UTILITY KNIFE

Abstract: A utility knife (10) employs a slide (16) having a cantilevered lever (138) for capturing a blade (18) therein. A leading blade in a reservoir (24) is capturable by the slide (16) using a tooth (158) resiliently affixed to the slide (16) which is positioned to enter a locking hole (82) in the blade (18). The tooth (158) may be withdrawn from the hole (82) in the blade (18) whereby the blade (18) may be removed for reversal and reinsertion or for discard. When the captured blade is removed, the slide (16) may be returned to the loading position for capturing the next blade from the reservoir. As long as a captured blade (18) is engaged by the tooth (158), the slide (16) is prevented from returning to the loading position, and the loading blade in the reservoir is prevented from advancing.

Description: The present invention relates to knives of a type conventionally known as utility knives. Utility knives are widely used in construction, business and hobby applications for cutting such materials as paper board, wallboard, string, and other objects. In a common embodiment, such utility knives have a handle into which is fitted a trapezoidal blade. The blade has a single cutting edge joining the adjacent edges in acute angles. As commonly used, such a utility knife includes means for clamping the blade in the handle with one of a portion of the cutting edge and one of the adjacent sides partially exposed whereby cutting is enabled on any part of the exposed edge. In many applications, the portion of the edge at the junction with the acute angle is most used. This portion becomes dulled before the remainder of the blade. Once the cutting edge revealed in one clamping position becomes dulled, the blade is removed and rotated end for end to place in use the other end of the cutting edge adjacent the opposed acute angle. When the cutting edge at the second end of the blade becomes dulled, the blade is generally discarded and replaced with another blade. Most utility knives employ a screw or similar means for clamping a single blade in one end thereof with the desired portion revealed. When the revealed edge becomes worn, the screw is removed to release the blade for turning end for end. Such installation and reversal of the blade is time consuming and requires the availability of a screwdriver, or other auxiliary tool. Prior patents have disclosed knives with a supply of blades in their handles. One such knife, disclosed in U.S. Patent No. 3,660,896, employs a spring urging a stack of blades from a reservoir into a position where the leading blade can be moved into an operating position. The spring exerts an urging force on the blade stack which varies in accordance with the number of blades in the stack. That is, when several blades are present in the stack, the spring is compressed more tightly and thus exerts a greater force on the stack than when only a single blade is present. The variable force makes the operation of this device less positive than is desirable. U.S. Patent No. 4,517,741 solves the variable-force problem of the above reference by employing a permanent magnet in a blade slide facing the blade reservoir. The leading blade in the blade reservoir is attracted into the blade slide with a force dependent upon the strength of the permanent magnet regardless of the number of blades in the reservoir. A yet further known utility knife disclosed by CH-A-637 057 (corresponding to US-A- 4 277 888) requires a comparatively large number of separate elements for performing the functions of controlling the removal of a single blade from the blade stack, of engaging such blade to slidably move it in a single plane between operative and retracted positions and of locking the blade appropriately in those positions. To this end, the known knife requires that a blade changing device be in an extended position and slide forwardly so that a pushing edge of a flat strip engages the initial blade in the stack and pushes it forward onto support rails of the blade magazine. The blade can then be controlled by a blade pusher, which is slided forward until the selected blade drops down below the support rails and is no longer in the initial plane. It can then be extended into an operative position outside of the housing. Upon further retraction of the pusher, the blade can drop into yet another plane onto gripper arms of a blade changing device and be released from the pusher by sliding the latter backwards. The blade can finally be withdrawn from the bottom of the stack by again removing the blade changing device. As a whole, this device includes numerous components and is considerably difficult to construct and to operate. SUMMARY OF THE INVENTION In order to overcome the drawbacks of the prior art constructions as described before, the present invention is based on the task to provide a utility knife with simplified structure which has a reduced number of separate parts, is easy to handle with regard to a stack of blades contained in the handle of the knife and only allows for advancing a leading blade into an operative