Abstract:
Embodiments according to the present invention provide improved rotary cutters and associated methods. A cutter includes a handle coupled to a plurality of rotary cutting elements which may be rotatable substantially within the same plane, within closely spaced parallel planes, or within intersecting planes, wherein the intersection of such planes occurs substantially tangential to the rotary cutting elements. The rotary cutting elements are preferably different sized and preferably becoming smaller distally from the handle. A method includes cutting an article with a plurality of rotary blades with a single motion of a human hand and/or arm. Such article may be, for example, a food article, such as pizza, or a textile article, such as leather, vinyl, or even gypsum board.

Description:
RELATED APPLICATIONS 
     This application claims the benefit of co-pending U.S. Provisional Application Ser. No. 61/406,115, filed 23 Oct. 2010 and entitled Rotary Cutter, which is incorporated herein by reference in its entirety. 
    
    
     BACKGROUND OF THE INVENTION 
     Embodiments according to the present invention relate generally to the field of cutting, and more particularly to handheld devices utilizing a plurality of rotating cutting members. 
     Though handled rotary cutters have long been used, what has heretofore been unrecognized is that the shape and arrangement of rotary cutting blades may serve a secondary utilitarian function, e.g., lifting or transport of a cut article, thereby eliminating the need for other utensils, such as serving or transport devices. 
     With prior embodiments of rotary cutters, once an article was cut, resort was had usually to a second device, beside the rotary cutters, to perform other functions on the cut article, such as transportation of the article from one supporting surface to another. As an example, if a conventional rotary cutter is utilized to cut a foodstuff, such as a pizza pie, then a second device, usually a fork or serving utensil such as a spatula, is used to transport the pizza slices from the baking surface, or other first support surface, to a second support surface, such as a serving plate. 
     Accordingly, there remains room in the art of cutting devices for rotary cutters providing one or more utilitarian features other than cutting. 
     SUMMARY OF THE INVENTION 
     One embodiment according to the present invention includes a rotary cutter providing one or more utilitarian features other than cutting. A device according to the present invention comprises a handle including a free end and a mounting frame coupled to the handle. A first blade is coupled to the mounting frame, and it is rotatable about a first axis. A second blade is also coupled to the mounting frame, and it is rotatable about a second axis. 
     According to one aspect of the present invention, the handle may be formed integrally with the mounting frame. 
     According to another aspect of the present invention, the mounting frame may comprise a first mounting rail through which a first axle is mounted and the first blade is coupled to the mounting frame by being rotatably supported on the first axle. 
     According to yet another aspect of the present invention, the mounting frame may comprise a second mounting rail through which a second axle is mounted and the second blade is coupled to the mounting frame by being rotatably supported on the second axle. The first axle may extend through the second rail and the second axle may extend through the first rail. 
     According to still another aspect of a device according to the present invention, the handle may be formed along a handle longitudinal axis and further wherein the first axis, the second axis and the handle longitudinal axis are coplanar. The first axis and the second axis may be parallel, and the handle longitudinal axis may be perpendicular to the second axis. 
     According to a further aspect according to a device according to the present invention, the first blade may be a first circular blade having a first major diameter and the second blade may be a second circular blade having a second major diameter, wherein the first major diameter is different than the second major diameter. The second axis may be disposed between the first axis and the handle, and the first major diameter may be smaller than the second major diameter. For instance, the second major diameter may be greater than twice the first major diameter, or even at least three times the first major diameter. A transfer surface may be formed by the blades, where a first tangent intersects a first point on the first blade and a second point on the second blade, and a second tangent intersects a third point on the first blade and a fourth point on the second blade. The first tangent and the second tangent preferably intersect at a tangent vertex, where the first blade is located between the second blade and the tangent vertex. The tangent vertex may be coplanar with the first axis and the second axis. The first tangent and the second tangent may be disposed at a transfer surface angle of between about thirty degrees to about forty-five degrees. 
     According to still another aspect of a device according to the present invention, the mounting frame comprises a mounting plate including left and right surfaces oppositely disposed and separated by a mounting plate thickness. The left and right surfaces may be substantially planar and the mounting plate preferably includes a blade slot formed between the left and right surfaces, where the blade slot configured to receive at least a portion of the blades. The first blade may be a first circular blade having a first major diameter and the second blade may be a second circular blade having a second major diameter, wherein the first major diameter may be smaller than the second major diameter and the second axis may be disposed closer to the handle than the first axis. The first axis and second axis may be separated by a distance that is greater than the sum of the first major diameter and the second major diameter. A first tangent may intersect a first point on the first blade and a second point on the second blade. A second tangent may intersect a third point on the first blade and a fourth point on mounting plate. The first tangent and the second tangent preferably intersect at a tangent vertex, where the first blade may be located between the second blade and the tangent vertex. The first tangent and the second tangent may be disposed at a transfer surface angle of between about thirty degrees to about forty-five degrees. 
