Abstract:
An apparatus for presenting a replacement blade from a cartridge includes a body and a carrier. The body includes a first side and a second side opposite the first side, a first position and a second position laterally spaced from the first position, and a trough aligned with the second position. The carrier is slidably coupled to the body and movable between the first position and the second position. When the carrier is in the first position, the carrier couples to a blade if a blade is present in the first position. When the carrier is in the second position, the carrier decouples from the blade such that the blade is deposited in the trough, if a blade is coupled to the carrier. When the carrier moves from the first position to the second position, the carrier causes a blade to move from the first position to the second position.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    The present application claims priority to U.S. Provisional Patent Application No. 61/738,155, filed Dec. 17, 2012. The contents of U.S. Provisional Patent Application No. 61/738,155 are incorporated herein by reference in their entirety. 
     
    
     BACKGROUND 
       [0002]    The present application relates generally to the field of rotary cutters. The present application relates more specifically to the field of apparatus and methods for replacing a blade on a rotary cutter. 
         [0003]    Rotary blades can be difficult to handle because they are relatively thin, with a circular shape in which the entire outer edge is sharpened. The blades may be packaged with coating, such as a light rust-preventative lubricant. When sold in quantity, the blades may be stacked together, and can be difficult to separate because of the coating. 
       SUMMARY 
       [0004]    One embodiment relates to an apparatus for presenting a replacement blade from a cartridge. The apparatus includes a body with a bottom side and a top side opposite the bottom side; a first position and a second position laterally spaced from the first position; and a trough aligned with the second position. The apparatus further includes a carrier slidably coupled to the body, the carrier movable between the first position and the second position. When the carrier is in the first position, the carrier couples to a blade if a blade is present in the first position. When the carrier is in the second position, the carrier decouples from the blade such that the blade is deposited in the trough, if a blade is coupled to the carrier. When the carrier moves from the first position to the second position, the carrier causes a blade to move from the first position to the second position. 
         [0005]    Another embodiment relates to an apparatus for presenting a replacement blade from a cartridge. The apparatus includes a body with a bottom side and a top side opposite the bottom side; a first position and a second position laterally spaced from the first position; at least one finger proximate the first position; and a trough aligned with the second position. The apparatus further includes a cartridge coupled to the first side of the body. The cartridge has at least one rotary blade therein and a spring providing a biasing force against the at least on rotary blade. The apparatus further includes a carrier slidably coupled to the second side of the body and movable between the first position and the second position. 
         [0006]    Yet another embodiment relates to a method for replacing a blade of a rotary cutting tool. The method includes providing a body comprising a first position and a second position laterally spaced from the first position, and a trough aligned with the second position; providing a carrier slidably coupled to the body, the carrier movable between the first position and the second position; and providing a blade proximate the first position. The method further includes coupling the carrier to the blade; moving the carrier from the first position to the second position; and depositing the blade in the trough. 
         [0007]    The foregoing is a summary and thus by necessity contains simplifications, generalizations, and omissions of detail. Consequently, those skilled in the art will appreciate that the summary is illustrative only and is not intended to be in any way limiting. Other aspects, inventive features, and advantages of the devices and/or processes described herein, as defined solely by the claims, will become apparent in the detailed description set forth herein and taken in conjunction with the accompanying drawings. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0008]      FIG. 1  is a top perspective view of a rotary blade replacement apparatus with the blade carrier in the second position, in accordance with an exemplary embodiment. 
           [0009]      FIG. 2  is a top perspective view of the body of the rotary blade replacement apparatus of  FIG. 1 . 
           [0010]      FIG. 3  is a bottom perspective view of a blade carrier for the rotary blade replacement apparatus of  FIG. 1 . 
           [0011]      FIG. 4  is a top perspective view of the cartridge of the rotary blade replacement apparatus of  FIG. 1 . 
           [0012]      FIG. 5  is a cross-section view of the rotary blade replacement apparatus of  FIG. 1  with the blade carrier in the first position, taken along line  5 - 5 . 
           [0013]      FIGS. 6A-6D  are sequential cross-section views showing the carrier moving a blade from the first position to the second position, taken along line  6 - 6 . 
