Abstract:
A utility knife including a handle, a blade, a first blade holder, and a spare blade holder. The spare blade holder is pivotal with respect to the handle between an open position where the recess is exposed to allow a spare blade to be removed from the spare blade holder and a closed position where the recess is within a slot of the handle to inhibit removal of the spare blade from the spare blade holder. The spare blade holder further including a cam surface and the cam surface of the spare blade holder engages a cam surface of the handle when the spare blade holder is in the closed position to urge the spare blade holder in a direction from a first longitudinal side of the handle toward a second longitudinal side of the handle to allow the first blade holder to pivot between extended and folded positions.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application claims priority U.S. Provisional Application No. 62/222,918, filed Sep. 24, 2015, U.S. Provisional Application No. 62/180,238, filed Jun. 16, 2015, U.S. Provisional Application No. 62/141,966, filed Apr. 2, 2015, the entire contents of which are hereby incorporated by reference herein. 
     
    
     BACKGROUND 
       [0002]    The present invention relates to utility knives. Utility knifes typically include a handle and a blade. In some utility knives, the blade slides relative to the handle from a retracted position, where the blade is stored inside the handle, to an extended position where the blade extends from the handle. In the extended position, the blade is used to cut a work-piece. In other types of the utility knives, the blade pivots relative to the handle. In both types of utility knifes the blade is typically replaceable. 
       SUMMARY 
       [0003]    In one embodiment, the invention provides a utility knife including a handle that includes a first longitudinal side, a second longitudinal side opposite the first longitudinal side, a top side, a bottom side, and a slot that extends through the bottom side. The slot is between the first and second longitudinal sides and the handle further including a cam surface. The utility knife further includes a blade and a first blade holder. The blade is removably coupled to the first blade holder, and the first blade holder is pivotal with respect to the handle between an extended position where the blade is exposed and configured to cut a work-piece and a folded position where the blade is within the slot of the handle. The utility knife further includes a spare blade holder including a recess configured to receive a spare blade. The spare blade holder is pivotal with respect to the handle between an open position where the recess is exposed to allow the spare blade to be removed from the spare blade holder and a closed position where the recess is within the slot of the handle to inhibit removal of the spare blade from the spare blade holder. The spare blade holder further including a cam surface and the cam surface of the spare blade holder engages the cam surface of the handle when the spare blade holder is in the closed position to urge the spare blade holder in a direction from the first longitudinal side of the handle toward the second longitudinal side of the handle to allow the first blade holder to pivot between the extended and folded positions. 
         [0004]    In another embodiment the invention provides a utility knife including a handle that includes a first longitudinal side, a second longitudinal side opposite the first longitudinal side, a top side, a bottom side, and a slot that extends through the bottom side, the slot between the first and second longitudinal sides. The utility knife further includes a blade and a blade holder. The blade is removably coupled to the blade holder and the blade holder is pivotal with respect to the handle between an extended position where the blade is exposed and configured to cut a work-piece and a folded position where the blade is within the slot of the handle. The utility knife further includes a locking mechanism including a biasing member and an actuator movable between a locked position and an unlocked position. The blade holder is pivotable with respect to the handle between the extended and folded positions when the actuator is in the unlocked position and the blade holder is held from pivotally movement relative to the handle when the actuator is in the locked position. The biasing member that biases the actuator toward the locked position. The handle further includes an accommodating portion that extends outwardly from the second longitudinal side and at least a portion of the biasing member extends into the accommodating portion when the actuator is in the unlocked position. 
         [0005]    In another embodiment the invention provides a utility knife including a handle that includes a first longitudinal side, a second longitudinal side opposite the first longitudinal side, a top side, a bottom side, and a slot that extends through the bottom side, the slot between the first and second longitudinal sides. The utility knife further includes a blade and a blade holder. The blade is removably coupled to the blade holder and the blade holder is pivotal with respect to the handle between an extended position where the blade is exposed and configured to cut a work-piece and a folded position where the blade is within the slot of the handle. The blade holder includes a first notch and a second notch. The utility knife further includes a coil spring and a locking mechanism including a push button movable between a locked position and an unlocked position. The blade holder is pivotable with respect to the handle between the extended and folded positions when the push button is in the unlocked position and the blade holder is held from pivotally movement relative to the handle when the push button is in the locked position. The push button includes a first portion of a first diameter and a second portion of a second diameter that is larger than the first diameter and a frusto-conical portion between the first and second portions. The second portion of the push button is received in the first notch of the blade holder to hold the blade holder in the extended position and the second portion of the push button is received in the second notch of the blade holder to hold the blade holder in the folded position. The coil spring biases the actuator toward the locked position. 
         [0006]    Other aspects of the invention will become apparent by consideration of the detailed description and accompanying drawings. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0007]      FIG. 1  is a perspective view of a utility knife according to an embodiment of the invention. 