position, while preventing other blades in the stack from interfering with a blade in the operative position. This task is accomplished as defined in claim 1 by a knife comprising a first body portion, including a blade reservoir for retaining a stack of knife blades therein, a second body portion matable with said first body portion to provide a knife housing including a blade opening, and a unitary slide member slidably disposed for motion in a predetermined direction within said knife housing, said unitary slide member including blade control means for controlling the removal of a single blade located in a predetermined plane from said stack of blades; blade engagement means for engaging said single blade in a fixed position with respect to said unitary slide member whereby said single blade may be slidably moved within said predetermined plane between at least one operative position projecting through said blade opening and a retracted position within said knife housing; and locking means for locking said unitary slide member in a plurality of fixed positions, including said at least one operative position, without disengaging said blade engagement means from said single blade. Thus, the present invention just requires a unitary, i.e. single, slide member for performing all of the essential functions of the knife instead of a plurality of separate elements for each of the functions, insofar as this single slide member both controls removal of a blade from the top of the stack and engagement of the blade so that it can be moved slidably between operative and retracted positions in a single plane, while the blade can be locked in these positions without necessitating disengagement of the blade engagement means from the blade. The above, and other features, functions and advantages of the present invention will become apparent from the subclaims and the following description read in conjunction with the accompanying drawings, in which like reference numerals designate the same elements. Fig. 1 is a side view of a utility knife in accordance with an embodiment of the invention. Fig. 2 is a side view of a reservoir portion of Fig. 1. Fig. 3 is a side view of a blade-slide portion of Fig. 1. Fig. 4. is a cross section taken along IV-IV in Fig. 2. Fig. 5 is a cross section taken along V-V in Fig. 2. Fig. 6 is a side view of a sleeve of Fig. 1. Fig. 7 is a cross section taken along VII-VII in Fig. 6. Fig. 8 is a side view of a blade suitable for use in the utility knife of Fig. 1. Fig. 9 is an inside view of the blade-slide portion of Fig. 3. Fig. 10 is a cross section taken along X-X in Fig. 9. Fig. 11 is a cross section taken along XI-XI in Fig. 9. Fig. 12 is a cross section taken along XII-XII in Fig. 9. Fig. 13 is a cross section taken along XIII-XIII in Fig. 9. Fig. 14 is an end view taken in a direction XIV-XIV in Fig. 1. Fig. 15 is a cross section taken along XV-XV in Fig. 9. Fig. 16 is a top view of a slide of Fig. 1. Fig. 17 is a bottom view of a slide of Fig. 1. Fig. 18 is a side view of a slide of Fig. 1. Fig. 19 is a cross section taken along XIX-XIX in Fig. 1 showing an operative position at one extreme of motion of the slide. Fig. 20 is a cross section similar to that in Fig. 19 except showing the opposite limit of operative motion of the slide. Fig. 21 is a cross section taken along XXI-XXI in Fig. 1 with the slide in its operative position blocking the exit of the leading blade from the trapezoidal reservoir. Fig. 22 is a cross section similar to that in Fig. 21 except with the slide in its loading position permitting the leading blade to exit the trapezoidal reservoir for engagement on the slide. Fig. 23 is a side view of the utility knife according to an embodiment of the invention with the slide in its loading position and a portion of the tail of the slide extending outside the body. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT Referring to Fig. 1, there is shown, generally at 10, a utility knife according to an embodiment of the invention. Utility knife 10 includes a body 12 consisting of two parts, to be later described, held together by a sleeve 14. A slide (unitary slide member) 16, only partly visible in the figure, controls the position of a blade 18. Good engineering design conventionally attempts to attain maximum function using a minimum amount of material. It is contemplated that parts of utility knife 10 will contain cavities and stiffening webs for reducing the amount and weight of material without sacrificing performance. Such cavities and webs are conventional and the added complication occasioned by their inclusion herein would interfere with an understanding of the invention. Thus, except where it bears a relationship to the invention herein, such structure is omitted. Referring now to Figs. 2 and 3, body 12 consists of a blade-slide portion (second body portion) 20 (also visible in Fig. 1) and a reservoir portion (first body portion) 22, fitted face to face and held in that position by sleeve 14 (Fig. 1) slid thereupon. Reservoir portion 22 includes a trapezoidal reservoir 24 passing completely