           [0014]      FIG. 7  is a detail cross section view of the rotary blade replacement apparatus of  FIG. 1  with the carrier in a position intermediate between the first position and the second position, taken along line  7 - 7 . 
           [0015]      FIGS. 8A-D  are sequential cross-section views showing the carrier being moved from the second position to the first position, taken along line  8 - 8 . 
           [0016]      FIGS. 9A-9L  are sequential perspective views of a method of replacing a rotary blade in a device utilizing the rotary blade replacement apparatus of  FIG. 1 . 
       
    
    
     DETAILED DESCRIPTION 
       [0017]    Referring generally to the FIGURES, a rotary blade replacement apparatus and components thereof are shown according to an exemplary embodiment. 
         [0018]    Before discussing further details of the rotary blade replacement apparatus and/or the components thereof, it should be noted that references to “front,” “back,” “rear,” “upward,” “downward,” “inner,” “outer,” “right,” and “left” in this description are merely used to identify the various elements as they are oriented in the FIGURES. These terms are not meant to limit the element which they describe, as the various elements may be oriented differently in various applications. 
         [0019]    It should further be noted that for purposes of this disclosure, the term “coupled” means the joining of two members directly or indirectly to one another. Such joining may be stationary in nature or moveable in nature and/or such joining may allow for the flow of fluids, electricity, electrical signals, or other types of signals or communication between the two members. Such joining may be achieved with the two members or the two members and any additional intermediate members being integrally formed as a single unitary body with one another or with the two members or the two members and any additional intermediate members being attached to one another. Such joining may be permanent in nature or alternatively may be removable or releasable in nature. 
         [0020]    Referring to  FIG. 1 , a rotary blade replacement apparatus  20  is shown according to an exemplary embodiment. The apparatus  20  is configured to facilitate the removal and storage of old blades from a device (e.g., a rotary cutting device) and provide a new blade for the device. The apparatus  20  includes a main body  22  with a left end  23  (e.g., left side, left end portion, etc.) and a right end  25  (e.g., right side, right end portion, etc.), a bottom side  27  (e.g., bottom portion, bottom surface, etc.), and a top side  29  (e.g., top portion, top surface, etc.). A carrier  26  is slidably coupled to the body  22  and is utilized to engage and move a blade  30  of the type depicted in  FIG. 4  from the left end  23  to the right end  25 . In an exemplary embodiment, and as represented in  FIG. 4 , a stack of blades  30  may be provided in a cartridge  28  that is coupled to the left end  23  of the body  22 . The carrier  26  is configured to index a single new blade  30  from within the cartridge  28  to an installation location on the right end  25  of the body  22 . Once the blade  30  is moved to the right end  25  of the body  22  by the carrier  26 , the blade  30  may be disengaged from the carrier  26  and coupled to the device. The body  22  may further include a location for the storage for old blades removed from the device, as shown in  FIG. 5  and discussed in more detail below. 
         [0021]    Referring to  FIG. 2 , the body  22  of the apparatus  20  is shown according to an exemplary embodiment. The left end  23  of the body  22  includes an opening  32  allowing blades to pass through the body  22  from the bottom side  27  to the top side  29  and a pair of blade stops  34  (e.g., members, fingers, arms, etc.) disposed over the opening. The blade stops  34  are flexible (e.g., resilient, deflectable, etc.) members that are configured to contact the top surface of the topmost blade  30  and control the position of the blade  30  relative to the body  22  and the carrier  26 . The blade stops  34  are coupled to the floor  36  of the body  22  at a first or proximal end and free on a second or distal end opposite the first end to allow the blade  30  to move from the left end  23  to the right end  25 . Each of the blade stops  34  includes a slot or groove  38  configured to receive a protrusion  56  on the carrier, as described in more detail below. The right end  25  of the body  22  includes a trough  40  (e.g., depression, hollow, recess, etc.) sized to receive a blade moved to the right end  25  by the carrier  26 . The trough  40  includes a central opening  42 . A recessed path  46  extends from the trough  40  to the opening to provide a clearance for a blade catch  52  of the carrier  26 . 