           [0008]      FIG. 2  is an alternative perspective view of the utility knife of  FIG. 1 . 
           [0009]      FIG. 3  is a perspective view of the utility knife of  FIG. 1  with a blade holder in the extended position. 
           [0010]      FIG. 4  is an alternative perspective view of the utility knife of  FIG. 1  with the blade holder in the extended position and a blade storage compartment in an open position. 
           [0011]      FIG. 5  is a perspective view of the utility knife of  FIG. 1  with a portion of the handle removed and the blade holder in a partially extended position. 
           [0012]      FIG. 6  is a side view of the utility knife of  FIG. 1  with the blade holder in the partially extended position. 
           [0013]      FIG. 7  is a cross-sectional view of the utility knife of  FIG. 1 , taken along line  7 - 7  in  FIG. 1 . 
           [0014]      FIG. 8  is a bottom view of the utility knife of  FIG. 1 . 
           [0015]      FIG. 9  is an exploded view of a portion of the utility knife of  FIG. 1 . 
           [0016]      FIG. 10  is a perspective view of a utility knife according to another embodiment of the invention. 
           [0017]      FIG. 11  is an alternative perspective view of the utility knife of  FIG. 10 . 
           [0018]      FIG. 12  is a perspective view of the utility knife of  FIG. 10  with a blade holder in the extended position. 
           [0019]      FIG. 13  is an alternative perspective view of the utility knife of  FIG. 10  with the blade holder in the extended position. 
           [0020]      FIG. 14  is a perspective view of the utility knife of  FIG. 10  with a portion of the handle removed and the blade holder in the extended position. 
           [0021]      FIG. 15  is a perspective view of a utility knife according to another embodiment of the invention. 
           [0022]      FIG. 16  is a partially-exploded view of a portion of the utility knife of  FIG. 15 . 
           [0023]      FIG. 17  is a perspective view of a blade holder of the utility knife of  FIG. 15 . 
           [0024]      FIG. 18  is an enlarged cross-sectional view of the utility knife of  FIG. 15 , taken along line  18 - 18  in  FIG. 15 . 
       
    
    
       [0025]    Before any embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its application to the details of construction and the arrangement of components set forth in the following description or illustrated in the following drawings. The invention is capable of other embodiments and of being practiced or of being carried out in various ways. 
       DETAILED DESCRIPTION 
       [0026]      FIGS. 1-4  illustrate a knife  10 , which is a utility knife in the illustrated embodiment. The knife  10  includes a handle  12  and a blade holder  14  that is pivotally coupled to the handle  12  and movable between a folded or retracted position ( FIG. 2 ) and an extended position ( FIG. 3 ). The handle  12  includes a front end portion  18  and a back end portion  20 . The blade holder  14  is pivotally attached to the front end portion  18  of the handle  12  via a fastener  22 . The handle  12  further includes a first longitudinal side  61 , a second longitudinal side  62  opposite the first longitudinal side  61 , a top side  63 , and a bottom side  64 . A slot  65  extends through the bottom side  64  between the first and second sides  61 ,  62 . The illustrated sides  61 ,  62  are generally flat. 
         [0027]    The back end portion  20  of the handle  12  includes a cutout or hook portion  26 . The cutout  26  exposes a portion of a blade  28  held by the blade holder  14  when the blade holder  14  is in the folded position so that the blade  28  can be used to cut wire, rope, line, etc. The back end portion  20  of the handle  12  further includes an aperture  30  that extends through the handle  12 . The aperture  30  provides a location for the user to attach the knife  10  to a lanyard, belt, clip, or the like. 
         [0028]    With reference to  FIGS. 5 and 7 , the knife  10  further includes a locking mechanism  23  located at the front end portion  18  of the handle  12  and operable to lock and unlock the blade holder  14  to allow the user to pivot the blade holder  14  relative to the handle  12 . The locking mechanism  23  includes a push button  24  and a spring  25 , which is a coil spring in the illustrated embodiment. The spring  25  biases the push button  24  in the direction of arrow A in  FIG. 7 . The push button  24  has a first portion  27  of a first diameter and a second portion  29  of a second diameter that is larger than the first diameter. The illustrated second portion  29  has a generally frusto-conical external surface  31  and a cylindrical recess  33 . One end of the spring  25  is received within the recess  33 , and an opposite end of the spring  25  is received within a recess  35  in the handle  12 . In the illustrated embodiment, a post  37  is provided within the recess  35  to stabilize the spring  25 . 
