Abstract:
A blade dispenser assembly includes a housing and an integrally formed shuttle mechanism which functions to dispense one blade at a time from the bottom of a stack of blades held within the housing. The shuttle mechanism is configured to engage a bottommost blade in the stack when in a closed position and to carry the engaged blade with it when the shuttle mechanism is moved to an opened position. In the opened position, the shuttle mechanism is partially extended from the housing and securely holds and displays the withdrawn blade. An exemplary preferred shuttle mechanism is pivotally coupled to the housing and includes an arm portion that allows a person to pivot the shuttle mechanism away from the housing while keeping the person&#39;s hand safely away from the blade being withdrawn. The blade dispenser assembly also includes a follower mechanism that is positioned adjacent the top of the stack of blades and mechanically coupled to the housing such that it descends with the stack of blades as successive blades are withdrawn from the bottom of the stack and such that it retains its position relative to the housing when the assembly is turned upside down, thereby functioning as a one-way ratchet that prevents the stack of blades from falling away from the shuttle mechanism.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS  
       [0001]    This application is related to U.S. design patent application Ser. No. ______ entitled “Blade Dispenser Apparatus” filed herewith. 
     
    
     
       BACKGROUND OF THE INVENTION  
         [0002]    1. Field of Invention  
           [0003]    The present invention relates generally to a blade dispenser and, more specifically, to a blade dispenser assembly with a housing, a shuttle mechanism for safely dispensing individual blades from a stack of blades stored within the housing, and a follower mechanism for providing a partition between new and used blade portions of the housing and for preventing the stack of blades from falling away from the shuttle mechanism when the blade dispenser assembly is turned upside down.  
           [0004]    2. Description of the Related Art  
           [0005]    A variety of apparatuses are known for dispensing a single razor blade at a time from a stack of blades. For example, U.S. Pat. No. 4,789,080 to Iten discloses a utility blade dispenser formed to expose the side edge of a utility blade while it is still at the bottom of the stack of blades within the dispenser, so that a sideways pushing force may be applied by a person&#39;s finger to separate this bottommost blade from the stack. Similarly, U.S. Pat. No. 4,826,042 to Vujovich discloses a blade dispenser with a knob that a person slides to eject a blade from the dispenser.  
           [0006]    While such blade dispensers are not likely to present a danger to a careful operator, it would nevertheless be desirable to be able to provide a blade dispenser apparatus that eliminates the need for a person to make any direct contact with a blade in order to effect an initial lateral separation of that blade from the other blades in the stack—a motion, that if not done carefully, can result in the blade rapidly ejecting from the dispenser and causing an injury. A clumsily withdrawn blade can also fall to the floor where it might get lost and later be discovered by a crawling infant or small child. It would also be desirable to be able to provide a blade dispenser apparatus that is free of mechanisms that potentially extend a blade from the dispenser toward the user&#39;s hand.  
           [0007]    It would be desirable to be able to simultaneously ensure the integrity of the stack of blades within the dispenser, independent of the orientation of the dispenser relative to the direction of forces such as gravity incident upon the dispenser. Moreover, it would be desirable to be able to provide a safe and convenient way to also use such a blade dispenser apparatus as a disposal mechanism for receiving used blades without interfering with the aforementioned functionality.  
         SUMMARY OF THE INVENTION  
         [0008]    A blade dispenser assembly according to an exemplary preferred embodiment of the present invention includes a housing and an integrally formed shuttle mechanism which functions to safely dispense one blade at a time from the bottom of a stack of new blades held within the housing. The shuttle mechanism is configured to engage a bottommost blade in the stack when in a closed position and to carry the engaged blade with it when the shuttle mechanism is thereafter moved to an opened position. In the opened position, the shuttle mechanism is partially extended from the housing and securely holds and displays the withdrawn blade. An exemplary preferred shuttle mechanism is pivotally coupled to the housing and includes an arm portion that allows a person to pivot the shuttle mechanism away from the housing while keeping the person&#39;s hand safely away from the blade being withdrawn.  
           [0009]    An exemplary preferred blade dispenser assembly also includes a follower mechanism which functions as a one-way ratchet that prevents the stack of blades from shifting their orientation within the assembly and separates the stack of new blades from a used blade receptacle within the assembly. The follower mechanism ensures the integrity of the stack of new blades within the housing and, more specifically, maintains the positioning of the stack of blades adjacent the shuttle mechanism.  
