Abstract:
A frame member for the handle of a folding knife or multipurpose tool includes an integral flange with an integral leaf spring. An internal frame member has an upper flange and an oppositely facing lower flange. Each flange includes an integral leaf spring. The leaf springs bear upon the base portions of folding tool blades that are pivotably pinned to the frame. Attaching side scales to the frame creates upwardly and downwardly facing tool pockets. Other frames are shown in the form of a channel with an integral external flange extending outwardly from the top of a channel wall in a direction away from the channel. Pivot pins extending through the channel and out the channel wall carry pivoting tool blades. An integral leaf spring on the external flange bears against the base of a blade pivotably connected to the frame outside of the channel. Other tool blades are carried inside the channel and pivot about the pivot pin.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application is a continuation of U.S. patent application Ser. No. 11/710,669, filed Feb. 22, 2007, which is a continuation of U.S. patent application Ser. No. 10/066,087, filed Jan. 30, 2002, now U.S. Pat. No. 7,182,001, both of which are hereby incorporated herein in their entirety by reference. 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    The present invention relates to implements such as knives and tools having folding blades or tool bits, and particularly to a frame member having a flange including an integral leaf spring. 
         [0003]    Most folding knives or tools have a spring of some fashion which interacts with a folding blade or bit to hold the blade or bit in folded or extended position relative to the handle. Such springs are typically biased to bear against the cam-shaped base of the folding blade or bit. The cam on the base is shaped such that increased force is required to move the blade or bit into or out of extended or folded position. The spring also applies a frictional force to the base as the blade or bit is being moved between folded and extended positions. For example, traditional folding pocket knives include an independent back spring, separate from and fastened to the frame or scales of the knife, that bears against the base of the blade. Folding multipurpose tools such as shown in U.S. Pat. Nos. 4,238,862, 5,697,114, 5,745,997 and 6,293,018 employ leaf springs, integral with a portion of the tool frame, to bear against the base of a blade or bit. These leaf springs are typically cut from a portion of a frame member and are located within a channel formed by one or more frame members. The folding multipurpose tool shown in U.S. Pat. No. 5,745,997 includes both an integral leaf spring and two independent beam springs arranged within a channel-shaped frame member. U.S. Pat. No. 6,014,787 discloses integral leaf springs located in the floor and sidewall of a channel-shaped frame member. 
       BRIEF DESCRIPTION OF THE INVENTION 
       [0004]    The present invention provides a new folding tool frame member having a flange with an integral leaf spring. 
         [0005]    The foregoing and other objectives, features, and advantages of the invention will be more readily understood upon consideration of the following detailed description, taken in conjunction with the accompanying drawings. 
     
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S) 
         [0006]    Having thus described the invention in general terms, reference will now be made to the accompanying drawings, which are not necessarily drawn to scale, and wherein: 
           [0007]      FIG. 1  is an isometric view of a folding tool, with the side scales omitted, including a first embodiment of a frame member according to the present invention. 
           [0008]      FIG. 2  is an isometric view of a folding tool including a second embodiment of a frame member according to the present invention. 
           [0009]      FIG. 3  is an isometric view of a folding tool including a third embodiment of a frame member according to the present invention. 
           [0010]      FIGS. 4 ,  5  and  6  are three views, respectively an end view, side view and isometric view, of the frame embodiment of  FIG. 1 . 
           [0011]      FIGS. 7 ,  8  and  9  are three views, respectively an end view, side view and isometric view, of the frame embodiment of  FIG. 2 . 
           [0012]      FIGS. 10 ,  11  and  12  are three views, respectively an end view, side view and isometric view, of another embodiment of a frame member according to the present invention. 
           [0013]      FIGS. 13 ,  14  and  15  are three views, respectively, an end view, side view and isometric view, of a further embodiment of a frame member according to the present invention. 
           [0014]      FIGS. 16 ,  17  and  18  are three views, respectively an end view, side view and isometric view, of the frame embodiment of  FIG. 3 . 