     According to an aspect of a method according to the present invention, such method includes the steps of providing a device configured to be supported in a single human hand, the device comprising a handle coupled to a plurality of blades, each blade being rotatably supported about a blade axis; and cutting, with one or more of the blades, an article supported on a first cutting surface to create a severed portion of the article. The method may further include the step of transferring, with the device, the severed portion of the article to a second supporting surface. The handle of the device may be formed along a handle longitudinal axis, and the method may further include the step of rotating the device about the handle longitudinal axis by ninety degrees prior to the step of transferring. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of a first embodiment of a rotary cutter according to the present invention. 
         FIG. 2  is a left elevation view of the embodiment of  FIG. 1 . 
         FIG. 3  is a top plan view of the embodiment of  FIG. 1 . 
         FIG. 4A  is a front elevation view of the embodiment of  FIG. 3 . 
         FIG. 4B  is a front elevation view of a second embodiment of a cutter according to the present invention. 
         FIG. 5  is a left elevation view of the embodiment of  FIG. 1 . 
         FIG. 6  is a left elevation view of the embodiment of  FIG. 1  shown in use on a first cutting surface. 
         FIG. 7  is a left elevation view of the embodiment of  FIG. 1  shown in use on a second cutting surface. 
         FIG. 8  is a left elevation view of the embodiment of  FIG. 1  shown in use serving a foodstuff. 
         FIG. 9  is a top plan view of the embodiment of  FIG. 1  shown in use serving a foodstuff. 
         FIG. 10  is a top plan view of a third embodiment of a cutter according to the present invention. 
         FIG. 11  is a left elevation view of a fourth embodiment of a cutter according to the present invention. 
         FIG. 12  is a left elevation view of a fifth embodiment of a cutter according to the present invention. 
         FIG. 13  is a left elevation view of a sixth embodiment of a cutter according to the present invention. 
         FIG. 14  is a left elevation view of a seventh embodiment of a cutter according to the present invention. 
         FIG. 15  is a top plan view of the embodiment of  FIG. 14 . 
         FIG. 16  is a left elevation view of an eighth embodiment of a cutter according to the present invention. 
         FIG. 17  is a left elevation view of a ninth embodiment of a cutter according to the present invention. 
         FIG. 18  is a top plan view of the embodiment of  FIG. 17 . 
         FIG. 19  is a left elevation view of the embodiment of  FIG. 17  shown serving a foodstuff. 
         FIG. 20  is a left elevation view of a tenth embodiment of a cutter according to the present invention. 
         FIG. 21  is a partial cross-section view taken along lines  21 - 21  of  FIG. 20 . 
     
    
    
     DESCRIPTION OF THE PREFERRED EMBODIMENT 
     Although the disclosure hereof is detailed and exact to enable those skilled in the art to practice the invention, the physical embodiments herein disclosed merely exemplify the invention which may be embodied in other specific structures. While the preferred embodiment has been described, the details may be changed without departing from the invention, which is defined by the claims. 
     Embodiments according to the present invention provide devices and methods of cutting an article. The devices and methods of the present invention may be utilized to cut, for example, substantially planar articles such as textiles or foodstuffs, such as pizza. 
     Turning now to the Figures, a first embodiment  100  of a cutter according to the present invention may be seen generally in  FIGS. 1-4A  and  5 - 9 . The cutter  100  includes a plurality of (at least two) rotary blades  102 , 104 , each of which is preferably rotatably supported about a blade axis  106 , 108 . The rotation of the blades  102 , 104  is preferably passive, such that an axle  110  on which a blade is supported does not turn synchronously with the blade. Rather, the blades  102 , 104  are preferably rotated about the axis  106 , 108  by a force imparted to them, such as proximate its outer edge or periphery. Each blade  102 , 104  preferably has a major diameter  112 , 114 , half of which would be a radius measured from the center of the blade axis  106 , 108  to the outermost portion of the blade. Each blade preferably has a sharpened edge  116  that is substantially smooth about the major diameter. One or more of the blades  102 , 104  may have radial indentations (not shown) provided radially inward to a minor diameter measured from the blade axis, where the minor diameter is smaller than the major diameter. 