         [0022]    Referring to  FIG. 3 , a bottom perspective view of the carrier  26  is shown according to an exemplary embodiment. The edges of the carrier  26  engage a pair of longitudinal guides or rails  44  extending between the left end  23  and the right end  25 . The rails  44  couple the carrier  26  to the top of body  22  and allow the carrier  26  to slide relative to the body  22 . The underside of the carrier  26  includes one or more bosses  50  providing a contact surface for the top surface of the blade  30 . The carrier  26  further includes a blade catch  52  that extends from the underside farther than the bosses  50  and is configured to engage or catch the blade  30  when it is received in the central opening or blade aperture  31  of the blade  30 . The blade catch  52  is coupled to a flexible arm  54 , allowing the blade catch  52  to be deflected relative to the main body of the carrier  26 . According to an exemplary embodiment, the blade apertures  31  are circular and the blade catch  52  is a cylindrical body configured to be received in the circular aperture  31 . According to other exemplary embodiments, the blade catch  52  may be shaped to fit other blade aperture shapes (e.g., square, hexagonal, etc.). The carrier  26  further includes one or more protrusions  56 . The protrusions  56  align with the corresponding grooves  38  in the blade stops  34 . When contacting the blade stops  34 , the protrusions  56  bias the blade stops  34  downward, away from the carrier  26 . When the protrusions  56  are received in the grooves  38 , the blade stops  34  are allowed to move towards the underside of the carrier  26  and return to a rest position. 
         [0023]    As shown in  FIG. 5 , the carrier  26  may include a handle  58  (e.g., a ridge, protrusion, grip, etc.) that may be grasped or otherwise engaged by a user to move the carrier  26  relative to the body  22 . In other embodiments, the carrier  26  may have a surface texture (e.g., knurling) to allow a user to engage the carrier  26 . The travel of the carrier  26  relative to the body is limited by fingers  59 , which extend radially outward from the carrier  26 . The fingers  59  are captured by the rails  44  and prevent the carrier  26  from sliding off the body  22 . 
         [0024]    Referring to  FIG. 4 , the cartridge  28  is shown according to an exemplary embodiment. The cartridge  28  is configured to hold one or more blades  30  and is coupled (e.g., via snap, bayonet, threaded fastener, etc.) to the bottom of the left end  23  of the body  22  such that the blades  30  are aligned with the opening  32  in the left end  23  of the body  22 . According to one embodiment, the cartridge  28  may be pre-loaded with five blades  30  in a stack. The cartridge  28  includes a recess  60  configured to receive the one or more blades  30  and a post  62  extending upward in the recess  60 . The post  62  is received in the blade apertures  31  and aligns the blades  30  with each other and the other components of the apparatus  20  (e.g., the carrier  26 ) when the cartridge  28  is coupled to the body  22 . The post  62  limits or constrains the lateral movement of the blades  30 , keeping the blades  30  generally centered within the cartridge  28  such that the sharpened edges of the blades  30  do not become dulled by contact with the side wall of the cartridge  28 . According to an exemplary embodiment, the post  62  comprises a cylindrical body configured for use with a blade  30  with a circular blade aperture  31 . According to other exemplary embodiments, the post  62  may be shaped to fit other blade aperture shapes (e.g., square, hexagonal, etc.). The cartridge  28  further includes one or more biasing features, shown as spring arms  64  in  FIG. 4 , that bias the stack of blades  30  towards the body  22  and against a stop face (for example, the blade stops  34 , the contact surfaces of the bosses  50  on the carrier  26 , etc.). 
         [0025]    Referring to  FIG. 5 , the body  22  may further include a storage area  66  for receiving and retaining old blades. The old blade storage area  66  allows for storage of old blades. The entire apparatus  20  can be disposed of (e.g., recycled) to safely dispose of the stored old blades. In other exemplary embodiments, the blades  30  or the entire storage area  66  may be configured to be removed from the apparatus  20  and disposed. According to another embodiment, the apparatus  20  may be configured such that a user can safely remove the blades  30  from the storage area  66  for disposal of the blades  30 . The body  22  includes retaining features  68  that hold the old blades in the storage area  66 . The storage area  66  is configured to allow for the blades to be added into the storage area  66  directly from the rotary cutting device without a user having to touch the blades. The storage area  66  may be configured to hold any number of blades, which may be chosen to be multiples of the number of blades pre-loaded in the cartridge  28 . 
