Patent Publication Number: US-6708413-B2

Title: Shape and envelope cutting system

Description:
This is a continuation-in-part of United States Patent Application No. 09/769,683, filed Jan. 25, 2001. 
    
    
     FIELD OF THE INVENTION 
     The present invention relates generally to a shape and envelope rendering systems. More particularly, the present invention relates to the field of marking devices, including cutting devices and templates. 
     BACKGROUND OF THE INVENTION 
     Devices for rendering marks upon materials such as paper, cardstock and photographs are generally well known. Such devices, including cutting devices, are typically configured for performing free-form marking or cutting. Many marking devices are also used in conjunction with a template for marking or cutting specific or predetermined shapes from a material. Cutting devices having an adjustable blade are also known and are typically used for cutting materials of varying thicknesses. Other cutting devices can include a swiveling blade which swivel or rotate about a longitudinal axis of the cutting device. Cutting devices typically are elongate members having housings which form a handle for grasping by a user during cutting. The housing usually connects at its lower end to the blade. The angular position of the cutting blade of the cutting device with respect to the material to be cut is typically determined by the user&#39;s hand. 
     Templates are also well known. Templates typically are flat sheets having first and second sides, and one or more openings are formed in a variety of different shapes. The cross-sectional shape, of the periphery of the template and the edges of the template at the openings, typically defines straight-cut edges extending perpendicularly from the first side to the second side. Templates are commonly made of semi-transparent, generally flexible material. Templates used to produce geometric or other shapes of varying sizes can also be configured as nested templates. Nested templates include a series of elongate, unconnected slots which form outlines of specific shapes. When using nested templates, the user is required to cut the portions of the material to be cut which extend between the ends of the slots in order to completely outline or cut out the desired shape. 
     Existing devices for rendering marks and existing templates have a number of drawbacks. Existing rendering or cutting devices are typically not securely orientated in regard to angle with respect to the material. As a result, the angular orientation of the device with respect to the material to be cut (e.g., the blade of a cutting device) is often inadvertently changed causing an error in the desired marking or cutting. Existing devices which do fix the angular orientation of the cutting device with respect to the material are typically configured for free-form cutting only and do not properly function in conjunction with templates. Other devices which fix the angular orientation of the cutting device with the material to be cut are large, expensive devices which are often difficult to operate and to transport. 
     Further, existing cutting devices are typically formed of non-transparent material which partially obstructs the user&#39;s view of the material to be cut. Also, many cutting devices utilize a bottom-load blade connection of the blade to the housing of the device. The bottom-load connection of the blade to the housing makes the blade susceptible to becoming dislodged from the housing during operation. Existing cutting devices also typically do not include blade depth indication which increases the likelihood of blade depth mis-adjustment. Existing cutting devices also typically do not accommodate spare blades or blade assemblies. Those cutting devices, which have a rotatable or swivelable blade, are not typically configured for use with a template. When not in operation, existing cutting devices often have exposed cutting blades which are susceptible to contact by the user. 
     Existing templates are not configured for effective operation with cutting devices, and in particular, with cutting devices wherein the housing and the blade assembly are maintained in a generally fixed orientation with respect to the template. The periphery and the edges at the openings of existing templates often cause existing rotatable or swiveling blade assemblies to bind which can result in mis-cuts. Also, existing nested templates produce incomplete shapes and require the user to undertake a secondary cutting or marking operation, typically without the aid of the template, to complete the cutting or marking of the desired shape. 
     Thus, there is a need for a device for rendering marks or cuts onto a material which maintains the marking assembly in substantially constant angular orientation with respect to the material to be cut and which is configured for use in either a free-form rendering mode or a template rendering mode. There is also a continuing need for a cutting device which is configured for single-hand operation and which can be adjusted without the use of tools. What is needed is a cutting device having a blade assembly which is not susceptible to separation from the lower portion of the housing and a cutting device which indicates the depth of the cutting blade. A cutting device configured to prevent contact by a person with the blade when the device is not in use is also needed. Further, there is a continuing need for a cutting device having many of these attributes which also accommodates spare blade assemblies and which enables the replacement of blades without the use of tools. Additionally, there is a need for a template which operates effectively with a rotatable or swiveling cutting blade of a cutting device. In addition, a template is needed which enables the continuous and uninterrupted cutting of shapes of varying sizes. 
     SUMMARY OF THE INVENTION 
     The present invention provides a shape and envelope cutting system for cutting a material having a surface. The shape and cutting system includes a cutting unit and at least one template. The cutting unit includes a frame, a blade adjustment assembly coupled to the frame, and a blade assembly coupled to the frame. The frame has a lower support surface. The blade assembly is positioned at least partially within the frame such that a longitudinal axis of the blade assembly is substantially perpendicular to the lower support surface of the frame. The blade assembly includes a blade retainer and a blade connected to the retainer which has a rigid collar. The blade assembly is rotatable about the longitudinal axis. The at least one template has first and second substantially flat surfaces, a periphery and at least one edge defining at least one opening. The frame of the cutting unit has a lower surface for contacting at least one of the first surface of the template and the material to be cut. The second surface of the template is configured for placement upon the material to be cut. The rigid collar of the retainer is configured to operatively engage either the periphery of the edge of the opening of the template. The engagement of the collar to the template enables the blade to cut a shape in the cutting material which assimilates the shape of at least a portion of the at least one of the periphery and the edge. 
     According to a principal aspect of a preferred form of the invention, a device is provided for rendering shapes upon a material wherein the device may be used in conjunction with at least one template. The device includes a frame, a marking device adjustment assembly and a marking device assembly. The frame includes a base and a housing. The base includes a substantially flat lower surface for contacting one of the material to be cut and the template. The housing is coupled to the base and also has first and second interconnected openings. The housing is supported by the base in at least one position above the lower surface of the base. A marking device adjustment assembly is coupled to the housing at the first opening. A marking device assembly is operatively coupled to the marking device adjustment assembly. The marking device assembly is at least partially enclosed by the housing at the second opening of the housing. The second opening of the housing is sized to enable a lower portion of the marking device assembly to partially and adjustably extend through the second opening and to prevent the marking device assembly from fully extending through the second opening. 