therethrough. A generally planar face 26 includes a plurality of cylindrical cavities 28 for engagement by matching cylindrical posts (not shown) protruding from blade-slide portion 20. A reduced-diameter portion 30 includes an abutment ledge 32, the hidden portion of which is shown in dashed line. Reduced-diameter portion 30 accommodates the thickness of material of sleeve 14 and limits the operational position of sleeve 14. Referring now momentarily to Figs. 4 and 5, a control slot 34 includes a stop boss 36 at an inner end thereof. A stop surface 38 on stop boss 36 faces control slot 34. Control slot 34, stop boss 36 and stop surface 38 are employed by utility knife 10 in controlling whether or not a new blade 18 may be selected from trapezoidal reservoir 24, as will be explained. First and second rectangular guide slots 40 and 42 are disposed in reservoir portion 22 for engagement by correspondingly shaped guide ribs (not shown) extending from blade-slide portion 20. Referring again to Fig. 3, a reduced-diameter portion 44 terminates at its inner end in an abutment ledge 46 corresponding, respectively, to reduced-diameter portion 30 and abutment ledge 32 of reservoir portion 22 (Fig. 2). A rectangular control slot 48 is disposed longitudinally in body 12. A control rib 50 is disposed adjacent to control slot 48. A longitudinal edge 52 is disposed on control rib 50. A mode-change slot 54 extends transverse to control slot 48 into control rib 50. Chamfers 56 and 58, at opposed sides of mode-change slot 54, provide guidance thereinto. Referring now to Figs. 6 and 7, sleeve 14 is a generally C-shaped member in cross section with a back 60, two opposed end surfaces 62 and 64, and two wings 66 and 68 extending toward each other. Wings 66 and 68 terminate in edges 70 and 72 defining a gap 74 therebetween. An end 76 includes an inclination substantially equal to an inclination of abutment ledge 32 (Fig. 2) and abutment ledge 46 (Fig. 3). The position and dimension of gap 74 permit sleeve 14 to slide onto reduced-diameter portion 30 and reduced-diameter portion 44 of blade-slide portion 20 and reservoir portion 22 with edge 70 guided along longitudinal edge 52 and edge 72 just clear of control slot 48. This assembled relationship is especially clear in Fig. 1. Although not illustrated in the figures, wings 66 and 68 may be angled inward in their unstressed condition. Springback in the metal forming sleeve 14 may then permit wings 66 and 68 to establish a resilient grip on the remainder of utility knife 10 for secure assembly thereof. In addition, frictional contact with the exterior of sleeve 14 may be improved by knurling on it surface or slots therethrough (both of which are conventional and thus are not shown). Referring now to Fig. 8, blade 18 includes a cutting edge 79 at one side thereof and a back edge 80 at the opposed side thereof. An aperture notch or locking hole 82 is disposed in blade 18. The outline of blade 18 may be of any convenient shape including rectangular. One common outline shape is the illustrated regular trapezoidal shape having first and second angled edges 84 and 86 meeting cutting edge 79 at acute angles 88 and 90, respectively. One skilled in the art, with the present disclosure for reference, will understand that the size, shape and position of locking hole 82 may be varied at will with corresponding changes in mating elements (described later) in utility knife 10. In particular, locking hole 82 may be replaced by one or more notches (not shown) extending inward from back edge 80 without departing from the spirit and scope of the invention. Referring now to Fig. 9, blade-slide portion 20 is shown rotated 180 degrees about its longitudinal axis to reveal internal details. It should be noted that elements in Fig. 9 are up-down inverted from corresponding elements in the other figures. An upper planar surface 92 outlines substantially all of an upper edge of blade-slide portion 20 as seen in the figure. Similarly, a lower planar surface 94 outlines substantially all of a lower edge of blade-slide portion 20 as seen in the figure. Cylindrical posts 96 extend outward from the plane of the figure for engagement in cylindrical cavities 28 of reservoir portion 22 (Fig. 2). With such engagement accomplished, upper planar surface 92 and lower planar surface 94 are disposed in abutment with planar face 26 (Fig. 2). Referring now also to Fig. 10, a tail slot 98 extends through a rear end 100 of blade-slide portion 20. Referring now also to Fig. 11, a head slide 102 is disposed adjacent an inner end of tail slot 98 and extends almost to a forward end 104 of blade-slide portion 20. An abutment stop 106 is disposed near forward end 104. It will be noted that control slot 48 is centrally disposed in head slide 102, extending almost the full length thereof. First and second blade-guide steps 108 and 110, disposed adjacent opposed edges of head slide 102, together form a blade guide for slidably guiding the opposed edges of a blade 18 (not shown in the presently referenced figures). Referring now to Fig. 12, head slide 102 is