     The blade axes  106 , 108  are preferably spaced a predetermined axis spacing  118  from each other, and may be substantially parallel, or disposed at a predetermined angle with respect to each other, as can be seen in the second embodiment  200  in  FIG. 4B . The space  118  between the blade axes  106 , 108  is preferably less than, but may be substantially equal to, or greater than the sum of the major radii of adjacent blades  102 , 104 . The blades  102 , 104  may have substantially the same major and/or minor diameters, or they may be significantly different. As shown in the Figures, a first distal blade  102  may have a smaller major diameter than a second proximal blade  104 . As is highlighted in  FIGS. 5 and 8 , such arrangement may create a transfer surface  120 , such as a serving surface for foodstuffs, such as pizza. In other words, tangent lines extending from the periphery of the distal blade  102  to the periphery of the proximal blade  104  preferably generally form a wedge shaped transfer surface  120  so as to facilitate the serving of wedge shaped foodstuff slices. Thus, the cutting blades  102 , 104 , themselves, may form a transfer surface  120  which approximates a predetermined cut-article shape, such as a wedge. The transfer surface  120  has a length  122  of preferably at least 60% of the expected length of a predetermined cut article, and more preferably at least 70% of such length. Thus, for a 12″ diameter substantially circular article to be cut into wedges, the transfer surface length  122  is preferably at least 60% of 6″, or at least 3.6″, but more preferably at least 4.2″. The shape of the transfer surface  120  may be formed generally by tangents to the outer edges  116  of the blades  102 , 104 , which may be disposed at a desired support surface angle  124 , such as about thirty degrees to about forty-five degrees. 
     A smaller distal rotary blade  102  also provides the advantage of a more complete cut towards the edge of a boxed foodstuff, and also allows for a precut by the distal blade  102  followed by through-cut by the proximal blade  104  in a single cutting stroke. In  FIG. 6 , a foodstuff is being sliced on a planar first support surface  180 . Such surface  180  may be a cutting board or a piece of cardboard. However, foodstuffs are commonly provided in a box, which includes a box rim  182  extending substantially perpendicularly upwards from a horizontal cutting surface  180 . As shown in  FIG. 7 , the major radius of the distal blade  102  is a limiting factor in cutting closer to the box rim  182 . Thus, if the proximal blade  104  has a major diameter of about 3″ and the distal blade  102  has a major diameter of about 1″, then the smaller distal blade  102  provides the ability to slice the foodstuff article one full inch closer to the box rim  182  than if a rotary cutter having a single blade  104  were used. 
     A preferred major blade diameter  114  for the proximal blade  104  is from about 3″ (preferred for serving smaller slices, or an about 12″ diameter article or foodstuff) to about 6″ (preferred for serving larger slices, or an about 22″ diameter article or foodstuff) and a preferred major blade diameter  112  for the distal blade is from about 0.75″ to about 1.75″. 
     As indicated, the blade axes may be disposed at a predetermined blade cant or tilt angle, such as the second embodiment  200  shown in  FIG. 4B , where similar reference numerals refer to similar or identical structure to the first embodiment  100 . This blade tilt angle  225  arrangement is particularly useful if the blade axes  206 , 208  are spaced a distance of less than the sum of adjacent major blade radii and if it is desirable to have a very narrow cutting kerf made by both blades  202 , 204  together in a single cutting stroke. Such arrangement may be suited for cutting textiles such as heavy leather or vinyl. A preferred tilt angle  225  is from zero degrees to about forty-five degrees. 
     The blades  102 , 104  may be supported on axles  110  that are either fixed to or rotatably mounted on a frame structure  130 . The frame structure  130  may include substantially planar, parallel rails  132 , 134 . While the outer surface of the rails  132 , 134  is preferably substantially planar, an inner surface thereof, which generally faces the blades  102 , 104  when the device  100  is assembled, may have staggered indentations to accommodate blade orientation, which can best be seen in  FIG. 3 . Although shown with two rails  132 , 134 , the frame structure  130  may be formed from only a single rail  132  or  134 . Also, while each rail  132 , 134  is shown coupled to both axles  110 , in another embodiment (not shown) where two rails  132 , 134  are used, then each rail may support only a single blade  102  or  104 . The blades  102 , 104 , rails  132 , 134 , and axles  110  are preferably formed from a stainless steel material. 