     According to another aspect of the invention, a device is included for rendering shapes upon a material wherein the device may be used in conjunction with at least one template. The device includes a frame, a marking device adjustment assembly, and a marking device assembly. The frame has a substantially flat lower surface for contacting one of the material to be cut and the template. The flat lower surface is sized to support the frame in an upright position. The marking device adjustment assembly is coupled to the frame. The marking device assembly is at least partially enclosed by the frame and is operatively coupled to the marking device adjustment assembly. The frame has a storage compartment for storing at least an additional marking device assembly. 
     According to another aspect of the invention, a template is included for facilitating the rendering of shapes onto a material by a rendering device. The template includes a substantially flat sheet having first and second sides, a periphery and at least one opening extending from the first side to the second side. The first side of the sheet is configured for placement upon the material to be cut. The second side of the sheet is configured to contact the rendering device. The sheet is made of a semi-transparent tinted template material. The first side laterally extends at the periphery and at the one opening farther than the second side to define a chamfer at the periphery and at the one opening of the template. 
     According to still another aspect of the invention, an envelope cutting system having a surface comprises a cutting unit including a frame having a lower support surface, a blade adjustment assembly coupled to the frame, and a blade assembly coupled to the frame. The blade assembly is positioned at least partially within the frame such that a longitudinal axis of the blade assembly is substantially perpendicular to the lower support surface of the frame. The blade assembly includes a blade retainer and a blade connected to the retainer, the retainer having a rigid collar, and the blade assembly rotatable about the longitudinal axis. At least one template includes first and second substantially flat surfaces, a periphery and at least one edge defining at least one opening forming the shape of an unfolded envelope. The lower support surface of the frame is configured for contacting at least one of the first surface of the template and the material to be cut. The second surface of the template is configured for placement upon the material to be cut, and the rigid collar of the retainer is configured to operatively engage at least one of the periphery and the edge of the opening of the template, thereby enabling the blade to cut a shape in the cutting material which assimilates the shape of at least a portion of the at least one of the periphery and the edge. 
     This invention will become more fully understood from the following detailed description, taken in conjunction with the accompanying drawings described herein below, and wherein like reference numerals refer to like parts. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     FIG. 1 is a perspective view of the cutting system, including a cutting unit and a template, in accordance with a preferred embodiment of the present invention; 
     FIG. 2 is an exploded perspective view of a cutting unit of the shape cutting system of FIG. 1; 
     FIG. 3 is a side view of the cutting unit of FIG. 1; 
     FIG. 4 is a detailed view of section A of FIG. 3; 
     FIG. 5 is a top perspective view of a template and a mat of the shape cutting system of FIG. 1; 
     FIG. 6 is a side view of the template of FIG. 5; 
     FIG. 7 is a detailed view of the template along the section B of the template of FIG. 6; 
     FIG. 8A is a side view of a blade assembly in accordance with an alternative preferred embodiment of the present invention; and FIG. 8B is a side view of a blade assembly in accordance with another alternative preferred embodiment of the present invention; 
     FIG. 9 is a top view of a template for cutting the shape of an envelope according to one embodiment of the present invention; 
     FIG. 10 is a top view of scoring plate for scoring the fold lines of the envelope defined by the template of FIG. 9; 
     FIG. 11 is a top view of a template for cutting the shape of an envelope according to an alternate embodiment of the present invention; 
     FIG. 12 is a top view of scoring plate for scoring the fold lines of the envelope defined by the template of FIG. 11; 
     FIG. 13 is a top view of a template for cutting the shape of an envelope according to yet another embodiment of the present invention; 
     FIG. 14 is a top view of scoring plate for scoring the fold lines of the envelope defined by the template of FIG. 14; 
     FIG. 15 is a top view of a template for cutting the shape of an envelope according to still another embodiment of the present invention; 
     FIG. 16 is a top view of scoring plate for scoring the fold lines of the envelope defined by the template of FIG. 15; 
     FIG. 17 is a top view of a template for cutting the shape of a box according to one embodiment of the present invention; 
     FIG. 18A is a top view of scoring plate for scoring the fold lines of the box defined by the template of FIG. 17; and 
     FIG. 18B is a perspective of a partially assembled box according to the embodiment shown in FIG. 17; 
     FIG. 19 is a top view of a template for cutting the shape of a plurality of memory pockets according to another embodiment of the present invention; 
     FIG. 20 is a top view of scoring plate for scoring the fold lines of the memory pockets defined by the template of FIG. 19; 
     FIG. 21A is an exploded view of an embossing system according to one embodiment of the present invention; and 
     FIG. 21B is an exploded view of an embossing system according to another embodiment of the present invention; 
     FIG. 22 is a perspective view of an embossing system according to an alternate embodiment of the invention; and 
     FIG. 23 is a perspective view of an embossing system according to yet another embodiment of the invention. 
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
     Referring to FIG. 1, a shape cutting system is indicated generally at  10 . The shape cutting system  10  includes a cutting unit  12 , at least one template  14  and further includes a cutting mat  15  (see FIG.  5 ). The cutting unit  12  is a lightweight, handheld positionable assembly configured for operation with one of the templates  14  and for application directly onto a material to be cut without templates. The cutting unit  12  is also configured to cut material such as paper, card stock, photographs, and other cutable goods into desired shapes or patterns. The cutting unit  12  functions in at least two operating modes. In the first operating mode, a free-form or free-hand mode, the cutting unit  12  is placed directly upon the material to be cut and is translated preferably by a single hand of the user, in the desired direction across the material to perform free-form cutting. In the second mode of operation, the template cutting mode, the cutting unit  12  works in conjunction with at least one of the templates  14  to cut a prescribed or predetermined pattern, segment or shape, as outlined by the template  14  and as desired by the user. In an alternative preferred embodiment, the shape cutting system  10  can be used to render marks, not including cuts, onto a material as opposed to cutting the material. In such a preferred embodiment, the cutting unit  12  would be substituted with another marking device, such as a writing instrument. The cutting unit  12  is sized for ambidextrous single hand operation and to be easily transported or stored. 