substantially deeper than tail slot 98, thus forming a step 112 at the junction thereof. In Fig. 9, it will be noted that head slide 102 is also wider than tail slot 98, thus forming an end wall 114 at the junction thereof. Referring now also to the cross section of blade-slide portion 20 in Fig. 13, a long locating rib 116 projects from upper planar surface 92 immediately adjacent blade-guide step 108. A short locating rib 118 projects from lower planar surface 94 immediately adjacent blade-guide step 110. Referring momentarily to Fig. 2, long locating rib 116 fits guidingly into guide slot 40 and short locating rib 118 fits guidingly into guide slot 42. One skilled in the art will recognize the value of long locating rib 116 and short locating rib 118 in their locations since they provide positive protection against a blade 18 (not shown in the presently referenced figures) sliding out of a crack formed between planar face 26 and abutting surfaces of upper planar surface 92 and lower planar surface 94. Referring now to the end view of utility knife 10 in Fig. 14, forward end 104 of blade-slide portion 20 contains a rectangular depression 120 which, with planar face 26 of reservoir portion 22, forms a slot through which blade 18 may be moved into its operational position shown in Fig. 1. Referring now to Figs. 9 and 15, an inner surface 122 of blade-slide portion 20 opposed to control rib 50, contains a plurality, suitably three, operational lock wells 124, 126 and 128, and a retraction lock well 130. Operational lock wells 124, 126 and 128 are suitably of rectangular cross section. Retraction lock well 130 may optionally also have a greater depth than operational lock wells 124, 126 and 128 in order to improve the positiveness of locking. The functions of operational lock wells 124, 126 and 128, and of retraction lock well 130, will be detailed hereinafter. Referring now to Figs. 16, 17 and 18, slide 16 cooperates with the remainder of utility knife 10 to obtain a single blade 18 from trapezoidal reservoir 24 of reservoir portion, transport it to, and lock it into, a selectable one of a plurality of operational positions or a retracted position, to release a blade 18 in order to permit its reversal or its discard, and to prevent another blade 18 from being moved to an operational position until a previously operational blade 18 is removed. Slide 16 includes a generally rectangular tail 134, a generally rectangular head 136 and a cantilevered lever 138. As best seen in Figs. 16 and 17, tail 134 is narrower than head 136. In addition, as best seen in Fig. 18. tail 134 is also thinner than head 136. A forward surface portion 142 of head 136 is recessed from a rear surface portion 144 thereof by a dimension substantially equal to a thickness of a blade 18. Forward surface portion 142 and rear surface portion 144 meet at a diagonal step 146 having an angle substantially equal to the angle made by an edge of blade 18. The surface of rear surface portion 144 is substantially coplanar with an adjacent surface 148 of tail 134. The illustrated embodiment of the invention conforms to the teaching of my prior referenced patent, whereby a permanent magnet 150 is embedded in forward surface portion 142 with its surface generally coplanar with forward surface portion 142. Cantilevered lever 138 is affixed to head 136 at an attachment point 152 for supporting a cantilevered portion 154 resiliently joined thereto by a thinned spring portion 156. Cantilevered portion 154 includes a tooth or dog 158 which, in the operational relationship between slide 16 and blade 18, aligns a tip 160 with locking hole 82. Dog 158 preferably includes tapered edges for reducing the precision of positioning required to attain penetration of locking hole 82. A control peg 162 extends from one side of attachment point 152. Control peg 162 may have any convenient cross-sectional shape including rectangular or circular, however, a circular shape with a flat surface 164 disposed facing away from tip 160 offers functional advantages. Referring specifically to Fig. 18, dog 158 has a locking position, shown in dashed line, wherein it penetrates a substantial distance through locking hole 82 for positive mechanical lock of blade 18 to slide 16. In its solid-line unlocking position, dog 158 is withdrawn from locking hole 82 whereby blade 18 may be separated from slide 16 by sliding it in a direction parallel to its plane. Blade removal is preferably performed with slide 16 in its fully rightward position with control peg 162 resting on the outer surface of control rib 50 rightward of mode-change slot 54. Even when unlocked, however, diagonal step 146 prevents blade 18 from being moved further to the left in Figs. 16-18. In addition, permanent magnet 150 attracts blade 18 toward it with a force effective for retaining blade 18 in a stationary position with respect to slide 16 by friction therebetween until blade 18 is slid positively toward the right, as by a user grasping and pulling it free. Referring now also to Fig. 9, slide 16 is installed in blade-slide portion 20 with tail 134 