Abstract:
The present disclosure relates to safety blades for use in utility knives, related assemblies and methods of manufacturing. More specifically, the present disclosure relates to safety blades for use in utility knives, related assemblies and methods of manufacture which limit user exposure to associated cutting edges.

Description:
FIELD OF THE INVENTION 
       [0001]    The present disclosure relates to safety blades for use in utility knives, related assemblies and methods of manufacturing. More specifically, the present disclosure relates to safety blades for use in utility knives, related assemblies and methods of manufacture which limit user exposure to associated cutting edges. 
       BACKGROUND 
       [0002]    Utility knives are used for a host of purposes, such as opening cardboard boxes, cutting sheet material, cutting web material, opening packages, etc. Injuries to the users of utility knifes are all too common due to inadvertent contact with cutting edges of associated blades. Injuries may be particularly severe when a given utility knife includes a standard razor blade. Even standard, single edge, razor blades are dangerous. 
         [0003]    Inadvertent contact with cutting edges of blades can be equally common during blade removal, insertion and handling. Inadvertent contact with the cutting edges is particularly problematic when a user is removing or inserting a double edge razor blade, or a single edge razor blade without a gripping tab, into an associated utility knife. 
         [0004]    Blades for use in utility knives, and utility knives which limit user exposure to the associated cutting edges, are desirable. Methods of manufacturing related blades and utility knives are also desirable. 
       SUMMARY 
       [0005]    A safety utility knife assembly may include a handle having a blade retainer receptacle and a blade retainer having a blade release mechanism and a blade catch, wherein the blade retainer includes a first half and a second half. The safety utility knife assembly further includes a replaceable safety blade having a blade tab and a blade securing aperture. A cutting edge of the replaceable safety blade extends perpendicular to a longitudinally extending axis of the handle. The replaceable safety blade is secured to the safety utility knife when the blade catch is engaged with the blade securing aperture. The replaceable safety blade is removable from the safety utility knife, when a user presses on the blade release mechanism and the blade catch is disengaged from the blade securing aperture. 
         [0006]    In another embodiment, a method of manufacturing a replaceable safety blade for use within a safety utility knife assembly may include providing a strip of blade material and forming a rough blade shape from the strip of blade material. The rough blade shape may include a blade tab and a blade securing aperture. The method may further include forming a blade cutting edge in the rough blade shape. 
         [0007]    In a further embodiment, a safety utility knife assembly may include a handle and a blade retainer having a blade release mechanism and a blade catch. The safety utility knife may further include a replaceable safety blade having a blade tab and a blade securing aperture. A cutting edge of the replaceable safety blade extends perpendicular to a longitudinally extending axis of the handle. The replaceable safety blade is secured to the safety utility knife when the blade catch is engaged with the blade securing aperture. The replaceable safety blade is removable from the safety utility knife, when a user presses on the blade release mechanism and the blade catch is disengaged from the blade securing aperture. 
         [0008]    The features and advantages described in this summary and the following detailed description are not all-inclusive. Many additional features and advantages will be apparent to one of ordinary skill in the art in view of the drawings, specification, and claims hereof. 
     
    
     
       BRIEF DESCRIPTION OF THE FIGURES 
         [0009]      FIGS. 1 and 2  depict an example safety utility knife assembly; 
           [0010]      FIGS. 3A-3H  depict various views and detail of the safety utility knife assembly of  FIGS. 1 and 2 ; 
           [0011]      FIGS. 4A-4H  depict various views and detail of an example handle for use within the safety utility knife assembly of  FIGS. 1 and 2 ; 
           [0012]      FIGS. 5A-5G  depict various views and detail of an example bottom half of a blade retainer for use within the safety utility knife assembly of  FIGS. 1 and 2 ; 
           [0013]      FIGS. 6A-6G  depict various views and detail of an example top half of a blade retainer for use within the safety utility knife assembly of  FIGS. 1 and 2 ; 
           [0014]      FIGS. 7A and 7B  depict various views and detail of an example safety blade for use within the safety utility knife assembly of  FIGS. 1 and 2 ; and 
           [0015]      FIGS. 7C-7H  depict example manufacturing methods for fabrication of the safety blade of  FIGS. 7A and 7B . 