           [0010]    According to an exemplary preferred embodiment of the present invention, a blade dispenser assembly includes: a housing defining a vertical channel that laterally supports a stack of blades thereabout; a shuttle mechanism mechanically coupled to the housing such that the shuttle mechanism withdraws a blade from the bottom of the stack when the shuttle mechanism is moved to an opened position in which a portion of the shuttle mechanism is extended from the housing; and a follower mechanism mechanically coupled to the housing such that the follower mechanism descends within the housing adjacent a top portion of the stack as blades are successively removed from the bottom of the stack. The shuttle mechanism is formed such that the blade withdrawn from the housing by the shuttle mechanism is accessible for removal from the shuttle mechanism when the shuttle mechanism is in its opened position, and such that a next blade of the stack is mechanically engaged by the shuttle mechanism after the blade withdrawn from the housing is removed from the shuttle mechanism and the shuttle mechanism is moved back to a closed position beneath the stack.  
           [0011]    In a preferred embodiment, the follower mechanism separates the housing into a lower portion for new blades and an upper portion for used blades, and the upper portion includes an aperture sized to receive the used blades. In a preferred embodiment, the follower mechanism is formed to function as a one-way ratchet such that when the blade dispenser assembly is turned upside down the follower mechanism maintains its position relative to the housing thereby preventing the unused blades from falling away from the shuttle mechanism.  
           [0012]    According to another exemplary preferred embodiment of the present invention, a blade dispenser assembly includes: a housing sized to receive a stack of blades; and a shuttle pivotally coupled to the housing and shaped such that a blade from the stack is engaged by the shuttle when the shuttle is in a closed position and such that the blade is drawn from the stack and extended from the housing when the shuttle is moved to an opened position.  
           [0013]    In a preferred embodiment, the shuttle includes a blade receiving surface and a plurality of ridges at peripheral portions of the blade receiving surface. In a preferred embodiment, the housing includes a front side with a recessed portion, and the shuttle includes an arm portion that fits within the recessed portion when the shuttle is in its closed position. In a preferred embodiment, the shuttle includes a stop member positioned to make contact with a portion of the housing once the shuttle has been pivoted a predetermined amount relative to the housing. In a preferred embodiment, the housing includes a post member, and the shuttle includes a sleeve that receives the post member therein pivotally coupling the shuttle to the housing. In a preferred embodiment, the post member and sleeve are formed such that a full bearing surface is provided for pivoting the shuttle relative to the housing.  
           [0014]    According to another exemplary preferred embodiment of the present invention, a blade dispenser assembly includes: a housing configured to hold a stack of blades and to facilitate dispensing one blade at a time from the housing; a shuttle member mechanically coupled to the housing and shaped such that the shuttle member engages a blade from the bottom of the stack when the shuttle member is in a closed position and such that the shuttle member extends from the housing with the engaged blade when the shuttle member is moved to an opened position; and a follower member positioned above the stack and mechanically coupled to the housing such that the follower member can only move in one direction within the housing, descending with a top portion of the stack as the stack becomes smaller.  
           [0015]    In a preferred embodiment, the housing is formed with a vertical channel and includes a follower guide member that faces the vertical channel, and the follower member includes a main portion shaped to fit within the housing and a cantilevered portion positioned between the vertical channel and the follower guide member. In a preferred embodiment, the follower member includes an attaching portion between the main portion and the cantilevered portion, the attaching portion fitting within the vertical channel. In a preferred embodiment, the main portion and the cantilevered portion approximately form a right angle.  
           [0016]    The above described and many other features and attendant advantages of the present invention will become apparent as the invention becomes better understood by reference to the following detailed description when considered in conjunction with the accompanying drawings. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0017]    Detailed description of preferred embodiments of the inventions will be made with reference to the accompanying drawings.  