           [0015]      FIG. 19  is a side view of a folding tool, with the side scales omitted, including the frame embodiment of FIGS.  3  and  16 - 18 . 
           [0016]      FIGS. 20 ,  21  and  22  are three views, respectively an end view, side view and isometric view, of a further embodiment of a frame member according to the present invention. 
           [0017]      FIGS. 23 ,  24  and  25  are three views, respectively an end view, side view and isometric view, of a further embodiment of a frame member according to the present invention. 
           [0018]      FIG. 26  is an isometric view of a further embodiment of a frame member according to the present invention. 
           [0019]      FIG. 27  is an isometric view of a further embodiment of a frame member according to the present invention. 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0020]    The present invention now will be described more fully hereinafter with reference to the accompanying drawings, in which some, but not all embodiments of the inventions are shown. Indeed, these inventions may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements. Like numbers refer to like elements throughout. 
         [0021]    FIGS.  1  and  4 - 6  show a first embodiment of a frame member  10 . An elongate plate  14  includes an integral, elongate partial upper flange  16  and an integral, elongate partial lower flange  20 . Both flanges extend outwardly from the plate in generally opposite directions, the upper flange  16  extending outwardly in a first direction along a portion of the upper edge  18  of the plate, and the lower flange  20  extending outwardly in a second direction along a portion of the lower edge  22  of the plate. In the exemplary embodiment the plate  14  is essentially planar and the flanges  16 ,  20  are oriented substantially perpendicular to the plate. Each flange  16 ,  20  includes an integral elongate leaf spring  24  at the outer end of the flange proximate an end of the plate. The portion of the flange that comprises the leaf spring  24  is separated from the adjacent portion of the plate  14  by an elongate cut  26 . Lightening holes  33  in the plate  14  reduce the weight of the tool  11  by removing excess material. 
         [0022]    Referring to  FIGS. 5 and 6 , plate  14  includes openings  28  at each end. As shown by the tool  11  in  FIG. 1 , these openings  28  are positioned to receive pivot pins  30  on which blades or tool bits  32  can be pivotably mounted. (“Tool bits” as used herein includes blades, pliers, scissors or other such implements.) When tool bits  32  are attached to the frame member  10 , the leaf springs  24  associated with the upper and lower partial flanges  16 ,  20  bear forcefully upon the bases  34  of the respective tool bits  32 . As shown in  FIGS. 1 and 19 , the bases  34  of the tool bits are cam-shaped such that the force of the spring upon the base of the bit tends to retain the bit in either folded or extended position. In order to move between folded and extended condition sufficient force must be applied to the tool bit  32  to overcome the spring force and bend the spring  24  upwardly away from the pivot pin  30 . 
         [0023]      FIG. 1  shows a tool bit  32 , in this case a knife blade, pivotably mounted by a pivot pin  30  to the far side of plate  14 , with the leaf spring  24  associated with partial upper flange  16 , engaging the base  34  of the blade. As shown in further detail in  FIG. 19 , the end of spring  24  provides an abutment against which a step  35  in base  34  of the tool bit  32  can rest, preventing further rotation and providing axial support for the knife blade. A second tool bit  32 , a screwdriver blade, is pivotably mounted by pivot pin  30  to the near side of plate  14 . The leaf spring  24  associated with the partial lower flange  20  engages the base  34  of the screwdriver blade  32 . 
         [0024]    Side scales  36 , such as those disclosed in  FIGS. 2 and 3 , can be attached to the tool assembly of  FIG. 1  by pivot pins  30  creating opposite facing tool pockets for receiving folding tool bits. In  FIG. 1 , a downwardly facing tool pocket on the far side of the plate would be defined by the plate  14 , a far side scale, and the partial upper flange  16  with spring  24 . The knife blade  32  can be stored in this pocket and pivot downwardly out of the pocket toward an extended position at one end of the plate. Similarly, an upwardly facing tool pocket on the near side of the plate would be defined by a near side scale, the plate  14  and the partial lower flange  20  with leaf spring  24 . The screwdriver blade  32  can be stored in this pocket and pivot upwardly out of the pocket toward an extended position at the other end of the plate. 