     Coupled to (or formed integrally with) and supported by the frame structure  130  is a handle  140 , preferably configured to be grasped by a human hand. The handle  140  may extend along a longitudinal axis  142 , substantially longitudinally away from the blades  102 , 104  to a free proximal end  144 . In this way, the handle longitudinal axis  142  may lie substantially orthogonal to each of the blade axes  106 , 108 . Accordingly, downward cutting pressure may be applied to the blades  102 , 104  through a levering action provided by a hand grasping the handle  140 . An optional blade guard  145  may be provided as extending from or coupled to the handle  140 . The blade guard  145  may have a first extension  147  and a second extension  149  extending radially outwardly from the handle  140 . While the first extension  147  and second extension  149  may be substantially symmetrical, one may be longer than the other. As shown, the first extension  147  has a surface  147   a  that runs substantially parallel to, but spaced from the outer edge  116  of the proximal blade  104 . The second extension  149  also has such a surface  149   a , but it extends about the proximal blade  104  for a shorter distance than the first extension  147 . 
     A third embodiment of a cutter  300  according to the present invention is shown in  FIG. 10 , where similar numerals refer to similar structure in the first embodiment  100 . In the third embodiment  300 , with the handle  340  extending substantially longitudinally away from the blades  302 , 304  to a free proximal end  344 , the handle longitudinal axis  342  may be angled slightly right (as shown) or left from the just described position by a predetermined angle  346  so as to facilitate the serving of foodstuffs, as can be seen in  FIG. 10 . A preferred predetermined handle angle  346 , measured relatively to a kerf  303  to be formed by the cutter  300  is zero degrees to about forty-five degrees. 
     Additionally or alternatively, the cutter frame structure or support surface may include serving support wings or rails, as shown in  FIGS. 11-13 . A fourth embodiment of a cutter  400  according to the present invention is shown in  FIG. 11 , where similar numerals refer to similar or identical structure in the first embodiment  100 . In the fourth embodiment  400 , a first support wing  426  and a second support wing  428  extend outward from the first support rail  432 , generally parallel to the blades  402 , 404 . The wings  426 , 428  may be formed from a solid piece of material, such as plastic or stainless steel, and be coupled to or formed integrally with the support rail  432 . The wings  426 , 428  may overlap one or both of the blades  402 , 404 , as shown, or the wings  426 , 428  may be disposed between the blades  402 , 404  so as to span some otherwise open space therebetween. The wings  426 , 428  preferably have outer edges  426   a , 428   a  that lie, with respect to each other, at an angle substantially equal to the support surface angle  424 . A fifth embodiment of a cutter  500  according to the present invention is shown in  FIG. 12 , where similar numerals refer to similar or identical structure in the first embodiment  100 . In the fifth embodiment  500 , a first support wire  526  and a second support wire  528  extend outward from the first support rail  532 , generally parallel to the blades  502 , 504 . The wires  526 , 528  may be formed from an extruded or stamped piece of material, such as stainless steel, and be coupled to or formed integrally with the support rail  532 . The wires  526 , 528  may overlap one or both of the blades  502 , 504 , as shown, or the wires  526 , 528  may be disposed between the blades  502 , 504  so as to span some otherwise open space therebetween. The wires  426 , 428  preferably have outer portions  526   a , 528   a  that lie, with respect to each other, at an angle substantially equal to the support surface angle  524 . 
     A sixth embodiment of a cutter  600  according to the present invention is shown in  FIG. 13 , where similar reference numerals refer to similar or identical structure in the first embodiment  100 . The sixth embodiment  600  may be substantially the same as the fourth embodiment  400  with the exception of the handle  640 . In the sixth embodiment, the handle axis  642  is preferably disposed at an acute angle relative to the first support rail  632 , or more particularly at an acute angle with respect to a line segment disposed between the blade axes  606 , 608 . In use, this design is expected to provide a user with increased cutting leverage. 
     Instead of having a handle aligned orthogonal to the blade axes, the handle may be positioned along a longitudinal axis that is located substantially orthogonally skew to the blade axes, such as the arrangements shown in  FIGS. 14-20 . A seventh embodiment of a cutter  700  according to the present invention is shown in  FIGS. 14-15 , where similar reference numerals refer to similar or identical structure in the first embodiment  100 . In this fashion, the handle  740  may extend between a free handle end  744  and a frame end  750  coupled to a frame structure  730  adapted to support the blades  702 , 704  and/or blade axles  710 . The handle axis  742  may run generally parallel to, and spaced a predetermined distance  752  from, a line that orthogonally intersects the two blade axes  706 , 708 . 