         [0029]    Referring to  FIGS. 2, 4, and 5 , the knife  10  further includes a spare blade holder  32  having a front end  39  and a back end  41 , which is pivotally attached to the back end portion  20  of the handle  12 . The spare blade holder  32  retains spare utility blades  28  in a recess  66  of the spare blade holder  32 . In one embodiment the spare blade holder  32  retains four or more spare utility blades  28 . The spare blade holder  32  is pivotable between a closed position ( FIG. 2 ) and an open position ( FIG. 4 ). A ball  34  ( FIG. 5 ) is biased by a spring  36  into an aperture  38  of the spare blade holder  32  to retain the spare blade holder  32  in the closed position. In one embodiment, the spare blade holder  32  includes a magnet to retain the spare blades  28  in the holder  32 . 
         [0030]    With reference to  FIGS. 8 and 9 , the front end  39  of the spare blade holder  32  includes an angled cam surface  43  that bears against a corresponding angled cam surface  45  provided on the handle  12  when the spare blade holder  32  is in the closed position. The engagement of the cam surfaces  43 ,  45  forces the spare blade holder  32  against the handle  12  in the direction of arrow B in  FIG. 8 . This arrangement inhibits the spare blade holder  32  from interfering with movement of the blade holder  14 . In some embodiments, the cam surface  43  defines an angle  47  between about 5 degrees and about 30 degrees ( FIG. 9 ). In the illustrated embodiment, the angle  47  is about 10 degrees. 
         [0031]    Referring to  FIGS. 3 and 5 , the blade holder  14  includes a front end portion  40  and a back end portion  42 . The blade holder  14  is pivotally attached to the handle  12  at the back end portion  42  of the blade holder  14  and the blade  28  extends from the front end portion  40  of the blade holder  14 . The back end portion  42  of the blade holder  14  includes notches  44 ,  46 , and  48 . When the second portion  29  of the push button  24  is received in the first notch  44 , the blade holder  14  is held in the folded or closed position. When the second portion  29  is received in the third notch  48 , the blade holder  14  is held in the fully extended position ( FIG. 3 ). When the second portion  29  of the push button  24  is received in the second notch  46 , the blade holder  14  is held in a partially extended or intermediate position illustrated in  FIGS. 5 and 6 , which is between the folded position and the fully extended position. The intermediate position may be more convenient and ergonomic for certain applications. For example, using the knife  10  with the blade holder  14  in the intermediate position is particularly advantageous for cutting carpet or for cutting materials overhead. The blade holder  14  preferably extends at an angle between about 30 degrees and about 60 degrees relative to the handle  12  when in the intermediate position. In the illustrated embodiment, the blade holder  14  extends at an angle of about 45 degrees relative to the handle  12  when in the intermediate position. 
         [0032]    The blade holder  14  further includes a top edge  50  and a bottom edge  52 . The bottom edge  52  include a recess  54  that exposes a portion of the blade  28  so that the blade  28  can be used to strip insulation from wire or to cut wire, rope, line, etc. An upwardly angled surface  56  is located along the top edge  50  at the front end  40  of the blade holder  14 . The surface  56  is upwardly angled at an angle  58  ( FIG. 3 ). In some embodiments, the angle  58  is between about 5 degrees and about 60 degrees. The surface  56  provides the user with a place to push with their finger (e.g., thumb when using the knife). Also, the surface  56  inhibits the user&#39;s finger (e.g., thumb) from sliding off of the front of top edge  50  when the user places their finger on the top edge  50  when using the knife to cut a work piece. The top edge  50  of the blade holder  14  further includes an enlarged surface  60  that extends out laterally from the top edge  50 . The surface  60  is integrally formed with the blade holder  14  and provides the user with another place to put their finger when cutting using the knife  10 . Also, as seen in  FIG. 2  and  FIG. 8 , the enlarged surface  60  inhibits the spare blade holder  32  from moving toward the open position when the blade holder  14  is in the folded position. 
         [0033]    In operation, to open the blade holder  14  to the intermediate position, the user presses the button  24  to move the second portion  29  out from within the first notch  44 , which allows the user to pivot the blade holder  14  from the folded position to the intermediate position ( FIG. 5 ). With the button  24  released, the spring  25  moves the button  24  in the biasing direction of arrow A until the second portion  29  engages the second notch  46  to retain the blade holder  14  in the intermediate position. The frusto-conical shape  31  on the second portion  29  allows the second portion  29  to wedge into the notch  46  ( FIG. 7 ). 
         [0034]    To further open the blade holder  14  to the fully extended position, the user presses the button  24  to move the second portion  29  out from within the second notch  46 , which allows the user to pivot the blade holder  14  from the intermediate position to the fully extended position ( FIGS. 3 and 5 ). With the button  24  released, the spring  25  moves the button  24  in the biasing direction of arrow A until the second portion  29  engages the third notch  48  to retain the blade holder  14  in the fully extended position. To bypass the intermediate position and pivot the blade holder  14  from the closed position to the fully extended position, the user need only maintain pressure on the button  24  until the blade holder  14  pivots beyond the intermediate position. 