         [0018]    [0018]FIG. 1 is a front perspective view of an exemplary preferred blade dispenser assembly according to the present invention shown with its shuttle mechanism in a closed position;  
         [0019]    [0019]FIG. 2 shows the blade dispenser assembly of FIG. 1 with the shuffle mechanism in an opened position;  
         [0020]    [0020]FIG. 3 is an exploded view of the blade dispenser assembly of FIG. 1;  
         [0021]    FIGS.  4 A- 4 C are front, side and top views, respectively, of the blade dispenser assembly of FIG. 1;  
         [0022]    [0022]FIG. 4D is a cross-sectional view of the blade dispenser assembly along line A-A of FIG. 4A;  
         [0023]    [0023]FIG. 4E is a back view of the blade dispenser assembly of FIG. 1;  
         [0024]    [0024]FIG. 4F is a cross-sectional view of the blade dispenser assembly along line B-B of FIG. 4A;  
         [0025]    [0025]FIG. 4G is a cross-sectional view of the blade dispenser assembly along line C-C of FIG. 4E;  
         [0026]    [0026]FIGS. 5 and 6 are back and front perspective views, respectively, of the back cover of the blade dispenser assembly of FIG. 1;  
         [0027]    FIGS.  7 A- 7 E are front, side, back, top and bottom views, respectively, of the back cover of the blade dispenser assembly of FIG. 1;  
         [0028]    [0028]FIGS. 8 and 9 are back and front perspective views, respectively, of the front cover of the blade dispenser assembly of FIG. 1;  
         [0029]    FIGS.  10 A- 10 F are front, right side, left side, back, top and bottom views, respectively, of the front cover of the blade dispenser assembly of FIG. 1;  
         [0030]    [0030]FIGS. 11 and 12 are top and bottom perspective views, respectively, of the shuttle mechanism of the blade dispenser assembly of FIG. 1;  
         [0031]    FIGS.  13 A- 13 E are front, right side, left side, top and bottom views, respectively, of the shuttle mechanism of the blade dispenser assembly of FIG. 1;  
         [0032]    [0032]FIG. 14 is a front perspective view of the follower mechanism of the blade dispenser assembly of FIG. 1; and  
         [0033]    FIGS.  15 A- 15 C are front, side and top views, respectively, of the follower mechanism of the blade dispenser assembly of FIG. 1. 
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0034]    The following is a detailed description of the best presently known mode of carrying out the invention. This description is not to be taken in a limiting sense, but is made merely for the purpose of illustrating the general principles of the invention.  
         [0035]    Referring to FIGS.  1 - 3 , an exemplary preferred blade dispenser assembly  100  according to the present invention includes a back cover  102 , a front cover  104 , a shuttle mechanism  106  and a follower mechanism  108 . The back cover  102  and the front cover  104  are shaped such that when they are assembled together they form a housing that receives and provides lateral support for a stack  110  of razor blades. The shuttle mechanism  106  provides longitudinal support for the stack  110  and is mechanically coupled to the back cover  102  such that it can be moved back and forth from a closed position (FIG. 1) to an opened position (FIG. 2). The shuttle mechanism  106  is shaped to perform the functions of engaging the bottommost blade of the stack  110  when in the closed position and withdrawing this engaged blade from the bottom of the stack  110  when moved toward the opened position. The follower mechanism  108  is positioned on top of the stack  110  of blades and, by virtue of its shape and how it mechanically interfits with portions of the back cover  102 , functions as a one-way ratchet that descends adjacent the topmost blade of the stack  110  as the stack decreases in height. The follower mechanism  108  also defines and functions as a partition between a lower portion of the housing, within which the stack  110  of blades is positioned, and an upper portion of the housing, within which used blades can be discarded. Accordingly, in the illustrated exemplary blade dispenser assembly  100 , the front cover  104  is formed with an aperture  112  sized to facilitate the insertion of used razor blades into the upper portion of the housing.  
         [0036]    Referring also to FIGS.  4 A- 4 G,  5 ,  6  and  7 A- 7 E, the back cover  102  includes a lower front portion  120  that is formed with a plurality of surfaces some of which are complementary to the shape of the shuttle mechanism  106 . In the illustrated exemplary blade dispenser assembly  100 , the lower front portion  120  includes a cylindrical post member  122 , a first shuttle support surface  124  (which is preferably formed with a groove  125  as shown), a second shuttle support surface  126  (which is preferably formed with a safety latch  127  as shown) and front recessed surfaces  128 ,  130  which are all complementary in shape to various surfaces of the shuttle mechanism  106 . Consequently, a lower front surface  132  of the back cover  102  is flush with a front surface of the shuttle mechanism  106  when the shuttle mechanism is in its closed position. As discussed below in greater detail, the cylindrical post member  122  and the first and second shuttle support surfaces  124 ,  126  additionally function to support the shuttle mechanism  106 , and the cylindrical post member  122  mechanically couples the shuttle mechanism  106  to the back cover  102 .  
         [0037]    The lower front portion  120  of the back cover  102  also includes a first angled side surface  134  that is formed with a recessed portion  136  as shown. The lower front portion  120  also includes a second angled side surface  138 . Preferably, but not necessarily, the first and second angled side surfaces  134 ,  138  are formed such that they are flush with corresponding angled side surfaces of the front cover  104  when the blade dispenser  100  is assembled. The illustrated exemplary back cover  102  also includes a mounting portion  140  formed with holes and/or some other mechanism for securing the blade dispenser assembly  100  to a wall or other surface.  