     While, above, the blades could be canted to provide a narrow cutting kerf, another option would be to space the blade axes at a distance greater than the sum of adjacent blade major radii, so as to allow for blade alignment. In such embodiment, the handle may have a thicker free end for a comfortable grip (which may include undulations  741 ) and extend into a thinner serving frame portion that may support a plurality of rotary blades, as shown in  FIGS. 16-20 .  FIG. 16  depicts an eighth embodiment of a cutter  800  according to the present invention, where similar reference numerals refer to similar or identical structure to the first embodiment  100 . This embodiment  800  includes as a mounting frame  830  a mounting plate including a first leg  831  extending from the handle  840  towards the first blade  802 , a second leg  833  extending from the handle  840  towards the second blade  804 , and a third reinforcement member  835  preferably extending generally between the two blades  802 , 804 . The mounting plate generally may include a left surface  830 L (visible in  FIG. 16 ) and an opposing right surface (e.g.,  930 R in  FIG. 18 ), each of which may be substantially planar. The left and right surfaces are separated by a mounting plate thickness  937 . Between the left and right surfaces, a blade slot (e.g.,  939  in  FIG. 18 ) may be configured to receive at least a portion of each blade, which is rotatably supported on a blade axle, which preferably extends through both the left and right surfaces. To assist in cleaning the device, one or more access apertures may be provided through the left and/or right mounting plate surfaces into the blade slot (e.g.,  939  in  FIG. 18 ). This embodiment  800  shows that other portions of the device  800 , other than the blades  802 , 804 , may be used to form a transfer surface. That is, a tangent formed between the blades  802 , 804  and a tangent formed along the mounting plate  830  and finger guard  847  may be disposed at transfer surface angle  824  of between about 30 degrees to about 45 degrees. When the word “about” is used, it generally refers to +/− one third of the measurement modified by such adjective. 
       FIGS. 17-19  depict a ninth embodiment of a cutter  900  according to the present invention, where similar reference numerals refer to similar or identical structure to the seventh  700  or eighth  800  embodiments. The ninth embodiment  900  is similar to the eighth embodiment  800 , but the handle  940  has been moved rearward and disposed along a handle longitudinal axis  942  which is situated substantially parallel to and at a predetermined handle spacing  952  from a reference plane that includes both the first blade axis and the second blade axis. In this embodiment  900 , the transfer surface angle  924  is formed by a first tangent that may be drawn between the blades  902 , 904 , and a second tangent that may be drawn between the first blade  902  and the mounting plate  930 , where such angle  924  is between about 30 degrees to about 45 degrees. 
       FIGS. 20-21  depict a tenth embodiment of a cutter  1000  according to the present invention, where similar reference numerals refer to similar or identical structure to the ninth embodiment  900 . This embodiment  1000  includes a secondary cutter component  1060  disposed on or formed integrally with the mounting plate  1030 , preferably on the first leg  1031 . The secondary cutter component  1060  includes a cutting gap  1062  and a cutting member  1064 . The gap  1062  is configured to receive, e.g., plastic foodwrap, and the cutting member  1064  is adapted to cut same. The cutting member  1064  may be formed integrally with the leg  1031 , such as by being a sharpened portion thereof, or it  1064  may be an inserted cutting member such as a blade. In this embodiment  1000 , the transfer surface angle  1024  is formed by a first tangent that may be drawn between the blades  1002 , 1004 , and a second tangent that may be drawn between the first blade  1002  and the mounting plate cutter component  1060 , where such angle  1024  is between about 30 degrees to about 45 degrees. 
     To use a device x 00  according to the present invention, an article, such as a foodstuff (e.g. pizza) is cut on a cutting surface to form a severed portion of the article. The device x 00  may then be used to transfer the severed portion from the cutting surface to another support surface. To transfer the severed portion, the device x 00  may be rotated, such as about the handle longitudinal axis x 42  by an angle of about ninety degrees to establish a transfer surface x 20  to slide under the severed article and support same during transfer. 
     Any handle X 40  according to the present invention is preferably formed from plastic or stainless steel, which may be formed integrally with the mounting frame X 30 , but it may include relatively soft (durometer) overmolding or grip portions, which may include one or more finger indentations X 41 , added to the plastic or stainless steel to aid in comfort. 
     The foregoing is considered as illustrative only of the principles of the invention. Furthermore, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described. While the preferred embodiment has been described, the details may be changed without departing from the invention, which is defined by the claims.