     FIG. 2 illustrates the cutting unit  12  in greater detail. The cutting unit  12  includes a frame  16 , a protective cover  18 , a blade adjustment assembly  20  and a swivel blade assembly  22 . The frame  16  is preferably a handheld, one-piece support structure. The frame  16  is preferably configured for supporting and partially enclosing the blade adjustment assembly  20  and the swivel blade assembly  22 . The frame  16  is also configured for removable contact with the template  14  or the material to be cut. The frame  16  is made of a durable, lightweight material, preferably, a clear, semi-transparent polycarbonate material. Alternatively, the frame  16  can be made of different materials such as, for example, other thermoplastic materials, metal, wood or glass. 
     The frame  16  includes a base  24 , a housing  26  and an arm  28 . The base  24  is a support structure having a substantially flat lower surface  30  and an aperture  32  defined within its center. The base  24  is coupled to the housing  26  by the arm  28 . The base  24  is configured to be easily translated over a surface of the material to be cut or an outer surface of one of the templates  14 . The base  24  is also configured to securely support the housing  26  in a fixed position. In a preferred embodiment, the base  24  securely and integrally supports the housing  26  in a position substantially perpendicular to the lower surface  30  of the base  24 . The aperture  32  is configured to enable the blade assembly  22  to partially extend therethrough during operation. The base  24  further includes a wall  34  upwardly extending from an upper surface  36  of the base  24 . The wall  34  and the upper surface  36  of the base  24  combine to provide an annular handle which is configured to be easily grasped by the user enabling the user to easily move the cutting unit  12  in any direction across a surface of the material to be cut or the template  14 . The base  24  is preferably an annular member. Alternatively, the base  24  can be formed in other shapes such as, for example, a rectangular shape, an oval shape, a U-shape, or other conventional shapes. 
     The housing  26  is a generally cylindrical body having first and second openings  38  and  40 . The housing  26  is preferably integrally connected to the arm  28  and coupled to the base  24 . The first and second openings  38  and  40  of the housing  26  are defined to interconnect and axially extend through the housing  26  along a longitudinal axis  42 . The housing  26  is removably connected to, and partially encloses, the blade assembly  22  at the second opening  40  and the blade adjustment assembly  20  at the first opening  38 . The housing  26  is configured to retain at least a portion of the blade assembly  22  and a portion of the blade adjusting assembly  20 . The housing  26  also allows top-loading of the blade assembly  22  into the housing  26  through the first opening  38 . The housing  26  is also configured to prevent the blade assembly  22  from fully extending through the second opening  40  of the housing  26 . This feature prevents the inadvertent separation or dislocation of the blade assembly  22  from the lower end of the housing  26  during operation. The housing  26  is also configured to enable the blade assembly  22  to move axially in a plurality of different positions based upon the adjustment of the blade adjustment assembly  20 , and to enable the blade assembly  22  to rotate, pivot and swivel about the axis  42  during operation. 
     The arm  28  is a curved support structure. The arm  28  is also preferably integrally connected to the base  24  and to the housing  26  for supporting the housing  26  above the aperture  32  of the base  24 . The arm  28  is configured to fixedly secure the housing  26  along the axis  42  in a position substantially vertical to the lower surface  30  of the base  24 . This configuration ensures that the blade assembly  22  is continuously maintained by the housing  26 , and the frame  16  is maintained in position in a substantially vertical position with respect to the base  24  when the base  24  is placed on a substantially horizontal surface. When in use, the arm  28  fixedly secures the angular orientation of the housing  26  with respect to the material to be cut. The configuration of the frame  16  eliminates the need for the user of the cutting unit  12  to adjust the angular orientation of the housing  26  and the swivel blade assembly  22  during operation. In alternative embodiments, the arm  28  can be configured to support the housing  26  and the blade assembly  22  in a plurality of different angular orientations with respect to the base  24 . 
     In a preferred embodiment, the arm  28  is a generally hollow structure and further includes an arm cover  44 . The arm  28 , including the arm cover  44 , forms a spare blade assembly storage compartment  46  for receiving at least one spare blade assembly. The arm cover  44  is a curved, and partially generally spherical, member having an opening  48  at its upper end. The arm cover  44  is pivotally connected to the upper end of the housing  26  at the opening  48 . The opening  48  is configured to receive the upper end of the housing  26  and is coaxially aligned with the first opening  38  of the housing  26 . The cover  44  is configured to pivot about the axis  42  to enable a user to releasably access the storage compartment  46 . The arm cover  44  is made of a lightweight durable substantially transparent material, preferably, a clear polycarbonate material. Alternatively, the arm cover  44  can be made of other materials such as, for example, other thermoplastic materials or glass. 
     The storage compartment  46  of the arm  28  is sized to hold at least one spare blade assembly. The semi-transparent material of the arm  28  readily enables the user to visually ascertain whether a replacement blade assembly is stored within the storage compartment  46  without having to reposition the arm cover  44  from the arm  28  or disassemble the cutting unit. Alternatively, the arm  28  can be formed in other shapes or configurations, and it can be formed out of two or more members extending from the base  24 . Additionally, the storage compartment can be located at other locations on the frame  16 , such as, for example, formed as part of the base  24 . 
     The protective cover  18  is a generally circular disk shape. The cover  18  is removably connected to the base  24  and covers the lower surface  30  of the base  24  including the aperture  32 . The cover  18  prevents a user from inadvertently contacting the blade assembly  22  when the cutting unit  12  is not in use or when the cutting unit  12  is removed from contact with the cutting material. The cap  18  is preferably made of a lightweight, flexible and durable material. Preferably, the cap  18  is made of a plastic, but alternatively, other conventional materials can also be used. The cover  18  provides a secure, lightweight, reusable and inexpensive means for safely protecting the user from contact with the blade assembly  22  when the cutting unit  12  is not in use. Alternatively, the cover  18  can be formed in other configurations which prevent contact with the blade assembly  22  installed in the frame  16 , such as a cap for the lower end of the housing  26  and the blade assembly  22 . In another alternative embodiment, the blade assembly  22  can be configured to be completely retractable within the housing  26 . 