       
    
    
     DETAILED DESCRIPTION 
       [0016]    The safety utility blades and safety utility knife assemblies of the present disclosure may incorporate various features that limit user exposure to associated cutting edges. The manufacturing methods of the present disclosure may be used to produce the disclosed safety utility blades and safety utility knife assemblies. 
         [0017]    With initial reference to  FIG. 1 , a safety utility knife assembly  100  may include a replaceable safety blade  125 . As described in detail herein, the replaceable safety blade  125  may be inserted into a blade retainer  112  which, in turn, may be inserted into a blade retainer receptacle  112  of an associated handle  105 . The safety utility knife  100  may include a blade release button  118 . The replaceable safety blade  125  may include a blade tab  128 . A user may remove the replaceable safety blade  125  from the safety utility knife assembly  100  by, for example, grasping the blade tab  128 , pressing the button  118 , and pulling the replaceable safety blade  125  from the blade retainer  115 . 
         [0018]    The handle  105  may include a first half  106  secured to a second half  107  forming, for example, the blade retainer receptacle  112  in one end for receiving a blade retainer  115 . The handle  105  may include an aperture  108  for hanging the safety utility knife assembly  100  on, for example, a peg or hanger of some sort. Alternatively, or additionally, the safety utility knife assembly  100  may be secured to a clip of, for example, a lanyard, a strap, a key chain, etc. (not shown). The handle  105  may include blade retainer receptacles  110 ,  111  configured to receive, for example, blade retainer snaps  121 ,  122 , respectively. The blade retainer  115  may include a first half  116  and a second half  117 . The first half  116  of the blade retainer  115  may include a first blade end offset  119 , a second blade end offset  120 , a first wedge  131 , and a second wedge  136 . The first wedge  131  and the second wedge  135  may be configured to, for example, prevent, or minimize, material buildup. The safety utility blade  125  may include a first cutting edge  126  and a second cutting edge  127 . Alternatively, the first and second cutting edges  126 ,  127  of a safety utility blade  125  may define a single, continuous, cutting edge. Further details of the handle  105 , the blade retainer  115 , and the replaceable safety blade  125  are described throughout this disclosure. 
         [0019]    Advantageously, when either of the first or second cutting edge  126 ,  127  becomes dull, or worn, a user may simply flip the safety utility knife assembly  100  over and use the other cutting edge  126 ,  127 . When both the first cutting edge  126  and the second cutting edge  127  are dull, or worn, a user may simply replace the replaceable safety blade  125  while reusing other components (e.g., handle  105  and safety utility blade retainer  115 ) of the safety utility knife assembly  100 . 
         [0020]    Turning to  FIG. 2 , a safety utility knife assembly  200  may include a first blade throat  230  defined by a first blade retainer tip  219  and a proximate portion of a blade handle  205 . The safety utility knife assembly  200  may be similar to, for example, the safety utility knife  100  of  FIG. 1 . In any event, the safety utility knife assembly  200  may include a second blade throat  235  defined by a second blade retainer tip  220  and a proximate portion of a blade handle  205 . The first blade throat  230  may be configured to, for example, limit access of a finger  241  of a hand  240  of a user to a first cutting edge  226  of an associated blade  225 . Similarly, the second blade throat  235  may be configured to limit exposure to a second cutting edge  227 . 
         [0021]    The safety utility knife assembly  200  may include a blade release button  218 . The replaceable safety blade  25  may include a blade tab  228 . A user may remove the replaceable safety blade  225  from the safety utility knife assembly  200  by, for example, grasping the blade tab  228 , pressing the button  218 , and pulling the replaceable safety blade  225  from the blade handle  205 . The handle  205  may include a first half  206  secured to a second half  207  for receiving a replaceable safety blade  225 . The handle  205  may include an aperture  208  for hanging the safety utility knife assembly  200  on, for example, a peg or hanger of some sort. Alternatively, or additionally, the safety utility knife assembly  200  may be secured to a clip of, for example, a lanyard, a strap, a keychain, etc. (not shown). The handle  205  may include blade retainer receptacles  210 ,  211  configured to receive, for example, blade retainer snaps  221 ,  222 , respectively. Further details of the handle  205  and the replaceable safety blade  225  are described throughout this disclosure. 
