Patent Description:
Cutting tools, such as utility knives, have been used in a variety of applications related to manufacturing, packaging, shipping, and construction in order to cut or remove material from an object or workpiece. Cutting tools and knives that incorporate cutting edges often include a means for securing and protecting the cutting edge during storage and transport. Utility knives are typically categorized by the type and method of deploying the blade. These types include fixed blade utility knives, folding utility knives, and retractable utility knives.

Fixed blade utility knives feature blades that are positionally fixed relative to their respective handle. The cutting edge may be fixed in an exposed position relative to the handle. Fixed blade utility knives often include a separate holster, sheath, or operating guard to cover the fixed blade when not in use.

Folding utility knives feature a blade that may be stored at least partially within the handle when the blade is in a closed position and that may be rotated out from a side of the handle into an exposed and open position. These knives often include a lever or mechanism to hold or lock the blade in an open position. When the blade is in the open position, a groove of the handle is typically left exposed (e.g., the groove in which the blade at least partially resides when closed and out of which the blade rotates into the open position). Undesirable material and/or debris may enter into the groove and prevent the knife from properly returning into the closed position. Because the blade typically rotates out of a side of the handle, users are typically unable to fully grip the handle of a folding utility knife during blade deployment or retraction, causing users to loosely or unsafely grip the handle during blade deployment/retraction. This can lead to undesirable outcomes, such as injury.

<CIT> discloses a hand cutter comprising a housing, a blade assembly, an actuator assembly, a gear assembly and a retraction means with the gear assembly connecting the actuator assembly to the blade assembly in such a manner that a movement of said actuator slide is transmitted to said blade assembly via said gear assembly with a gear ratio of said gear assembly such that moving said actuator slide moves said blade assembly by a larger distance. Retractable or out-the-front ("OTF") utility knives are generally considered safer and easier to operate because the blade is deployed and retracted from a front end of the knife handle. Most retractable utility knives are deployed and retracted by means of an actuator that advances and retracts a blade holder holding the blade. However, for conventional retractable utility knives, the actuator or sliding button travel distance is typically equal to the blade travel distance (or greater than the blade travel distance, such as for snap blade utility knives). To cause the actuator to traverse the entire travel distance (especially for large utility blades), users often reposition their grip on the utility blade handle during blade deployment or retraction, which can present dangers to users and/or cause user fatigue. Alternatively, users hold the handle with one hand and use their other hand to cause the actuator to traverse the travel distance, which can disrupt the flow of work for which the utility blade will be utilized. Although some retractable utility knives can be spring loaded to facilitate rapid blade deployment, spring loaded utility knives are not legal in many jurisdictions.

A further example of prior art is given by the patent documentation <CIT>.

Accordingly, there is a need for improved utility knives.

Rather, this background is only provided to illustrate one example technology area where some embodiments described herein may be practiced.

The present disclosure may facilitate improvements over existing utility knives by providing an improved utility knife that uses a pinion gear mechanism to safely deploy the blade. The utility knife advances and rotates a pinion gear against a fixed rack and an opposing moving or sliding rack to permit blade deployment and blade retraction. The pinion gear is mounted to an actuator and rotates about an axis that linearly translates along a housing with the actuator. Advancing the pinion gear while the pinion gear is engaged with the fixed rack causes the pinion gear to rotate as it advances. The pinion gear is further engaged with the opposing moving rack, and the moving rack is advanced by both the travel and rotation of the pinion gear in the same direction as the translational direction of the pinion gear.

Utilizing a pinion gear to facilitate blade deployment and retraction as described herein can facilitate various benefits over existing utility knife deployment mechanisms. For instance, the use of a pinion gear may facilitate an actuator travel distance that is less than a blade travel distance for deployment or retraction. Such functionality can enable users to easily actuate the actuator along its full travel distance using a single digit of their hand while maintaining a full grip on the handle of the utility knife. Enabling users to maintain a full grip on the handle of the utility knife during blade deployment and/or retraction can improve user safety, improve user efficiency, and/or reduce user fatigue and/or strain injury when using the utility knife. Furthermore, pinion gear driven utility knives as presently disclosed may enable rapid blade deployment and/or retraction while avoiding reliance on spring loading or other biasing components, allowing the utility knives of the present disclosure to be used in jurisdictions that prohibit spring loaded knives.