     The blade assembly  22  is removably inserted and substantially enclosed by the housing  26 . The blade assembly  22  is inserted through the first opening  38  of the housing  26  and extends along the axis  42  within the housing  26  such that the lower portion of the blade assembly  22  outwardly extends from the second opening  40  of the housing  26 . 
     The blade assembly  22  includes a blade retainer  50  and a cutting blade  52 . The blade retainer  50  is preferably a cylindrical body having an enlarged upper end  54  and a lower end formed having a diameter which is smaller than the diameter of the main portion of the retainer  50 . The lower end of the retainer  50  forms a collar  56 . The retainer  50  is sized to fit within the first opening  38  of the housing  26 , to extend through the interior of the housing  26 , and to partially and adjustably extend through the second hole  40  of the housing  26 . The retainer  50  is also sized to angularly rotate or swivel about the axis  42  during operation in either a clockwise or counter-clockwise direction. The swiveling or rotating feature of the blade assembly  22  with respect to the frame  16  enables the blade  52  to follow a profile or shape defined in one of the templates  14 . The swiveling blade  52  can follow the free-form movement of the user&#39;s hand across a surface without requiring the separate adjustment of the blade  52  by the user during operation. The retainer  90  is configured to adjustably and axially extend within the housing  26  in response to the adjustment of the blade adjustment assembly  20 . The retainer  50  is made of a lightweight durable inexpensive material, preferably a plastic. Alternatively, other materials can also be used such as, for example, wood or metal. In an alternative embodiment, the retainer  50  can be configured to retain more than one of the blades  52  or blades of varying sizes. 
     The upper end  54  of the retainer  50  is sized so as to prevent the retainer  50  from fully extending in an axial manner through the second opening  40  of the housing  26 . The upper end  54  also includes an upper bearing surface which is configured to removably and operatively contact the blade adjusting assembly  22 . This enables the retainer  50  to rotate or swivel with respect to the axis  42  and with respect to the blade adjustment assembly  20 , or to move axially along the axis  42 . 
     The collar  56  is configured to removably contact an edge of one of the templates  14  and is configured to facilitate the operation of the blade assembly  22  in conjunction with one of the templates  14 . Specifically, the collar  56  is configured to slide along and rotate as necessary with respect to an edge or the periphery of the template  14 , thereby enabling the blade  52  to conform to the shape defined in the template  14 . 
     The blade  52  is preferably a conventional single-edged blade which is also preferably press-fit to the lower end of the retainer  50 . The blade  52  downwardly extends from the lower end of the retainer  50  and includes a cutting edge. The cutting blade  52  is most preferably made of a metallic material. In an alternative embodiment, the blade  52  can be a double edged blade  53  (see FIG.  8 A), a rotary blade  55  (see FIG. 8B) or comprise multiple blades for cutting materials such as, for example, paper, cardboard and cloth. In another alternative embodiment, the blade  52  can be replaced with a writing or marking implement or a tool, such as a drill bit. 
     Referring to FIG. 2, the blade adjustment assembly  20  is an adjustable device removably connected to the base  24  at the first opening  38  of the housing  26 . The blade adjustment assembly  20  is operatively coupled to the blade assembly  22 . The blade adjustment assembly  20  is configured for the application of varying amounts of downward pressure to the blade assembly  22 , which results in a corresponding variation in the amount of downward pressure applied to the blade assembly  22  for the cutting of material. 
     The blade adjustment assembly  20  includes a knob  60 , a plunger  62  and a biasing device  64 . The knob  60  is a generally cylindrical member having an operating mode indicating portion  70  formed between an enlarged upper end  66  and a smaller lower end  68 . The lower end  68  of the knob  60  is removably connected to the housing  26  at the first opening  38 . The lower end of the knob  60  is also operatively coupled to the plunger  62  and the biasing device  64 . In a preferred embodiment, the lower end  68  of the knob  60  includes external threads which engage internal threads formed in the housing  26  at the first opening  38 . The knob  60  is configured to enable a user to grasp and rotate the upper end  66  of the knob  60  in order to adjust the spring tension applied to the blade assembly  22 , or to remove the knob  60  from the housing  26 . The knob  60  is also configured to retain the plunger  62  and the biasing device  64  such that the blade adjustment device  20  maintains an adjustable downward force upon the blade assembly  22 . The knob  60  is made of a lightweight durable material, preferably a plastic. Alternatively, the knob  60  can be made of other materials such as wood, metal or glass. The upper end  66  of the knob  60  preferably includes a plurality of outwardly extending projections to facilitate grasping and rotation of the knob  60 . The upper end  66  also preferably further includes an opening  72  for receiving a tool, such as an “Allen” key. The lower end  68  of the knob  60  includes a plunger receiving hole  74  for receiving a portion of the plunger  62 . The lower end  68  of the knob  60  is also configured to attach or connect to one end of the biasing device  64 . 
     The plunger  62  is a cylindrical body having an upper portion and an enlarged lower contact region  76 . The plunger  62  is coupled to the knob  60  via the hole  74  and is operatively connected to the blade assembly  22  at the retainer  50 . The plunger  62  also is connected to and preferably partially surrounded by the biasing member  64 . The plunger  62  contacts the retainer  50  of the blade assembly  22  to transmit the downward force caused by the adjustment of the knob  60  by the user for adjusting the axial position of the blade assembly  22  with respect to the housing  26 . The plunger  62  is made a durable lightweight material, preferably, a plastic. Alternatively, the plunger  62  can be made out of other materials, such as, for example, wood or metal. 
     The biasing device  64  is connected at one end to the knob  60  and at a second end to the plunger  62 . The biasing device  64  is preferably a helical spring. The biasing device  64  provides the adjustable downward force upon the lower end of the plunger  62  to continuously urge the blade assembly  22  downward and to resist upward movement of the blade assembly  22  during operation. The configuration of the cutting unit  12  advantageously eliminates the need for a user to axially orientate the cutting unit during operation. 