         [0025]      FIGS. 10-12  show a frame member similar to that shown in FIGS.  1  and  4 - 6 . However, the embodiment of  FIGS. 10-12  includes a full upper flange  17  extending along the entire upper edge of the plate  14 . The full upper flange includes a second leaf spring  24  at the end of the flange opposite the first leaf spring. The second spring allows additional tool bits to be positioned on the near side of the plate. Although the drawings show a single tool bit interacting with a particular leaf spring, a single spring could engage more than one tool bit. 
         [0026]      FIGS. 7-9  show a further embodiment of a frame member. This embodiment has a full upper flange  17  with leaf springs at both ends of the flange, and a full lower flange  21  with leaf springs  24  at both ends, enabling tool bits  32  to be arranged at both ends of the plate on both sides of the plate.  FIG. 2  shows a tool  12  including a frame member as shown in  FIGS. 7-9 , and further including tool bits  32 , pivot pins  30  and side scales  36 . The side scales  36  cooperate with the flanges  17 ,  21 , springs  24  and plate  14  to form two tool pockets  38 , one on each side of the plate. The near tool pocket  38  faces downwardly and the tool bits  32  pivot downwardly out of the pocket  38  from each end of the tool. The far tool pocket faces upwardly and two tool bits  32  pivot upwardly out of the pocket from each end of the tool. As may be seen from  FIG. 2 , tool bits  32  on the same end pivot in opposite directions, as do tool bits in the same pocket. 
         [0027]      FIGS. 13-15  show a further embodiment of the frame member, similar to that shown in  FIGS. 10-12 , except that this embodiment includes an intermediate leaf spring  40  associated with the partial lower flange  20 . The intermediate leaf spring  40  is located on an inner end of the partial lower flange proximate the middle of the plate  14  rather than out at the end of the flange proximate the end of the plate. The intermediate spring  40  facilitates mounting an intermediate tool bit not shown, such as corkscrew or awl, that is adapted to be used in an extended position substantially perpendicular to the general orientation of the plate. An intermediate hole  42  in plate  14  is capable of receiving a pivot pin about which an intermediate tool bit could pivot between folded and extended positions. 
         [0028]    As can be seen from the end views of the frame members in  FIGS. 4 ,  7 ,  10  and  13 , the frame embodiments of  FIGS. 1 ,  2  and  4 - 15  are all “z-shaped” with plate  14  arranged centrally and upper and lower flanges  16 ,  17 ,  20  and  21  extending outwardly from upper and lower edges on opposite sides of the plate, thus enabling pivoting tool bits  32  to be carried on both sides of the plate. The flanges may extend only partially along the upper  18  or lower  22  edges of the plate as shown in  FIG. 6 , along the entire length of the plate as shown in  FIG. 9  or combinations of partial and full, upper and lower, as shown in  FIGS. 10-12  and  13 - 15 . Leaf springs may be located at ends of the flanges proximate the ends of the plate, or at an end of a partial flange toward the middle of the plate as shown in  FIGS. 13-15 . These embodiments of the z-shaped frame member are only exemplary and other embodiments not shown may be within the scope of the invention as defined by the claims. 