         [0035]      FIGS. 10-14  illustrate a knife  110 , which is a utility knife in the illustrated embodiment according to another embodiment. The utility knife  110  includes features similar to the utility knife  10  of  FIGS. 1-9 , and like components have been given like reference numbers plus 100. The utility knife  110  further includes an arcuate recess  167  along a bottom edge  152  of blade holder  114 . The arcuate recess  167  provides a convenient and comfortable grip when the user grips the knife  110  on a portion of the blade holder  114 . 
         [0036]      FIGS. 15-18  illustrate a knife  210 , which is a utility knife in the illustrated embodiment, according to another embodiment. The utility knife  210  includes features similar to the utility knife  10  of  FIGS. 1-9 , and like components have been given like reference numbers plus 200. The utility knife  210  includes a handle  212  and a blade holder  214  that is pivotally coupled to the handle  212  and movable between a folded or retracted position (not shown) and an extended position ( FIG. 15 ). The handle  212  includes first handle portion  213  and a second handle portion  215  opposite the first handle portion  213 . A fastener  222  extends through the handle portions  213 ,  215  and the blade holder  214  to pivotally couple the blade holder  214  to the handle  212 . 
         [0037]    With reference to  FIG. 16 , the knife  210  further includes a locking mechanism  223  operable to lock and unlock the blade holder  214  to allow the user to pivot the blade holder  214  relative to the handle  212 . The locking mechanism  223  includes a push button  224  and a spring  225 . Referring to  FIG. 18 , the push button  224  has a first portion  227  of a first diameter and a second portion  229  of a second diameter that is larger than the first diameter. The illustrated second portion  229  includes a generally frusto-conical external surface  231 . The spring  225  in the illustrated embodiment is a spring plate having a resilient finger  225   a  that is engageable with the push button  224 . The finger  225   a  may be formed by removing (e.g., by punching or cutting) a portion of the spring plate  225 . The finger  225   a  is bent out of plane with the remainder of the spring plate  225 , and a free end of the finger  225   a  engages the push button  224  to bias the push button  224  in the direction of arrow C in  FIG. 16 . 
         [0038]    With reference to  FIGS. 15 and 18 , the second handle portion  215  includes an accommodating portion  249  that projects outwardly beyond the remainder of the second handle portion  215 . In the illustrated embodiment, the accommodating portion  249  is tapered from a maximum thickness proximate the fastener  222  to a minimum thickness in a direction toward a back end portion  220  of the handle  212 . The accommodating portion  249  is generally hollow and is aligned with the finger  225   a . As such, the accommodating portion  249  accommodates deflection of the finger  225   a  in the direction of arrow D in  FIG. 18 , allowing the thickness of the remainder of the handle  212  to be minimized. 
         [0039]    With reference to  FIG. 15 , the illustrated utility knife  210  further includes a belt clip  251  coupled to the second handle portion  215 . The belt clip  251  is coupled to the second handle portion  215  by a single fastener proximate a front end portion  218  of the handle  212 . In other embodiments, the belt clip  251  may be coupled to the handle  212  in other ways or orientations. In some embodiments, the belt clip  251  may be reversible, such that it may be coupled to either the first handle portion  213  or the second handle portion  215 . In the illustrated embodiment, the belt clip  251  substantially overlies the accommodating portion  249  such that the accommodating portion  249  is disposed between the belt clip  251  and the remainder of the second handle portion  215 . 
         [0040]    Referring to  FIG. 16 , the blade holder  214  includes a front end portion and a back end portion, opposite the front end portion. The back end portion of the blade holder  214  includes a first notch  244  and a second notch  248 . When the second portion  229  of the push button  224  is received in the first notch  244 , the blade holder  214  is held in the retracted position. When the second portion  229  of the push button  224  is received in the second notch  248 , the blade holder  214  is held in the extended position. The blade holder  214  further includes a beveled surface  253  adjacent the second notch  248  ( FIG. 17 ). The beveled surface  253  generally follows the contour of the external surface  231  of the second portion  229 . This provides a relatively large contact area between the blade holder  214  and the push button  224 , thereby producing a stronger, more secure locking engagement. 
         [0041]    In the illustrated embodiment, the blade holder  214  is made from powdered metal, using a suitable powdered metal manufacturing process. For example, the blade holder  214  may be produced by compaction and sintering, metal injection molding (MIM), or any other suitable process. By making the blade holder  214  from powdered metal, the various complex features of the blade holder  214 , such as the notches  248 ,  244  and the beveled surface  253 , can be integrally formed without requiring additional machining steps. 
         [0042]    Although the invention has been described in detail with reference to certain preferred embodiments, variations and modifications exist with the scope and spirit of one or more independent aspects of the invention as described.