In one embodiment, a utility knife comprises a blade, a blade holder, a housing, a pinion gear, and an actuator. The actuator accessible from an exterior of a handle or housing of the knife and configured to be operated by a thumb or finger(s) of a user. In some instances, the length of actuator may extend across a significant portion of the full length of the housing to permit operation of blade extension and retraction from multiple grip positions (the advantageously large length of the actuator may be enabled by the short actuator travel distance needed to extend/retract the utility blade, as provided by the principles discussed herein).

In one embodiment, the blade holder provides a mount and guide for the blade. The blade holder runs in an internal channel or space formed by the housing. The blade holder includes a sliding rack that is driven by the displacement and rotation of the pinion gear. The blade holder may comprise one or more components that are separate from the blade and that are configured to selectively receive and secure the blade (e.g., enabling various types of blades to be mounted to the blade holder).

In one embodiment, the housing of the knife comprises first and second sidewalls (or first and second scales) and a spacer. The spacer provides a space or channel for the blade, blade holder, and/or pinion gear to function between first and second sidewalls. The spacer includes a fixed rack that induces rotation of the pinion gear as the pinion gear is advanced or retracted by the actuator. The spacer may provide a space or channel to receive the blade holder and allows the blade holder to slide between extended and retracted positions.

In one embodiment, the pinion gear is configured to rotate and linearly translate through a channel of the housing to facilitate deployment of the blade. The pinion gear may contain one or more sets of teeth. The one or more sets of teeth of the pinion gear engage both the fixed and sliding racks. The pinion gear can be coupled to the actuator by a mating post. The pinion gear may be positioned within a clearance space between the first and second sidewalls and may be coupled to the mating post by a fastener.

In an alternative embodiment, the utility knife comprises a blade, a blade holder, a housing, a pinion gear with a stepped configuration (e.g., with multiple sets of teeth and with each set comprising a different diameter), and an actuator. The blade is configured to interact with a desired workpiece and may have one or more knife edges. The blade includes a tang that may feature one or more notches or indentations to engage with the blade holder.

In one embodiment, the blade holder provides a mount for the blade and is configured to engage with the tang of the blade (e.g., by engaging with the notches or indentations of the tang). The blade holder runs in an internal channel formed by the housing. The blade holder includes a sliding rack that is driven by displacement and rotation of the pinion gear. The blade holder features a lever that is configured to selectively engage with and disengage from the tang of the blade to permit replacement of the blade. The lever may feature a biasing element, such as a spring or elastic component, to facilitate joining of the blade tang and blade holder. In one embodiment, the blade holder comprises a magnet configured to bias the blade and/or blade holder into various configurations (e.g., a closed/retracted configuration, an open/deployed configuration, etc.).

In one embodiment, the housing of the knife comprises first and second sidewalls or scales that provide a space or channel for the blade, blade holder, and pinion gear to function between the first and second scales. The first scale includes a fixed rack that induces rotation of the pinion gear as the pinion gear is advanced via the actuator. The first scale includes an elongate opening to facilitate engagement of the actuator and pinion gear. The elongate opening creates a path or track for the actuator to travel between open and closed ends of the knife.

In one embodiment, the pinion gear features a first set of teeth with a first diameter and a second set of teeth with a second diameter. The second diameter is greater than the first diameter. The first set of teeth is configured to engage with the fixed rack, and the second set of teeth is configured to engage with the sliding rack. In one embodiment the pinion gear is located alongside the blade holder (while still permitting both the pinion gear and the blade holder to translate along the length of the utility knife at different rates) to reduce the overall length of the knife housing. The stepped pinion gear configuration allows for a blade travel distance that is greater than or equal to the actuator travel distance (e.g., permitting longer blades with a shorter actuation travel). Additionally, the stepped pinion gear configuration, i.e., the pinion gear having more than one set of teeth, allows the blade to extend at a speed or rate that is greater than the speed or rate of displacement of the actuator. The stepped pinion gear may include one or more intermediate gears that are driven by the pinion gear to further increase the distance and speed of blade travel relative to the distance and speed of actuator travel.