         [0038]    The illustrated exemplary back cover  102  additionally includes a blade contact piece  142  that spans between the lower front portion  120  and the mounting portion  140 . The blade contact piece  142  is preferably formed as shown with a vertical channel  144 , and the back cover  102  further includes a guide member  146  that faces the vertical channel  144 . The vertical channel  144  and the guide member  146  are further discussed infra with reference to the follower mechanism  108 .  
         [0039]    Referring also to FIGS. 11, 12 and  13 A- 13 E, the illustrated exemplary shuttle mechanism  106  includes a blade receiving surface  150  and a plurality of ridges  152 ,  154 ,  156  formed thereabout. When the shuttle  106  is in its closed position, the bottommost blade in the stack is engaged, or positioned on the blade receiving surface  150  with the ridges  152 ,  154 ,  156  situated thereabout. When the shuttle  106  is moved toward its opened position, the bottommost blade is withdrawn from the stack, i.e., laterally repositioned relative to the stack and extended from the housing along with the blade receiving surface  150 . Preferably, the shuttle mechanism  106  is also formed with a stop member  158  that is sized and positioned to fit within the groove  125  in the first shuttle support surface  124 . The length of the groove  125  and positioning of the stop member  158  on the shuttle mechanism  106  define the maximum extent to which the shuttle mechanism  106  can be extended from the housing, i.e., the opened position. In the illustrated exemplary embodiment where the shuttle mechanism  106  is formed with a sleeve  160  that fits about the post member  122 , contact between the stop member  158  and the end of the groove  125  limits how far the shuttle mechanism  106  can pivot away from the lower front portion  120 . The post member  122  and sleeve  160  are preferably formed such that the post provides support at both the top and bottom of the sleeve, thus providing a full bearing surface for pivoting the shuttle.  
         [0040]    The shuttle mechanism  106  is preferably formed with a plurality of surfaces that are complementary to surfaces of the back and front covers  102 ,  104 . The illustrated exemplary shuttle mechanism  106  includes perimeter support rails  162 ,  164 ,  166  and a diagonal support rail  168 . The perimeter support rail  162  spans from the stop member  158  to the sleeve  160 . The perimeter support rail  164  spans between another portion of the sleeve  160  and the perimeter support rail  166 . The diagonal support rail  168  spans between the perimeter support rail  166  and the stop member  158 . The illustrated exemplary shuttle mechanism  106  is also formed with an arm portion  170  that continues from the perimeter support rail  166  and also extends downward. Preferably, the arm portion  170  is sized to fit against the front recessed surfaces  128 ,  130  of the back cover  102  such that the arm portion  170  and the lower front surface  132  of the back cover  102  are flush when the shuttle mechanism  106  is in its closed position. The illustrated exemplary shuttle mechanism  106  also includes a bottom surface  172  parallel to the blade receiving surface  150 . Preferably, the shuttle mechanism  106  is also formed with an indented edge surface  174  that adjoins the blade receiving surface  150  and the bottom surface  172 . The indented edge surface  174  allows a user of the blade dispenser assembly  100  to grasp both sides of a blade that has been withdrawn from the stack and carried with the shuttle mechanism  106  to its opened position. Thus, surfaces of the back cover  102  and the shuttle mechanism  106 , respectively, that are preferably complementary in shape include: the cylindrical post member  122  and the sleeve  160 ; the first shuttle support surface  124  and the perimeter support rails  162 ,  164 ,  166  and the diagonal support rail  168 ; the groove  125  and the stop member  158 ; the second shuffle support surface  126  and the bottom surface  172 ; and the first and second recessed surfaces  128 ,  130  and the arm portion  170 .  
         [0041]    During pivoting of the shuttle mechanism  106  back and forth between its closed and opened positions, the diagonal support rail  168  serves to limit “sagging” of the shuttle mechanism  106  thereby ensuring shuttle movement precision. The safety latch  127  performs a catching function and helps the shuttle mechanism  106  to stay closed when not in use. Significantly, the arm portion  170  extends below the blade receiving surface  150  which keeps a user&#39;s hand away from an engaged blade as the blade is being laterally separated from the other blades in the stack. As an added safety feature, the stop member  158  limits movement of the shuttle mechanism  106  such that only a portion of the shuttle mechanism  106  extends from the lower front portion  120  of the back cover  102 , even when the shuttle is in its fully opened position. Consequently, a blade that has been carried with the shuttle mechanism  106  to the opened position remains “pinned” between the blade receiving surface  150  and the front cover  104  until it is slid out of the shuttle mechanism  106  by the user. Accordingly, the design of the shuttle mechanism  106  and the integral way in which it mechanically interfaces the other components of the blade dispenser assembly  100  together prevent a blade from accidentally being flying off of the blade receiving surface  150  as the shuttle mechanism  106  is moved toward its opened position.  