     FIG. 3 illustrates the cutting unit  12  in greater detail in a side view. Specifically, the substantially flat lower surface  30  of the base  24  and the operating mode indicating portion  70  of the knob  60  are illustrated. The lower surface  30  of the base  24  is also configured to place in tension the material to be cut in order to smooth out the material for efficient cutting. The operating mode indicating portion  70  is configured to reflect the operating mode of the blade assembly  22  (see FIG.  2 ). 
     FIG. 4 illustrates the operating mode indicating portion  70  of the knob  60  in even greater detail. The operating mode indicating portion  70  includes a free-form operating range segment  78  and a template cutting operating range segment  80 . When the cutting unit  12  is operating in the free-form range, the upper end  66  of the knob  60  is positioned further away from the housing  26 , thereby exposing the free-form portion  78  of the operating mode indicating portion  70  of the knob  60  above the first opening  38  of the housing  26 . This indicates to the user that the cutting unit  12  is in a free-form operating mode. When in the free-form mode of operation, the upward extension of the knob  60  reduces the pressure applied from the knob  60  to the biasing device  64  by enabling the biasing device  64  to upwardly extend (see FIG.  2 ). The decreased pressure on the biasing device  64  results in a corresponding decrease in the pressure applied from the biasing device  64  to the plunger  62  and to the blade assembly  22 . The reduced pressure exerted onto the blade assembly  22  correspondingly results in less pressure or force exerted by the blade  52  onto the material to be cut. The free-form operating range enables the blade  52  to more easily upwardly and axially deflect during operation. The reduced pressure exerted onto the blade assembly  22  results in more efficient and effective free-form movement and cutting of the blade assembly  22  during free-form operation. 
     When the user desires to operate the cutting unit  12  in the template cutting mode of operation, the user simply re-positions the upper end  66  of the knob  60  closer to the housing  26 , until the free-form operating range segment is disposed within the housing  26  and the template cutting operating range segment  80  is visible above the first opening  38  of the housing  26 . This repositioning of the upper end  66  increases the downward pressure exerted on the biasing device  64  which correspondingly results in an increase in the pressure exerted by the biasing device  64  onto the blade assembly  22 . The increased pressure exerted onto the blade assembly  22  results in an increase in the pressure or force of the blade  52  against the material to be cut. When operating in the template cutting mode of operation, the blade assembly  22  deflects upward  14  less easily than when in the free-form operating mode. The increased downward pressure applied to the blade assembly  22  during the template cutting mode of operation enables the collar  54  of the blade assembly  22  to effectively contact and operate with the edges of a template while maintaining an effective cutting force on the material to be cut. The blade assembly  22  retains the ability to swivel during operation in either the free-form or the template cutting operating modes. The pressure with which the blade  52  presses against the material to be cut is determined by the position of the upper end  66  of the knob  60  with respect to the housing  26 . Rotating or screwing the knob  60  down, gradually increases the pressure on the blade  52  and subsequently allows a thicker medium to be cut. 
     Referring to FIG. 5, the template  14  and the cutting mat  15  are illustrated in greater detail. The template  14  is a substantially flat sheet having first and second sides  84  and  86  (see FIGS.  5  and  6 ), a periphery  88  and at least one opening  90  extending from the first side  84  to the second side  86 . The second side  86  of the template  14  is configured for placement upon the material to be cut. The first side  84  of the template  14  is configured to contact the cutting unit  12 . The template  14  is also configured to facilitate the cutting of shapes or the rendering of marks upon a material. The template  14  is made of a lightweight and durable material. Preferably, the template  14  is made of a flexible and semi-transparent tinted material. In a particularly preferred embodiment, the template  14  is made of a thermoplastic material including an edge glow substance. The edge glow substance disposal of the semi-transparent material of the template  14  is configured to redirect light passing through the template  14  to the periphery, or to the edge of the at least one opening, of the template  14 . The edge glow substance is a colorant, such as the colorant supplied by Clariant International, Ltd. The edge glow substance disposed within the material of the template  14  provides the periphery  88  and the edge of the openings  90  within the template  14  with a glowing appearance. The glowing appearance of the template  14  facilitates the placement of the cutting unit  12  onto the template  14 , enhances the user&#39;s ability to view the overall template positioning, and provides the template  14  with an aesthetically appealing appearance. 
     The edges of the periphery  88  of the template  14  can be formed into a variety of different shapes such as illustrated in FIG.  5 . The openings  90  each describe a complete shape, thereby eliminating the need for secondary cutting or operation. The openings  90  can also be formed in a variety of different shapes or families of shapes such as, for example, hearts, stars, geometric shapes and alphanumeric shapes. In a preferred embodiment, as shown in FIG. 1, the template  14  can include alphanumeric indicia  92  positioned at each opening  90  indicating of the size and/or the shape of each opening  90 . For example, the indicia  92  could include “3.50″×2.50″ OVAL″ or 3.0″ HEART”. Alternatively, the indicia could be a numerical value next to an opening indicating the size of the opening  90 . 
     Referring again to FIG. 5, the template  14  further includes gridlines  94  formed into the first surface of the template  14 . The gridlines  94  facilitate the alignment of the template  14  onto the material to be cut. The template  14  can also include binder ring openings  96  for receiving a ring of a binder (not shown). Alternatively, the openings  96  can be used in conjunction with a clamping system or for template orientation. 
     The mat  15  is a sheet configured for placement underneath the material to be cut. The mat is configured to support the material to be cut without impeding the operation of the cutting device and to protect the surface upon which the mat  15  and the material to be cut rests. In a preferred embodiment, the mat  15  is made of a material having short or tight nap. The mat  15  is preferably made of a firm, flexible and inexpensive materials, and preferably the mat  15  is made of a thermoplastic material. 