         [0026]      FIGS. 6A-6D  show the apparatus  20  with the carrier  26  being moved from a first position to a second position, moving a blade from the left end  23  of the body  22  to the right end  25  of the body  22 . According to the exemplary embodiment described, the replacement apparatus  20  transfers the new blade  30  from the cartridge  28  to the trough  40  without touching a sharpened edge of the blade  30 . As shown in  FIG. 6A , when the carrier  26  is in the first position and is aligned with the opening  32  in the body  22  and the blades  30  in the cartridge  28 , the blade catch  52  is received in the blade aperture  31  and makes contact with inner walls of the blade aperture  31 . The blade catch  52  extends beyond the bosses  50  by a distance approximately equal to the thickness of the blade  30  to ensure that the blade catch  52  only contacts the inner wall of the blade aperture  31  of the topmost blade  30  (e.g., the blade  30  directly against the bottom face of the blade stops  34  and the bosses  50 ). As shown in  FIG. 6B , the carrier  26  moves the top blade  30  away from the stack of blades  30  held in the cartridge  28  via the engagement of the blade aperture  31  by the blade catch  52  as the carrier  26  is moved away from the first position towards the second position. 
         [0027]    As shown in  FIG. 6C  and  FIG. 7 , the top blade  30  is supported by multiple surfaces. The bottom of the blade  30  may contact a portion of the floor  36  of the body  22 , while the top of the blade  30  may contact the contact surfaces of the bosses  50  extending from the underside of the carrier  26  and the blade stops  34 . As the blade clearance protrusions  56  exit the grooves  38  in the blade stops  34 , the blade clearance protrusions  56  pass over the distal end of the blade stop  34 . The contact between the blade  30  and the floor  36  of the body  22  inhibits downward movement of the blade to decouple the blade  30  from the blade catch  52  of the carrier  26 . In addition, the blade  30  is sufficiently resilient to allow enough distortion (flex) to allow downward deflection of the stops  34  without preventing linear travel of the carrier  26  from the left  23  to the right  25 . As shown in  FIG. 7 , the features integral to the body  22  and carrier  26  ensure contact between the blade aperture and the blade catch  52  until the blade  30  is sufficiently above the installation location formed by the trough  40  at the right end  25  of the body  22 , at which time the blade  30  is allowed to fall away from the blade catch  52 , into the trough  40 . In other exemplary embodiments, the carrier may include a deflectable member or portion that can be actuated by a user to push the blade  30  off the blade carrier  52  into the trough  40 . 
         [0028]      FIGS. 8A-8E  show the apparatus with the carrier being moved from the second position to the first position after depositing a blade  30  in the trough  40  at the right end  25  of the body  22 , as shown in  FIG. 8A . Referring to  FIG. 8B , returning from the second position to the first position, the protrusions  56  engage the distal ends of the blade stops  34 , causing the blade stops  34  to deflect downward from a first or un-deflected state to a second or deflected state. The deflection of the blade stops  34  pushes any blades  30  in the cartridge  28  downward, deflecting the spring arms  64 . The blade catch  52  extends downward farther than the bosses  50 . This downward movement of the blade stops  34  and blades  30  is sufficient to create a clearance for the blade catch  52 , allowing the blade catch  52  to translate over and past the sharpened edges of the blades  30  without being damaged by catching the edge of the blades  30 . Referring to  FIG. 8C , as the carrier  26  is further advanced, the protrusions  56  enter the grooves  38 , allowing the blade stops  34  to return to the first or un-deflected state. The blades  30  are then biased upward by the spring arms  64  and contact the bottom surface of the blade catch  52 . When the carrier  26  is in the first position (shown in  FIG. 8D ), located directly above the cartridge  28 , the blade catch  52  drops into the blade aperture  31  to engage the topmost blade  30  in the stack. The length of the blade catch  52  and the difference in heights between the blade catch  52  and the bosses  50  is such that the blade catch  52  engages only the top cutting blade  30  and not the lower cutting blades  30  in the stack. 