positioned in tail slot 98, head 136 positioned in head slide 102, and part of cantilevered lever 138 passing through control slot 48. Reservoir portion 22 (Fig. 2) may then be installed on blade-slide portion 20 and slide 16, and the entire assembly of utility knife 10 may be completed by sliding sleeve 14 into place over blade-slide portion 20 and reservoir portion 22. A supply of blades 18 may be installed in trapezoidal reservoir 24 before sleeve 14 is fully engaged. Operation of utility knife 10 may be divided into positioning a blade 18 in one of a plurality of operational positions and a retracted position, in loading a blade 18, and in releasing a blade 18 for reversal or disposal. For establishing all operational and retracted positions, control peg 162 is disposed within head slide 102 in engagement with one of operational lock wells 124, 126, or 128 or with retraction lock well 130. A resilience provided by thinned spring portion 156 is effective for maintaining positive engagement in any of these positions. Referring now to Figs. 19 and 20, in any of the operational positions or the retracted position, dog 158 is urged through and beyond locking hole 82 into control slot 34. In its forward-most position (Fig. 19), dog 158 is stopped by contact with forward end 104. This is the fully extended position shown in Fig. 1. Blade 18 is held firmly by dog 158 in this condition and cannot be removed. In its rear-most position in which blade 18 is fully retracted into utility knife 10 (Fig. 20), dog 158 is stopped by contact with stop surface 38 of stop boss 36. Even if blade 18 is not installed on head 136 at this time, the thickness of head 136 at rear surface portion 144 holds a leading blade 18 within trapezoidal reservoir 24 rather than permitting it to move into an interfering position. Referring also momentarily to Figs. 1 and 9, loading and/or release of a blade 18 is performed by sliding slide 16 until control peg 162 is aligned with mode-change slot 54 (Figs. 1 and 9) and pulling upward on cantilevered portion 154 until control peg 162 is disposed on the outside of blade-slide portion 20. This action withdraws dog 158 from locking hole 82 (Figs. 19 and 20), as well as moves it out of possible contact with stop surface 38 of stop boss 36. Sliding cantilevered lever 138 forward or backward out of alignment with mode-change slot 54 permits control peg 162 to slide along the outside of control rib 50 (Fig. 1). With dog 158 removed from locking hole 82, blade 18 may be removed from utility knife 10 by pulling forward thereon. Blade 18 may be discarded or may be reversed and reinserted onto forward surface portion 142. Magnet-induced friction between abutting surfaces of blade 18 is sufficient to maintain blade 18 in aligned contact with forward surface portion 142, while head 136 is drawn backward into utility knife 10 for engaging locking hole 82 with dog 158. Referring now to Fig. 21, at any time except when slide 16 is in position to load a blade 18, tail 134 faces a leading blade 18 in trapezoidal reservoir 24. The thickness of tail 134 is great enough that the leading blade 18 is prevented from moving into contact with blade-guide step 108 and blade-guide step 110 and is thus retained in trapezoidal reservoir 24. Referring now to Fig. 22, when slide 16 is moved into its loading position, forward surface portion 142 of head 136 faces trapezoidal reservoir 24. Forward surface portion 142, being recessed from the remainder of slide 16, permits the leading blade 18 to move into contact with blade-guide step 108 and blade-guide step 110 and to be moved forward into may be captured as previously described. Referring now to Fig. 23, utility knife 10 is shown in the loading condition of Fig. 22. It will be noted that cantilevered lever 138 is in its fully leftward position and control peg 162 is disposed on the outside supported by control rib 50. Tail 134 of slide 16 is shown protruding from utility knife 10 in this condition. Such protrusion is not a necessary element of utility knife 10 but is conveniently availed of in order to reduce the required lengths of blade-slide portion 20 and reservoir portion 22. Alternatively, these elements could be made long enough to contain all of tail 134 in its loading position. One skilled in the art, with the guidance of the present disclosure, will recognize that the use of permanent magnet 150 (Figs. 16, 17 and 22) to aid in urging the leading blade 18 toward slide 16 is a convenient way to accomplish this effect. The invention should not be considered to be limited to such an embodiment, however. It is contemplated that the attractive urging of permanent magnet 150 could be replaced by repulsive urging of a spring (not shown) behind the trailing blade 18 in trapezoidal reservoir 24 without departing from the spirit and scope of the invention. Indeed, embodiments of the invention having both permanent magnet 150 and a spring are foreseen. In addition, both permanent magnet 150 and a spring may be omitted from an embodiment which relies on gravity for urging blade 18 into contact with slide 16.