         [0022]    With reference to  FIGS. 3A-3H , a safety utility knife assembly  300   a - h , may include a replaceable safety blade  325   a - e ,  325   g,    325   h  retained by a handle  305   a - c . The safety utility knife assembly  300   a - h  may be similar to, for example, either the safety utility knife assembly  100  of  FIG. 1  or the safety utility knife assembly  200  of  FIG. 2 . The cross-section view of the safety utility knife  300   b  of  FIG. 3B  is taken along the section-line  3 B- 3 B of  FIG. 3A . The cross-section view of the safety utility knife  300   d  of  FIG. 3D  is taken along the section-line  3 D- 3 D of  FIG. 3A . The cross-section view of the safety utility knife  300   e  of  FIG. 3E  is taken along the section-line  3 E- 3 E of  FIG. 3A . The cross-section view of the safety utility knife  300   f  of  FIG. 3F  is taken along the section-line  3 F- 3 F of  FIG. 3A . The cross-section view of the safety utility knife  300   g  of  FIG. 3G  is taken along the section-line  3 G- 3 G of  FIG. 3A . 
         [0023]    The handle  305   a - c  may include a first half  306   a - h  secured to a second half  307   a - h , a first aperture  308   a,    308   b,  a second aperture  309   a,    309   b,    309   h,  a third aperture  311   h,  and a fourth aperture  311   h.  The safety utility knife assembly  300   a - h  may include a first blade retainer half  316   a - h  having a first wedge  331   h  and a second wedge  336   h,  and a second blade retainer half  317   a - h  having a blade release button  318   a,    318   b,  a blade retention catch  323   g,    323   h,  a first blade retainer pin  321   f,    321   h,  and a second blade retainer pin  322   f,    322   h.  The replaceable safety blade  325   a - e ,  325   g,    325   h  may include a blade tab  328   a - c ,  328   h  and a blade retention aperture  329   g ,  329   h.  The replaceable safety blade  325   a - e ,  325   g,    325   h  may be retained within the safety utility knife assembly  300   a - h  when the blade retention catch  323   g,    323   h  is received within the blade retention aperture  329   g,    329   h.  The safety utility knife assembly  300   a - h  may include a first blade throat  330   h  configured to, for example, limit access to a first cutting edge  326   h.  Similarly, the safety utility knife assembly  300   a - h  may include a second blade throat  335   h  configured to limit exposure to a second cutting edge  327   h.    
         [0024]    Turning to  FIGS. 4A-4H , a handle  400   a - h  for use within a safety utility knife assembly (e.g., safety utility knife assembly  100  of  FIG. 1 , safety utility knife assembly  200  of  FIG. 2 , or safety utility knife assembly  300   a - h  of  FIGS. 3A-3H ) may include a first half  406   e - h  and a second half  407   a - d . The first half  406   e - h  may be similar to, for example, the first half  106  of  FIG. 1  or the first half  206  of  FIG. 2 . The second half  407   a - d  may be similar to, for example the second half  107  of  FIG. 1  or the second half  207  of  FIG. 2 . The cross-section view of the first half  406   h  of  FIG. 4H  is taken along the section-line  4 H- 4 H of  FIG. 4E . The cross-section view of the first half  406   g  of  FIG. 4G  is taken along the section-line  4 G- 4 G of  FIG. 4E . The cross-section view of the second half  407   c  of  FIG. 4C  is taken along the section-line  4 C- 4 C of  FIG. 4A . The cross-section view of the second half  407   e  of  FIG. 4E  is taken along the section-line  4 E- 4 E of  FIG. 4A . The first half  406   e - h  may include a first aperture  408   e,    408   h,  a second aperture  409   e,  a third aperture  411   e,    411   g,  and a fourth aperture  412   e,    412   h.  The second half  407   a - d  may include a first aperture  408   a,    408   g,  a second aperture  411   a,    411   c,  and a third aperture  412   a,    412   c.    