     Referring to FIGS. 6 and 7, the template  14  is illustrated in further detail. The template  14  is preferably formed with a chamfer  98  at the periphery  88  and at the edges of the openings  90  within the template  14 . The chamfer  98  is defined within the template  14  such that the first surface  84 , which contacts the cutting unit  12 , laterally and outwardly extends to a greater extent than the second surface which contacts the material to be cut. The chamfer  98  facilitates the operation of the template  14  with the cutting unit  12  by enabling the collar  56  of the blade assembly  22  to operatively engage the edge or periphery of the template  14  during operation. The chamfer  98  reduces the surface area in contact with the collar  56  of the blade assembly  22  of the cutting unit  12 , thereby reducing the susceptibility of the blade assembly  22  (see FIG. 2) to bind during operation. The chamfer  98  also enables the user to more easily reposition or move the cutting unit  12 , along the edge of one of the openings  90  (see FIG. 5) or the periphery  88  of the template  14 , thereby facilitating the rendering or cutting of shapes onto the material to be cut. The chamfer  98  shown in FIG. 7 thus further prevents the blade  52  of the blade assembly  22  from contacting an edge, or the chamfer  98  of, the template  14  during use, thereby preserving the integrity of the edge, or the chamfer  98  of the template  14 . 
     Additionally, referring to FIG. 5, the corners of the template  14  are configured to enable the cutting unit  12  to continuously and efficiently travel around one or more of the corners during cutting operation. This feature greatly reduces the amount of alignment required by the user when attempting to create a corner having an edge substantially similar to the template periphery  88 . 
     The system described herein can also be used for cutting and forming a variety of types of envelopes and/or packages of various shapes and sizes. FIG. 9 shows an example of an envelope template  100  with an opening  102  formed therein. The opening  102  corresponds to the shape of an envelope, shown as a shape or opening  99  in FIG. 10, before it is folded into a position such that it is capable of receiving materials. As in FIG. 9, the cutting unit  12  cuts the material along an edge  104  of the template  100  to form the unfolded envelope shape. 
     As shown in FIG. 10, a scoring plate  110  is used to make scores or impressions on the unfolded envelope  99  once it has been cut by the cutting unit  12 . In the embodiment shown in FIG. 10, the scoring plate  110  includes an opening  114  with an outer edge  116  which defines the area to be scored when the user desires to create fold lines in the unfolded envelope  99 . The user presses firmly using a stylist or other hardened tool against the outer edge  116  while the unfolded envelope  99  is aligned with the outer envelope edge  119  on the scoring plate  110 . The scoring plate  110  also includes a plurality of bonding slots  118 . The bonding slots  118  comprise additional openings through which the user may place glue or another adhesive directly onto the unfolded envelope  99  which is placed below the scoring plate  110 . 
     After the adhesive has been placed in the bonding slots  118 , the envelope  99  is fully assembled as follows: a first side panel  111  and a second side panel  113  of the envelope  99  are folded inwardly such that they are substantially in contact with a center portion  121 . The user then folds the lower panel  115  such that the adhesive that has been placed on the lower panel  115  comes into direct contact with the first and second side panels  111  and  113 . The adhesive then bonds to the first and second side panels  111  or  113 , forming a pocket in which the material may be placed. The upper panel  117  may then be folded atop the lower panel  115 . 
     A similar template  100  and scoring plate  110  may be used to make an envelope  99  having different shaped panels, as shown in FIGS. 13 and 14. 
     As shown in FIGS. 11 and 12, it is also possible to form another form of envelope  99  resulting in an increased thickness such that thicker materials may be placed inside the envelope  99  once fully formed. As shown in FIG. 12, the scoring plate  110  includes additional fold lines  119  which are to be scored by a user. These additional fold lines  119  result in intermediate panels  120 ,  124 ,  128  and  132 , adding additional thickness to the resulting envelope  99 . In this particular embodiment of the invention, no bonding material is applied to the envelope  99 . Instead, a joining slot  131  is cut into a lower panel  126 . In this embodiment of the invention, the assembly of the envelope  99  is as follows. The first and second side panels  130  and  134  are joined to each other via hooks  137  formed in each of the panels  130  and  134 . The lower panel  126  is then folded, and the upper panel  122  is folded such that it passes into the adjoining slot  131  on the lower panel  126 . 
     As shown in FIGS. 11 and 13, it is also possible to include a variety of other shapes  106  into the individual template  100 . These additional shapes  106  can be used either inside the envelope  99  as embossments or used to cut different edges into the unfolded envelope  99 . 
     FIGS. 15 and 16 show yet another embodiment of the invention in which additional intermediate regions  169  are formed adjacent the first and second side panels  162  and  166 . After the first and second side panels  162  and  166  are folded, the lower panel  164  is folded, followed by the upper panel  166 . A tab  161  formed within the upper panel  166  is then fed between a pair of tabs  165  forming the lower panel, securing the envelope  99 . 
     FIGS. 17,  18 A and  18 B show still another embodiment of the invention in which a multi-sided box  179  is formed. After the individual fold lines  116  are embossed using the scoring plate  110 , a plurality of center portions  180  are formed and is surrounded by first through sixth tabs  190 ,  192 ,  177 ,  194 ,  196  and  198  on one side and seventh through twelfth tabs  191 ,  193 ,  195 ,  197 ,  199  and  201  on the other side. After glue or another adhesive is placed within the bonding slot  118 , the unfolded box is folded such that an end tab  182  is folded onto the adhesive that was placed through the bonding slot  118 , forming a tube. On one side of the center panels  180 , the first tab  190  is folded over the tube, and the second and third tabs  192  and  177  are folded on top of the first tab  190 . The fourth tab  194  is folded over the third tab  177  and hooked under the tip of the first tab  190 . The fifth and sixth tabs  196  and  198  are also consecutively folded and hooked under the tip of the first tab  190 . This procedure is repeated for the seventh through twelfth tabs  191 ,  193 ,  195 ,  197 ,  199  and  201  on the opposite side of the center panels  182 . A perspective view of the box  179  in the partially assembled position is shown in FIG. 18 b.    
     As shown in FIG. 17, it is also possible to include a variety of other shapes, such as hexagons  101 , diamonds  103 , hearts  105 , ovals  107  and circles  109 , into the individual template  100 . These additional shapes can be used for a variety of purposes. For example, the hexagon  106  serves as a box inset which can be cut out and used to reinforce the bottom of the box  179  being created. The hexagon  106  is sized to fit snugly with the walls of the box when assembled and can be placed inside the assembled box  179  with or without adhesive. 