In one embodiment, the utility knife features a non-locking retention system to provide blade retention in extended and retracted blade positions. The utility knife provides a resistance to movement by the actuator until a desired force is reached, thus providing a snap-acting deployment and retraction. In some implementations, the retention system further provides increased safety by allowing automatic retraction of the blade if the blade is unintentionally plunged into an object or surface. The non-locking retention system may include a detent between (i) the blade holder, the blade, and/or the actuator and (ii) a component of the housing. In one embodiment, the detent features are provided by a magnet on the blade holder or blade and corresponding first and second magnets at different positions along the housing (e.g., first and second opposing magnets). The magnets may be positioned such that (i) the magnet of the blade holder is forced toward the first opposing magnet of the housing when the blade holder is translated to a retracted position and (ii) the magnet of the blade holder is forced toward the second opposing magnet of the housing when the blade holder is translated to an extended position. The configuration of magnets can create a bias toward retracted and extended blade configurations. During intentional use, the extended positioning of the blade can be maintained as forces are exerted on the blade (e.g., by using the blade to perform work) by the user gripping the knife handle and maintaining force on the actuator. If an unintentional event occurs while the blade is in the extended configuration, such as dropping of the knife, the user's force on the actuator will no longer be present, and minimum force exerted on the blade (e.g., by the ground, or even a user's shoe) may overcome the attraction between the magnet of the blade holder and the second opposing magnet, thereby causing retraction of the blade and potentially preventing damage that could result from the blade being locked in the extended position during such an event. The magnet configuration may additionally or alternatively facilitate rapid extension and/or retraction of the blade. For example, to extend the blade, a user may apply force to the actuator, which is initially counteracted by the attractive force between the magnet on the blade holder and the first opposing magnet. This causes a buildup of potential energy that is released when the force exerted by the user overcomes the attractive force, which can cause the blade to rapidly advance into the extended configuration, causing a "snap" opening effect. The same is true without loss of generality for facilitating rapid retraction of the blade.

In one embodiment, the utility knife includes a blade with integrated operative features. For example, the actuator may form a significant portion of the housing, such that a portion of the housing is extended or retracted relative to another portion of the housing via engagement with a user's hand. The actuator may extend along a significant length of the housing between an open end (through which the blade extends during extension/retraction) and a closed end. The actuator can be operated by a thumb and/or finger(s) of a user and, as such, may include anatomically appropriate grip formations to allow for multiple grip positions.

In one embodiment, the blade comprises a tang that includes a sliding rack, such that the sliding rack is integrally formed with the blade. Such embodiments may omit a blade holder. The sliding rack is configured to engage with a pinion gear. The housing is formed of a first scale and second scale that form a channel for the blade so that the cutting edge of the blade may be stored. The pinion gear engages with both the sliding rack and a fixed rack via one or more sets of teeth. The pinion gear engages with the actuator through an elongate opening of the first scale and is configured to rotate about a first axis.

In one embodiment, the pinion gear and first axis linearly translate between the open end and closed end of the housing while the pinion gear rotates. The actuator advances the pinion gear while the pinion gear is engaged with the fixed rack, which causes the pinion gear to rotate as it advances. The pinion gear is further engaged with the sliding rack that is advanced by both the travel and rotation of the pinion gear. A first set of teeth of the pinion gear is configured to engage with the fixed rack and a second set of teeth of the pinion gear is configured to engage with the sliding rack. In one embodiment, the first set of teeth and second set of teeth are integrated into the same pinion gear and share the first axis during actuation and operation of the blade. Alternatively, the first set of teeth and second set of teeth may be formed on separate gears that are positioned adjacent to each other to form the pinion gear (thereby sharing the first axis).

In one embodiment, the tang of the utility knife comprises a magnet (e.g., in combination with a fixed rack) that forms a part of a blade retention system (e.g., a non-locking blade retention system). For example, the magnet may interact with first and second opposing magnets associated with the knife housing to bias the blade into an extended or retracted configuration. This can provide various safety benefits (e.g., allowing a small amount of force or contact pressure to cause blade retraction in the case of unintended blade events when the user ceases to maintain a force on the actuator) and/or may facilitate rapid extension and/or retraction of the blade.

These and other aspects of the disclosed utility knife, as well as the methods of operation and functions of the related elements of structure and the combination of parts and economies of manufacture, will become more apparent upon consideration of the following description and the appended claims with reference to the accompanying figures, all of which form a part of this specification.