         [0042]    Referring also to FIGS. 8, 9 and  10 A- 10 F, the front cover  104  is formed in such a manner that it can be fitted to the back cover  102 . The illustrated exemplary front cover  104  is formed with left and right inner edge portions  180 ,  182  that are shaped to snap fit over complementary left and right outer edge portions  184 ,  186  of the back cover  102 , respectively. Other interconnection structures can also be employed for the purpose of securing the front cover  104  to the back cover  102 .  
         [0043]    In the illustrated exemplary embodiment of the blade dispenser assembly  100 , the aperture  112  in the front cover  104  is formed and positioned such that it will be clearly visible from the front, top and side of the assembly. Accordingly, users of the blade dispenser assembly  100  are more likely to also utilize the assembly as a used blade receptacle, rather than dispose of used blades by simply tossing them into the nearest trashcan thereby subject trash collection personnel and others to potential injury. Additionally, labels or other visible indicia (e.g., stickers, silk screening or molded-in lettering with operating instructions, safety warnings, corporate logos, advertisements, etc.) can be applied to the outer surfaces  188 ,  190 ,  192 ,  194  of the front cover. The outer surfaces  190  and  194  are preferably, but not necessarily, formed with recesses  196  which are shaped and positioned to provide contact surfaces for a screwdriver or other tool during removal of the front cover  104  from the back cover  102 . Preferably, the front cover  104  is also formed with ridges  198  to provide for better gripping of the blade dispenser assembly  100 , and the front cover  104  in particular.  
         [0044]    The follower mechanism  108  is mechanically coupled to the housing provided by the back cover  102  and the front cover  104  such that the follower mechanism  108  descends within the housing adjacent a top portion of the stack as blades are successively removed from the bottom of the stack. The follower mechanism  108  is also mechanically coupled to the housing such that when the blade dispenser assembly  100  is turned upside down the follower maintains its position thereby preventing the blades in the stack from falling away from the shuttle mechanism  106 . Thus, the follower mechanism  108  functions as a one-way ratchet.  
         [0045]    Referring also to FIGS. 14 and 15A- 15 C, the illustrated exemplary follower mechanism  108  includes a main portion  200 , a cantilevered portion  202  and an attaching portion  204  formed as shown. The main portion  200  is shaped to fit within the housing and is positioned on top of the stack of blades. The cantilevered portion  202  is shaped to fit between the vertical channel  144  and the guide member  146 . The attaching portion  204  is sized to fit within the vertical channel  144  with the main portion  200  and the cantilevered portion  202  positioned as previously described.  
         [0046]    The illustrated exemplary cantilevered portion  202  is generally rectangular in shape and greater in width than in height. The main portion  200  and the cantilevered portion  202  approximately form a right angle. By way of example, the angle formed by the main portion  200  and the cantilevered portion  202  is between 90° and 100°. It should be appreciated, however, that this angle can be varied depending upon the height and thickness of the cantilevered portion  202  and the distance between the vertical channel  144  and the guide member  146 .  
         [0047]    The blade dispenser  100  can be assembled as follows: First, attach the shuttle mechanism  106  to the lower front portion  120 . Next, attach the follower mechanism  108  to the top portion of the blade contact piece  142 . Turning the front cover  104  upside down, load a stack of blades, e.g., 100 blades, into the front cover  104 . Next, snap together the back cover  102  and the front cover  104 . Labels, decorations or the like can be applied to the blade dispenser  100  before or after it is assembled.  
         [0048]    With regard to materials, exemplary preferred back and front covers  102 ,  104  comprise Acrylonitrile-Butadiene-Styrene (ABS) plastic. An exemplary preferred shuttle  106  comprises Poly-Pro. An exemplary preferred follower mechanism  108  comprises steel or aluminum. It should be appreciated, however, that other materials can be employed to fabricate the various components of the blade dispenser assembly  100 .  
         [0049]    Although the present invention has been described in terms of the preferred embodiment above, numerous modifications and/or additions to the above-described preferred embodiment would be readily apparent to one skilled in the art. It is intended that the scope of the present invention extend to all such modifications and/or additions.