     As shown in FIGS. 19 and 20, it is also possible to have a single template  200  include multiple openings that are used for a variety of purposes. For example, a first opening  202  in the template  200  corresponds to a first memory pocket  246 . The first memory pocket is capable of containing a small photograph therein. The unassembled first memory pocket  246  comprises a center portion  233  surrounded by a first tab  230 , a second tab  232 , a third tab  234 , a fourth tab  236 , a fifth tab  238  and a sixth tab  240 . To assemble the first memory pocket  246 , the first tab  230  is folded atop the center portion  233 . The second and third tabs  232  and  234  are then consecutively folded on top of the first tab  230 . The fourth tab  236  is folded over the third tab  234  and hooked under the tip of the first tab  230 . The fifth and sixth tabs are sequentially folded down and also hooked under the first tab  230 . All of these folds occur along the fold lines  216  that are embossed onto the unfolded first memory pocket  246 . First and second star mats  402  and  404  are used to define and set the photograph to be displayed. In particular, the first star mat  402  is used to crop the photograph (not shown), while the second star mat  404  is used to create a backing for the cropped photograph. The cropped photograph is joined to the backing with adhesive or similar joining mechanisms before being placed inside the first in the first memory pocket  246 . These components may be bonded to the inside of the first memory pocket  246  or simply placed inside the first memory pocket without any bonding materials. 
     The second opening  204  in the template  200  allows the user to form a second memory pocket  215 . The unassembled second memory pocket  215  comprises a center portion  223  surrounded by a first tab  220 , a second tab  222 , a third tab  224  and a fourth tab  226 . The second memory pocket  215  is assembled as follows. The first tab  220  is folded on top of the center portion  223 . The second tab  222  is then folded on top of the first tab  220 . The third tab  224  is folded on top of the second tab  222  and hooked under the tip of the first tab  220 . The fourth tab  226  is then folded atop the third tab  224  and hooked under the tip of the first tab  220 . All of these folds occur along the fold lines  216  that are embossed onto the unfolded second memory pocket  215 . First and second square mats  406  and  408  are used to define and set the photograph to be displayed. In particular, the first square mat  406  is used to crop the photograph (not shown), while the second square mat  408  is used to create a backing for the cropped photograph. The cropped photograph is joined to the backing with adhesive or similar joining mechanisms before being placed inside the first in the first memory pocket  246 . These components may be bonded to the inside of the first memory pocket  246  or simply placed inside the first memory pocket without any bonding materials. 
     The envelope cutting system of the present invention may also be used in conjunction with an embossing system as described in U.S. patent application Ser. No. 10/036,843, filed on Dec. 21, 2001 and entitled “Embossing System” and incorporated herein by reference. One such embossing system  310  is generally shown in FIGS. 21A-23. The embossing system  310  includes an upper template  312  and a lower template  314 . As shown in FIG. 21B, a textured plate  316  may be positioned generally below the lower template  314 . The textured plate  316  may include a variety of textured surfaces that may include grooves, ridges, undulations, or other textures. Alternatively, the textured plate  316  may include no texture at all depending upon the user&#39;s specific needs. The upper template  312 , the lower template  314  and the textured plate  316  are al′ removably positioned on top of a base plate  318 . 
     The upper template  312  includes a plurality of upper template shapes  322 . The upper template shapes  322  may vary greatly and could also include, for example, lettering, numbering or other designs. The lower template  314  includes a plurality of lower template shapes  324 . The lower template shapes  324  may also vary but are substantially identical in both shape, size and position to the upper template shapes  322  on the upper template  312 . In other words, the lower template shape  324  at a particular position on the lower template  314  is substantially identical to the upper template shape  322  at the same position on the upper template  312 . 
     In one particular embodiment, the upper template shapes  322 , although identical to the corresponding lower template shapes  324 , are slightly larger than the corresponding lower template shapes  324 . The slight different in sizes between the upper template shapes  322  and the corresponding lower template shapes  324  permit a user to make an improved, more crisp embossment along the edge of the shape to be embossed. In one embodiment, each upper template shape is about 0.050 larger in cross-section than the corresponding lower template shape  324 . 
     The upper template  312 , the lower template  314  and the textured plate  316  are all sized to fit on top of the base plate  318  in a close fitting relationship. As shown in FIG. 21B, the base plate  318 , according to one embodiment, includes a small depression  330  which is sized such that the textured plate  316  and/or the upper template  322  and the lower template  324  fit therein. 
     According to a preferred embodiment, the upper template  312  and the lower template  314  matingly engage the base plate  318 . This engagement is accomplished through the use of removable alignment pegs  320  positioned on the base plate  318  and corresponding upper template holes  332  and lower template holes  334 , along with a plurality of base plate holes  356  located along the base plate  318 . The alignment pegs  320  and the base plate holes  356  are positioned along an outer edge  344  of the base plate  318 . It is also possible to have additional ones of the base plate holes  356  on the sides of the base plate  318  for storage purposes, as shown in FIG.  21 A. 
     For each one of the alignment pegs  320 , there is an upper template hole  332  and a lower template hole  334  located in an identical position on the upper template  312  and the lower template  314 , respectively. The upper template holes  332  and lower template holes  334  are sized to closely fit with the alignment pegs  320  on the base plate  318 . When the upper template holes  332 , the lower template holes  334  and the alignment pegs  20  are in a mating engagement, the upper template  312  and the lower template  314  are impeded from moving relative to the base plate  318 . This feature greatly aids the user in operating the embossing system  310  without the risk of inadvertent movement of the upper template  312  or the lower template  314 . Additionally, this arrangement permits the upper template  312  and the lower template  314  from being completely removed from the base plate  318 . This permits the user to use different types of templates on the same base plate  318 , while also allowing the user to change the textured plate  316  depending upon the particular user needs. 
     According to one embodiment, the individual alignment pegs  320  are removable such that the user is able to use larger pieces of paper or other oversized mediums without bending the medium when a medium  326  is disposed inside the embossing system  310 . This arrangement also permits the user of other templates of varying sizes which may or may not be provided with the embossing system  310 . 
     In one embodiment, the embossing system  310  includes a storage compartment  350  with a lid  352 . The storage compartment  350  and the lid  352  may be used to store a stylus  328 , other marking instruments and/or the alignment pegs  320 . A variety of types of locking mechanisms may be used to secure the lid  352 , enclosing the storage compartment  350 . 