         [0029]      FIGS. 16-19  show a different general type of frame member, namely a channel-shaped frame member with an external flange. Referring first to  FIGS. 16-19 , a channel-shaped frame member  44  includes an integral full external flange  46  extending outwardly along the upper edge of plate  50   a  and a partial internal flange  48  extending outwardly from the lower edge of plate  50   a  in a direction generally opposite the external flange  46 . The internal flange  48  is integral with and co-joins opposed plates  50   a  and  50   b . The full external flange includes two leaf springs  24 , one at each end of the flange. As described above and shown in  FIG. 19 , these leaf springs  24  bear upon the cam-shaped bases  34  of tool bits  32  which are pivotably attached to the frame member  44  by pivot pins  30  arranged in openings  28 . As may be seen in  FIGS. 16 and 18 , the frame member  44  is channel-shaped with plates  50   a  and  50   b  serving as channel walls, and the partial internal flange  48  serving as a channel floor. The channel-shaped frame member  44  defines an upwardly facing internal tool pocket  52  within the channel. This internal tool pocket  52  may be seen in the lower handle of the tool  13  shown in  FIG. 3 . The addition of side scales to the embodiment shown in  FIGS. 16-19  would create a second, downwardly facing, external tool pocket adapted to receive tool bits  32  such as shown in  FIG. 19 . 
         [0030]    Turning to  FIG. 27 , a channel-shaped frame member  44  has an integral partial external flange  66  and an integral partial internal flange  48 . The partial internal flange includes an internal leaf spring  64  positioned to interact with tool bits stored in the internal tool pocket  52 , while the spring  24  of the partial external flange is positioned to interact with tool bits carried on the other side of plate  50   a  and stored in an external tool pocket. 
         [0031]    A partial internal flange  48  shown in  FIGS. 16-18  and  26  accommodates use of independent springs similar to those shown in U.S. Pat. No. 5,745,997 to interact with tool bits stored in the internal tool pocket and pivotable about a pivot pin, not shown, at the right hand end of the frame member  44 . 
         [0032]      FIG. 3  illustrates a folding multipurpose tool including channel-shaped frame members with an external flange as shown and described in  FIGS. 16-19 . In this case, the folding scissors tool  13  includes two handles  60   a  and  60   b , each having a frame member  44  as described above. Referring to the lower one of the handles  60   a  shown in  FIG. 3 , the side scale  36  obscures a clear view of plate  50   a , but the full external flange  46  extending outwardly from plate  50   a  may seen. Plate  50   b  with lightening holes  33  is clearly visible in tool pocket  52 . A tool bit  32  is shown folded in the external tool pocket. Leaf spring  24  at the scissors end of the handle engages the base  34  of tool bit  32 . When tool  13  is fully folded, one of the scissor blades  56  is received in the internal tool pocket  52 . 
         [0033]    Further details of the handles are discernable from the view of the upper handle  60   b . Tool bit  32  is located in the external tool pocket. The partial internal flange  48  is visible as are two independent springs  62  located within the channel and positioned to bear against the base  34  of the scissors blades  56 . 
         [0034]    While the frame embodiment shown in  FIGS. 16-19  is shown in  FIG. 3  the context of a two-handled scissors tool  13 , it could also be used with a single-handled tool such as shown in  FIGS. 1 and 2 . 
         [0035]    In the embodiment shown in  FIGS. 3 ,  16 - 19  and  26 , the inner flange  48  does not extend the length of the opposed plates  50   a  and  50   b , and independent springs  62  shown in  FIG. 3  are used to bear upon the bases  34  of the scissor blades  56 . However, as shown in  FIG. 27 , an internal leaf spring  64  may also be used to interact with folding tool bits located within the channel formed by the channel-shaped frame member  44 . The internal leaf spring  64  could be used alone, or in combination with independent springs. The internal flange  48  could extend the length of the frame member  44 , and could include more than one leaf spring, one at either end of the flange, for example, to act on tool bits. Similarly, independent springs could be used to bias tool bits pivotably mounted in the internal tool pocket at both ends of the channel-shaped frame member. For example, although the partial internal flanges  48  are shown herein as being located toward one end of the channel, they could be located centrally within the channel as disclosed in applicant&#39;s U.S. Pat. No. 6,622,327, leaving room for independent springs to act on tool bits at both ends of the channel. As described with regard to the z-shaped frame member, the channel-shaped frame member with external flange can be configured in a variety of arrangements, all of which are not shown. 