         [0025]    With reference to  FIGS. 5A-5G , first half  500   a - g  of a blade retainer (e.g., blade retainer  115  of  FIG. 1 ) for use within the safety utility knife (e.g., safety utility knife assembly  100  of  FIG. 1 , safety utility knife assembly  200  of  FIG. 2 , or safety utility knife assembly  300   a - h  of  FIGS. 3A-3H ). The first half  500   a - g  may be similar to, for example, the first half  116  of  FIG. 1 , the first half  216  of  FIG. 2 , or the first half  316   a - h  of  FIGS. 3A-3H . The cross-section view of the first half  500   g  of  FIG. 5G  is taken along the section-line  5 G- 5 G of  FIG. 5B . The cross-section view of the first half  500   c  of  FIG. 5C  is taken along the section-line  5 C- 5 C of  FIG. 5D . 
         [0026]    The first half  500   a - g  may include a first blade throat  530   a,    530   b,    530   e  configured to, for example, limit access to a first cutting edge (e.g., first cutting edge  126  of  FIG. 1 , first cutting edge  226 , or first cutting edge  326   h  of  FIG. 3H ). Similarly, the first half  500   a - g  may include a second blade throat  535   a,    535   b,    535   e  configured to, for example, limit access to a second cutting edge (e.g., first cutting edge  127  of  FIG. 1 , second cutting edge  226 , or second cutting edge  326   h  of  FIG. 3H ). The first half  500   a - g  may include a blade release button  518   a - f  and a blade retention catch  523   a - f  pivotally attached via a flex  543   a - b ,  543   d.  The first half  500   a - g  may include a first spacer/retainer  540   a - f , a second spacer/retainer  541   a - e , and a third spacer/retainer  542   a - d ,  542   f.  The first spacer/retainer  540   a - f , the second spacer/retainer  541   a - e , and the third spacer/retainer  542   a - d ,  542   f  may be configured to secure the first half  500   a - g  within an associated safety utility knife assembly (e.g., safety utility knife assembly  100  of  FIG. 1 , safety utility knife assembly  200  of  FIG. 2 , or safety utility knife assembly  300   a - h  of  FIGS. 3A-3H ). 
         [0027]    The first half  500   a - g may include a first wedge  532   b,    532   g  and a second wedge  537   b . As illustrated in  FIG. 5G , the first wedge  532   h,    532   g  may define a ten degree angle with respect to a surface  516   f  of the first half  500   a - g . More generally, the first wedge  532   h,    532   g  may define between a five and fifteen degree angle with respect to a surface  516   f  of the first half  500   a - g . The second wedge  537   b  may be, for example, similar to the first wedge  532   b,    532   g.    
         [0028]    As illustrated by the dashed line in  FIG. 5A , the first half  500   a - g , may include a finger/thumb blade access  524   a  configured to allow use of a safety blade (not shown in  FIGS. 5A-5G ), that, for example, does not include a blade tab (e.g., blade tab  128  of  FIG. 1 ). In such an embodiment, a user may remove an associated replaceable safety blade by grasping a portion of the replaceable safety blade within the finger/thumb blade access  524   a.  Thus, an associated safety utility knife assembly (e.g., safety utility knife assembly  100  of  FIG. 1 , safety utility knife assembly  200  of  FIG. 2 , or safety utility knife assembly  300   a - h  of  FIGS. 3A-3H ) may include any readily available replaceable blade having a blade securing hole (e.g., blade securing hole  746   c   3  of  FIG. 7C ). 