Claims: A knife comprising a first body portion (22), including a blade reservoir for retaining a stack of knife blades (18) therein, a second body portion (20) matable with said first body portion to provide a knife housing including a blade opening, and a unitary slide member (16) slidably disposed for motion in a predetermined direction within said knife housing (20, 22), said unitary slide member including a) blade control means (150, 136, 142, 144, 146) for controlling the removal of a single blade (18) located in a predetermined plane from said stack of blades, b) blade engagement means (158) for engaging said single blade in a fixed position with respect to said unitary slide member whereby said single blade may be slidably moved within said predetermined plane between at least one operative position projecting through said blade opening and a retracted position within said knife housing, and c) locking means (124, 126, 128, 130 and 162) for locking said unitary slide member in a plurality of fixed positions, including said at least one operative position, without disengaging said blade engagement means from said single blade. The knife according to claim 1 wherein said knife blades (18) include at least one aperture (82), and wherein said blade engagement means comprises a tooth (158), said tooth being movable between a first position within said predetermined plane and a second position outside of said predetermined plane. The knife according to claim 1 or 2 wherein said blade control means comprise a head portion (136) including a rear surface (144) disposed parallel to said predetermined plane when said unitary slide member (16) is disposed within said knife housing, and a recessed portion (146) including a forward surface (142) disposed parallel to said rear surface, said forward surface being displaced from said rear surface by a distance substantially corresponding to the thickness of said single blade such that said slidable movement of said unitary slide member (16) across said stack of blades in said predetermined plane results in the removal of said single blade therefrom. The knife according to claim 3 wherein said blade control means further include magnet means (150) disposed in said second surface to maintain said single blade (18) thereagainst. The knife according to any one of claims 1 to 3 wherein said locking means comprise a plurality of locking wells (124, 126, 128, 130) disposed on the inner surface of said second body portion (20) and parallel to said predetermined direction, and control peg (162) projecting from said blade engagement means (158), which are designed to move between a first blade engaging position in which said control peg is disposed in one of said locking wells, and a second blade engaging position in which said control peg is displaced from said locking walls. The knife according to claim 5 wherein said tooth (158) as said blade engagement means and said control peg (162) are resiliently attached (156) to said unitary slide member (16). The knife according to claim 6 wherein said second body portion (20) includes a control slot (48), whereby said control peg (162) can pass through said control slot, with said first blade engaging position being located within said knife housing and said second blade engaging position being located outside of said knife housing. The knife according to any one of claims 1 to 3 wherein a sleeve (14) is fitted over said first and second body portions (22,20). The knife according to claim 8 wherein said sleeve (14) has a generally C-shaped configuration and is slidable over said first and second body portions (22,20). The knife according to claim 8 or 9 wherein a part of said body portions (22,20) is recessed with regard to the remainder thereof such as to receive said sleeve (14) in a manner to lie flush with said remainder.

Inventors: CASTELLUZZO, JAMES
Applicants: CASTELLUZZO, JAMES
Application year: 1987
Main classification: B26B1
IPC codes: B26B1, B26B5