     The overall size of the embossing system  310  may vary depending upon the particular user requirements. In one embodiment, the embossing system  310  will be of a size to correspond to standard 8 ½″ by 11″ paper. Alternatively, the embossing system  310  could be sized to better fit standard greeting cards or other paper items. The embossing system may include a plurality of feet  354  coupled to the underside of the base plate  318 . The feet  354 , which may be formed from rubber or other materials, prevent or impede the base plate  318  from sliding along the surface upon which the embossing system  310  is placed. 
     The upper template  312  and the lower template  314  may be formed from PET or biaxially oriented film or mylar and can be transparent and/or tinted. The upper template  312  may include a preprinted upper template grid  352 , and the lower template  314  may include a preprinted lower template grid  350 . The upper template grid  352  and the lower template grid  350  may be used for properly aligning the medium  326 . The embossing system  310  may also include a self-healing cutting mat (not shown). The thickness of the upper template  312  and the lower template  314  may vary depending upon the particular use. 
     In a preferred embodiment, the lower template  314  has a thickness of about 0.010-0.020 inches and is formed from an opaque, colored plastic material. In a most preferred embodiment, the lower template  314  has a thickness of about 0.010 inches. It has been observed that when the lower template  314  has a thickness of about 0.010 inches, the medium is less likely to be torn during the embossing process than when the lower template  314  has a greater thickness. In a most preferred embodiment, the upper template  312  has a greater thickness than the lower template, and it has been found that there is improved quality in the embossment when the upper template  312  and the lower template  314  have different thicknesses. In a preferred embodiment, the upper template has a thickness of about 0.015-0.020 inches, with a most preferred thickness of about 0.015 inches. Other thicknesses for the upper template  312  and the lower template  314  may be used, and it is also possible for the upper template  312  and the lower template  314  to be of substantially identical thicknesses. 
     The upper template  312  and the lower template  314  may be laser cut, water jet cut, die cut, or punched out of sheet material. In one particular embodiment, the base plate  318  is injection molded. 
     The embossing system  310  includes the stylus  328  or similar marking mechanism for embossing or scoring the medium  326 . A variety of types of marking mechanisms may be used. One exemplary form of marking device includes a ball bearing at one end thereof. One such device is currently marketed under the name EMPRESSOR™ Alternatively, a pencil or other drawing instrument could be used in place of the stylus  328 . The embossing system  310  can be used on a variety of the medium including without limitation paper, card stock, bond paper, thirty pound vellum, metal foil, and other such materials. 
     The operation of the embossing system  310  is generally as follows. When a user desires to emboss a particular material, the user first selects the proper textured plate  316  and locates the selected textured plate  316  within the depression  330  of the base plate  318 . The user selects the particular shape to be embossed on the material, and places the lower template  314  containing that shape atop the base plate  318 , aligning the lower template holes  334  with the alignment pegs  320 . The user then positions the medium  326  on top of the lower template  314  in such a position as to cover the particular shape to be scored. Once the medium  326  is in a proper position, the user locates the upper template  312  on top of the medium  326  and the lower template  314 , aligning the upper template holes  332  with the alignment pegs  320 . The user maneuvers the stylus  328  within the particular upper template shape  322  which is to be embossed on the material  326 . During this process, the user may maneuver the stylus  328  along only the outer edge of the upper template shape  322 , or may maneuver it throughout the region. When the user is done maneuvering or scoring the upper template shapes  322 , the user removes the upper template  312 . The material  326  then includes an embossment corresponding to the upper template shape  322  and the lower template shape  324 . 
     According to an alternate embodiment and as shown in FIG. 22, the upper template  312  and the lower template  314  can be a variety of shapes and may also only include the upper template holes  332  and the lower template holes  334  on an upper template margin  336  and a lower template margin  338 , respectively. Although the positioning of the individual upper template holes  332  and the lower template holes  334  can vary, the upper template holes  332  and the lower template holes  334  still operate to fix the position of the upper template  312  and lower template  314  so long as they mate with the alignment pegs  320  on the base plate  318 . In one embodiment, the upper template holes  332  and the lower template holes  34  are positioned to align with the standard European and/or American binder hole arrangements. 
     In still another embodiment and as shown in FIG. 23, the upper template  312  and the lower template  314  are joined together at a single margin  340  that includes margin alignment holes  342 . The single margin  340  provides the user the added benefit of keeping the upper template  312  and the lower template  314  together at all times, minimizing the risk of at least one of the upper template  312  or the lower template  314  being lost. In this particular, the upper template  312  and the lower template  314  are hingedly or flexedly connected to each other such that the medium  326  can be easily positioned and removed from the embossing system  310 . 
     In yet another embodiment, an integrated clamp (not shown) may be used to further clamp the individual components of the embossing system  310  in place. For example, the integrated clamp can be used as a ruler for measuring and alignment of the medium  326  or other items in the embossing system  310 . The clamp can be spring tensioned to hold the individual components securely in place. 
     The embossing system  310  may also include a storage lid (not shown) sized to fit on top of the upper and the lower templates  312  and  314 , the textured plate  316  and the base plate  318 , mating with the alignment pegs  320  to safely secure all of the components. Additionally, a small light (not shown) may be positioned inside the depression  330 . The light may be used to illuminate the material  326  being embossed, making it easier for the user to identify whether the material  326  has been embossed and, if so, the degree of embossment. 
     While the preferred embodiments of the present invention have been described and illustrated, numerous departures therefrom can be contemplated by persons skilled in the art, for example, the cutting unit  12  can include alternative blade adjustment assembly designs comprising a gear assembly or a remotely operated assembly. Additionally, the cutting unit can be configured to reciprocate or continuously rotate about the axis. A variety of envelopes and packages of different shapes could formed, and the types of structures used for joining portions of the envelopes and packages to each other could comprise a variety of types of adhesives, slots, hooks, and other mechanisms known to those in the art. Therefore, the present invention is not limited to the foregoing description but only by the scope and spirit of the appended claims.