         [0029]    Turning to  FIGS. 6A-6G , a second half  600   a - g  of a blade retainer (e.g., blade retainer  115  of  FIG. 1 ) for use within the safety utility knife (e.g., safety utility knife assembly  100  of  FIG. 1 , safety utility knife assembly  200  of  FIG. 2 , or safety utility knife assembly  300   a - h  of  FIGS. 3A-3H ). The second half  600   a - g  may include a body  617   a - g , a first blade throat  630   a,    630   c,  and a second blade throat  635   a,    635   c.  The second half  600   a - g  may include dimensions as shown in  FIG. 6B , however, any the second half  600   a - g  may include any other suitable dimensions as long as an associated first half and an associated safety blade are provided with corresponding dimensions. 
         [0030]    The second half  600   a - g  may include a first wedge  633   a - b ,  633   e,    633   g  and a second wedge  638   a - b . As illustrated in  FIG. 6G , the first wedge  633   a - b ,  633   e,    633   g  may define a ten degree angle with respect to a body  617   g  of the first half  600   a - g . More generally, the first wedge  633   a - b ,  633   e,    633   g  may define between a five and fifteen degree angle with respect to a surface  617   g  of the first half  600   a - g . The second wedge  638   a - b  may be, for example, similar to the first wedge  633   a - b ,  633   e,    633   g.    
         [0031]    As illustrated by the dashed line  624   a  in  FIG. 6A , the second half  600   a - g , may include a finger/thumb blade access  624   a  configured to allow use of a safety blade (not shown in  FIGS. 6A-6G ), that, for example, does not include a blade tab (e.g., blade tab  128  of  FIG. 1 ). In such an embodiment, a user may remove an associated replaceable safety blade by grasping a portion of the replaceable safety blade within the finger/thumb blade access  624   a.  Thus, an associated safety utility knife assembly (e.g., safety utility knife assembly  100  of  FIG. 1 , safety utility knife assembly  200  of  FIG. 2 , or safety utility knife assembly  300   a - h  of  FIGS. 3A-3H ) may include any readily available replaceable blade having a blade securing hole (e.g., blade securing hole  746   c   3  of  FIG. 7C ). 
         [0032]    With reference to  FIGS. 7A and 7B , a safety blade  700   a,    700   b  for use within the safety utility knife (e.g., safety utility knife assembly  100  of  FIG. 1 , safety utility knife assembly  200  of  FIG. 2 , or safety utility knife assembly  300   a - h  of  FIGS. 3A-3H ) may include a first cutting edge  726   a,  a second cutting edge  727   a,    727   b,  and a blade tab  728   a,    728   b.  The first cutting edge  726   a  and the second cutting edge  727   a,    727   b  may define a single, continuous cutting edge. The safety blade  700   a,    700   b  may be similar to, for example, the safety blade  125 ,  225  of  FIGS. 1 and 2 , respectively. In lieu of the safety blade  700   a,    700   b,  a blade in accordance with any of the blades described and mentioned in commonly assigned U.S. patent application Ser. No.: 13/866,074, along with an associated blade retainer, may be used with the handle  400   a - 400   h  and  400   j  of  FIGS. 4A-4H and 4J , respectively. The safety blade  725   a,    725   b  may include dimensions as shown in  FIGS. 7A and 7B  or, alternatively, may include any suitable dimensions provided associated a blade retainer are provided with corresponding dimensions. 
