FIG. 9). In addition, the projection50defined by the safety48engages with the recess52in the casing12to prevent inadvertent inward movement or operation of the actuator36.

To deploy the blade14, the user first moves the safety48to the unlock position (FIG. 6) by sliding the safety48to the right or rear of the switchblade10to overcome the bias provided by the second spring56. As a result of this movement of the safety48, the projection50of the safety48is no longer engaged with the recess52in the casing12, and the safety48is in the unlock position that enables operation of the actuator36. While holding the safety48in the unlock position, the user may then depress the actuator36into the cavity20to overcome the actuator spring42bias and align the relief slot40with the blade14(FIG. 7). In this alignment, the actuator36is in the release position that permits movement of the blade14with respect to casing12, and the charging spring26pushes the blade14linearly and parallel to the longitudinal axis22to move the blade14from the retracted position to the deployed position (FIG. 1). The blade14is fully deployed when stop pins64in the blade14reach the end of grooves66in the scale16(FIG. 2). The user may then release the actuator36and safety48, allowing the actuator spring42to bias the actuator36outward to return the actuator36to the hold position and the second spring56to bias the safety48forward to the lock position. With the actuator36again in the hold position and the blade14fully deployed, the relief slot40is no longer aligned with the blade14, and the inner portion of the actuator36engages with an end70of the blade14to again prevent movement of the blade14with respect to the casing. The blade14is now in the deployed position with the actuator36in the hold position to prevent the blade14from retracting and the safety48in the lock position to prevent inadvertent operation of the actuator36.

To retract the blade14, the user moves the safety48to the unlock position (FIG. 6) by sliding the safety48to the right or rear of the switchblade10to overcome the bias provided by the second spring56. As a result of this movement of the safety48, the projection50of the safety48is no longer engaged with the recess52in the casing12, and the safety48is in the unlock position that enables operation of the actuator36. While holding the safety48in the unlock position, the user may then depress the actuator36into the cavity20to overcome the actuator spring42bias and align the relief slot40with the blade14(FIG. 7). In this alignment, the actuator36is in the release position that permits movement of the blade14with respect to casing12.

The user may then pinch the ends of the latches58together to overcome the latch spring62bias to disengage the latches58from the casing12. With the actuator36depressed and the latches58disengaged from the casing12, the user may then withdraw the charging handle34from the casing12or cavity20. As the charging handle34is withdrawn, the charging handle34engages with a charging pin70connected to the blade14to compress the charging spring26and pull the blade14linearly and parallel to the longitudinal axis22back inside the casing12or cavity20. As the blade14begins to move back into the casing12or cavity20, the user may release the actuator36and safety48. However, the sliding blade14is aligned with the relief slot40(FIG. 7), preventing the actuator36from returning to the hold position. When the blade14reaches the fully retracted position, the detent38in the blade14aligns with the inner portion of the actuator36. As a result, the actuator spring42biases the actuator36outward to return the actuator36to the hold position, and the second spring56biases the safety48forward to return the safety48to the lock position. The user may then push the charging handle34back into the casing12or cavity20and release the latches58. The latch springs62pivotally bias the latches58into engagement with the casing12. The blade14is again in the retracted position, with the actuator36in the hold position to prevent the blade14from deploying and the safety48in the lock position to prevent inadvertent operation of the actuator36. The charging handle34is also in the home position and held in place by the latches58.