         [0029]    Referring ,to  FIGS. 9A-9L , a user may use the replacement apparatus  20  to replace the blade  30  on a rotary cutting tool  70 . Preferably, the replacement apparatus  20  enables a user to replace the blade  30  on a rotary cutting tool  70  without needing to touch the blade  30 . The user may remove or actuate a retaining feature (e.g., nut, clips, etc.) from the rotary cutter  70  (see  FIG. 9A ) and orient the cutting tool  70  such that the blade  30  desired to be remove d (e.g., the old blade) decouples from the cutting tool  70  (decouples from the axle or post of the cutting tool) (see  FIG. 9B ). 
         [0030]    According to one embodiment, when the cutter is in a first position, the old blade decouples from the rotary cutter by the force of gravity. According to the embodiment shown, a portion of the cutting tool  70  may be removed with the blade  30 . In this embodiment, the cutting tool  70  (e.g., the removable portion of the cutting tool  70 ) includes a magnet to retain the blade. The replacement apparatus  20  may be turned upside down to access the old blade storage area (see  FIG. 9C ), and the blade  30  and any removable portion of the cutting tool  70  to which the blade  30  is coupled to may be aligned with the storage area (see  FIG. 9D ). The blade  30  may be engaged by retaining features and held in the storage area while the removable portion of the cutting tool  70  is removed (see  FIG. 9E ). In this embodiment, the retaining features are stronger than the magnet incorporated in the cutting tool  70 , and the retaining features cause the decoupling between the cutting tool  70  and the blade  30 . The replacement apparatus  20  may then be turned over (see  FIG. 9F ) and actuated as described above to index a new blade from a first side of the apparatus  20  to the second side (see  FIGS. 9F-9H ). The removable portion of the cutting tool  70  may then be positioned such that the axle passes through the hole in the blade  30  in the trough of the replacement apparatus  20  (see  FIG. 91 ). According to the embodiment shown, the magnet of the removable portion attracts and retains the blade  30  to the removable portion. According to another embodiment, the cutting tool  70  and the replacement apparatus  20  may be reoriented (e.g., inverted) such that the new blade  30  exits the trough and is supported on the axle of the cutting tool  70  by gravity. The replacement apparatus  20  may then be decoupled and/or removed from the cutting tool  70  (see  FIG. 9J ). According to the embodiment shown, the removable portion of the cutting tool  70  may be re-coupled to the cutting tool  70 , and the retaining feature on the cutting tool  70  may be actuated or re-attached (see  FIG. 9K ). The cutting tool  70  may then be utilized with a new blade  30  (see  FIG. 9L ) 
         [0031]    The applicant notes that elements in the figures may be shown inaccurately due to limitations in the CAD software used to create the drawings. For example, the spring arms  64  are shown in an uncompressed or undeflected state in the cross-section views such that they pass through the blades  30 . However, those skilled in the art will understand from the figures and the description herein that the spring arms  64  press against the underside of the bottommost blade held within the cartridge  28  and are deflected downward into the cavity  60  by the blades  30 . 
         [0032]    The construction and arrangement of the elements of the rotary blade replacement apparatus as shown in the exemplary embodiments are illustrative only. Although only a few embodiments of the present disclosure have been described in detail, those skilled in the art who review this disclosure will readily appreciate that many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter recited. For example, elements shown as integrally formed may be constructed of multiple parts or elements. The elements and assemblies may be constructed from any of a wide variety of materials that provide sufficient strength or durability, in any of a wide variety of colors, textures, and combinations. Additionally, in the subject description, the word “exemplary” is used to mean serving as an example, instance, or illustration. Any embodiment or design described herein as “exemplary” is not necessarily to be construed as preferred or advantageous over other embodiments or designs. Rather, use of the word “exemplary” is intended to present concepts in a concrete manner. Accordingly, all such modifications are intended to be included within the scope of the present disclosure. Other substitutions, modifications, changes, and omissions may be made in the design, operating conditions, and arrangement of the preferred and other exemplary embodiments without departing from the scope of the appended claims. 
         [0033]    The order or sequence of any process or method steps may be varied or re-sequenced according to alternative embodiments. Any means-plus-function clause is intended to cover the structures described herein as performing the recited function and not only structural equivalents but also equivalent structures. Other substitutions, modifications, changes and omissions may be made in the design, operating configuration, and arrangement of the preferred and other exemplary embodiments without departing from the scope of the appended claims.