         [0033]    Turning to  FIGS. 7C and 7H , a manufacturing method for fabrication of the replaceable safety blade of  FIGS. 7A and 7B  for use in a safety utility knife assembly (e.g., safety utility knife assembly  100  of  FIG. 1 , safety utility knife assembly  200  of  FIG. 2 , or safety utility knife assembly  300   a - h  of  FIGS. 3A-3H ) may include providing a strip of blade material  700   c  (block  770   g ). A rough blade shape  710   c   1  may be formed by removing material  750   a  (block  775   g ). A blade securing hole  746   c   3  may be formed in the rough blade shape  710   c   1  by any suitable method, such as laser cutting, water jet cutting, machining, drilling, stamp shearing, etc. (block  780   g ). A sharpened portion  740   c   2 ,  740   c   3  may be formed by any suitable method, such as those disclosed in U.S. Pat. Nos. 4,265,055, 5,842,387, 6,860,796 or 8,206,199, for example (block  785   g ). The sharpened portion  740   c   2 ,  740   c   3  may define a shoulder  741   c   2 ,  741   c   3  and a cutting edge  742   c   2 ,  742   c   3 . The blade  710   c   3  may be separated from the strip of blade material  700   c  by removing material  752   c,    753   c  (block  790   g ). A blade end  751   c  may form an angle  713   c  with respect to a linear edge of the strip of blade material  700   c  of approximately 60°. Alternatively, the angle  713   c  may be between approximately 55° and approximately 70°. 
         [0034]    With reference now to  FIGS. 7D-7F and 7H , a method  700   h  of manufacturing a blade  710   a,    710   b  for use in a safety utility knife assembly (e.g., safety utility knife assembly  100  of  FIG. 1 , safety utility knife assembly  200  of  FIG. 2 , or safety utility knife assembly  300   a - h  of  FIGS. 3A-3H ) may include blade blanks  700   d  that may be formed from a strip of blade material  700   c  (block  775   h ). Rough blade shapes  710   d  may be formed from the blade blanks  700   d  (block  780   h ). A blade securing hole  746   f  may be formed in the rough blade shape  700   d  by any suitable method, such as laser cutting, water jet cutting, machining, drilling, stamp shearing, etc. (block  785   h ). A sharpened portion  740   e,    740   f  may be formed on a blade blank  710   e,    710   f  by any suitable method, such as those disclosed in U.S. Pat. Nos. 4,265,055, 5,842,387, 6,860,796 or 8,206,199, for example (block  790   h ). The sharpened portion  740   e,    740   f  may define a shoulder  741   e,    741   f  and a cutting edge  742   e,    742   f.    
         [0035]    A safety utility knife assembly (e.g., safety utility knife assembly  100  of  FIG. 1 , safety utility knife assembly  200  of  FIG. 2 , or safety utility knife assembly  300   a - h  of  FIGS. 3A-3H ) for use in, for example, a food industry may include a handle (e.g., handle  105  of  FIG. 1 ), a replaceable safety blade retainer (e.g., replaceable safety blade retainer  115  of  FIG. 1 ), and a replaceable safety blade (e.g., replaceable safety blade  125  of  FIG. 1 ) that are each made from, for example, metal such that any portion of, or all of, the safety utility knife assembly  100  that is, for example, dropped into a batch of associated food may be detected and/or removed via associated metal detection/removal equipment. 
         [0036]    A safety utility knife assembly (e.g., safety utility knife assembly  100  of  FIG. 1 , safety utility knife assembly  200  of  FIG. 2 , or safety utility knife assembly  300   a - h  of  FIGS. 3A-3H ) may include various features as described, for example, in commonly assigned U.S. patent application Ser. No. 12/620,999, which was filed on Nov. 18, 2009, and U.S. patent application Ser. No. 13/866,074, which was filed on Apr. 19, 2013, the disclosures of which are incorporated in their entireties herein by reference thereto. 
         [0037]    The figures depict preferred embodiments of safety blades for use in utility knife assemblies, utility knife assemblies and methods of manufacturing. One skilled in the art will readily recognize from the corresponding written description that alternative embodiments of the structures and methods illustrated herein may be employed without departing from the principles described. 
         [0038]    Upon reading this disclosure, those of skill in the art will appreciate still additional alternative structural and functional designs for safety blades for use in utility knife assemblies, utility knife assemblies and methods of manufacturing. Thus, while particular embodiments and applications have been illustrated and described, it is to be understood that the disclosed embodiments are not limited to the precise construction and components disclosed herein. Various modifications, changes and variations, which will be apparent to those skilled in the art, may be made in the arrangement, operation and details of the apparatuses and methods disclosed herein without departing from the spirit and scope defined in the appended claims.