         [0036]      FIGS. 20-26  show embodiments of a channel-shaped frame member with two external flanges. Referring first to the specific embodiment shown in  FIGS. 20-22 , an elongate channel-shaped frame member  70   a  includes a full external upper flange  72  extending outwardly from the upper edge of side plate  50   b , a partial internal flange  74  connecting side plates  50   a  and  50   b  and a partial external upper flange  76  extending outwardly from side plate  50   a . All portions of frame member  70   a  are integral with each other. The full upper flange  72  includes two integral leaf springs  24 , one at either end of the flange. Each of these springs  24  is capable of interacting with base  34  of at least one tool bit. The frame member  70   a  defines an upwardly facing tool pocket capable of receiving tools that are pivotable about pins extending between the two side plates  50   a  and  50   b  in openings  28  at either end of the frame. As described above, these tool bits may be biased by an internal leaf spring as disclosed in  FIG. 27 , or independent springs  62  as shown in  FIG. 3 . The partial external upper flange  76  includes a single leaf spring  24  at the outer end of the elongate partial flange. This spring is capable of interacting with the base of at least one tool bit. The addition of side scales, not shown in these figures, create two downwardly facing external tool pockets, one on either side of the internal, upwardly facing tool pocket. 
         [0037]    Turning now to the embodiment shown in  FIGS. 23-25 , an elongate channel shaped frame member  70   b  includes a first full external upper flange  72  extending outwardly from the upper edge of plate  50   b , and a partial internal flange extending outwardly from the lower edge of plate  50   b  and connecting plate  50   b  to the lower edge of plate  50   a . A second full upper external flange  72  extends outwardly from the upper edge of  50   a . Addition of side scales would again create two downwardly facing external tool pockets, except this frame embodiment includes a second leaf spring  24  on the second full external upper flange  72  enabling mounting at least one other folding tool bit in the external tool pocket adjacent side plate  50   a.    
         [0038]      FIG. 26  is another view of the frame member  70   a  shown in  FIGS. 20-22  with a full external upper flange  72 , not shown, extending outwardly from side plate  50   b  and a partial external upper flange  76  extending outwardly from side plate  50   a . The frame member  70   a  shown in  FIG. 26  is oriented to provide a clear view of the bottom portion of the frame showing how the partial internal flange  74  extends outwardly from side plates  50   a  and  50   b  in a direction substantially opposite the extension of flanges  72  and integrally joins side plates  50   a  and  50   b . Although the Figures show the channel-shaped frames  44 ,  70   a  and  70   b  with partial internal flanges, a tool with a full internal flange is within the scope of the invention. 
         [0039]    In the preferred embodiments shown herein the frame members  10 ,  44 ,  70   a  and  70   b  are constructed from a single piece of sheet metal bent to form plates and flanges, and cut to create the leaf springs. While the exemplary embodiments show the flanges extending outwardly from the plates in a direction substantially perpendicular to the plate, this arrangement is not necessary and other orientations are possible. Similarly, while the exemplary embodiments show the plates as planar, this is not considered to be crucial to the invention. Also, while the plates and flanges are shown herein as parallel, this is not a requirement. Further, it is not necessary to have a spring at both ends of a full flange. Nor is it necessary that a spring bear upon a base of a tool blade. For example, a frame member having a full flange and a spring at both ends of the flange could have a tool bit  32  associated with one flange, and use a spacer to engage the other spring. Although the embodiments disclosed herein show the springs  24  bent downwardly toward the frame, it is not necessary that the springs be preloaded in this fashion. 
         [0040]    The terms and expressions which have been employed in the foregoing specification are used therein as terms of description and not of limitation, and there is no intention, in the use of such terms and expressions, of excluding equivalents of the features shown and described or portions thereof, it being recognized that the scope of the invention is defined and limited only by the claims which follow. 
         [0041]    Many modifications and other embodiments of the inventions set forth herein will come to mind to one skilled in the art to which these inventions pertain having the benefit of the teachings presented in the foregoing descriptions and the associated drawings. Therefore, it is to be understood that the inventions are not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.