For purposes of summarizing the disclosed utility knife, certain aspects, advantages and novel features of the utility knife have been described herein. It is to be understood that not necessarily all such advantages may be achieved in accordance with any particular embodiment of the utility knife. Thus, the utility knife may be embodied or carried out in a manner that achieves or optimizes one advantage or group of advantages as taught herein without necessarily achieving other advantages as may be taught or suggested herein.

References will be made to embodiments of the disclosure, examples of which may be illustrated in the accompanying figures. These figures are intended to be illustrative, not limiting. Although the disclosure is generally described in the context of these embodiments, it should be understood that it is not intended to limit the scope of the disclosure to these particular embodiments. Items in the figures are not necessarily drawn to scale.

A better understanding of different embodiments of the disclosure may be had from the following description read with the accompanying drawings in which like reference characters refer to like elements.

While the disclosure is susceptible to various modifications and alternative constructions, certain illustrative embodiments are in the drawings and are described below. It should be understood, however, there is no intention to limit the disclosure to the specific embodiments disclosed.

<FIG> depict an example embodiment of a utility knife <NUM>. The utility knife <NUM> comprises a blade <NUM> that extends and retracts through an open end <NUM> of a housing <NUM>. The knife <NUM> comprises an actuator <NUM> that is located on an external surface <NUM> of the housing <NUM> and configured to extend and retract the blade <NUM>. The blade <NUM> extends through the open end <NUM> of the housing <NUM> as the actuator <NUM> moves toward the open end <NUM> of the housing <NUM>. The blade <NUM> retracts through the open end <NUM> of the housing <NUM> as the actuator <NUM> moves away from the open end <NUM> of the housing <NUM>.

In some embodiments, the actuator <NUM> forms a significant portion of the housing <NUM>, such that actuation of the actuator amounts to actuation of a portion of the housing <NUM> relative to another portion of the housing <NUM> via engagement with a user's hand. In some embodiments, the actuator <NUM> extends across a significant length of the housing <NUM> between the open end <NUM> and a closed end <NUM>. For instance, the actuator <NUM> may have a length that is greater than the travel distance associated with the actuator for facilitating extension and/or retraction of the blade <NUM>. In some implementations, the length of the actuator is between <NUM>% and <NUM>% of the full length of the housing. For example, if the length of the housing is <NUM> (<NUM> inches), the length of the actuator may be between <NUM> (<NUM> inches) and <NUM> (<NUM> inches). In some implementations, the length of the actuator is between <NUM>% and <NUM>% of the full length of the housing. For example, if the length of the housing is <NUM> (<NUM> inches), the length of the actuator may be between <NUM> (<NUM> inches) and <NUM> (<NUM> inches). In some implementations, the actuator has a length that is within a range having endpoints selected from any two of the foregoing ranges of values. The actuator <NUM> is configured to be operated by a thumb or finger(s) of a user and, as such, may include anatomically appropriate grip formations to allow for multiple grip positions.

Referring to <FIG>, the example embodiment of the utility knife <NUM> comprises a blade <NUM> and blade holder <NUM>. The housing <NUM> may be formed of a first sidewall or scale <NUM> and second sidewall or scale <NUM> that form a channel <NUM> for the blade <NUM> and blade holder <NUM>. The blade holder <NUM> may travel longitudinally within the channel <NUM> to facilitate (i) extension of the edge <NUM> of the blade <NUM> through the open end <NUM> and (ii) retraction of the edge <NUM> of the blade into the channel <NUM> (e.g., so that the edge <NUM> of the blade <NUM> may be stored during non-use). The knife <NUM> may feature a tail cap <NUM> that forms a rear portion of the channel <NUM>. The tail cap <NUM> may comprise a pocket clip <NUM>, as demonstrated in <FIG>, which may be arranged on a side of the knife <NUM> that does not include the actuator <NUM> to avoid interfering with blade extension or blade retraction.

The blade holder <NUM> comprises a mount <NUM> for receiving the blade <NUM>. The blade holder <NUM> may comprise various components/features for retaining the blade <NUM> within the blade holder <NUM> and for facilitating selective withdrawal of the blade <NUM> from the blade holder <NUM>. In the example of <FIG>, the blade holder <NUM> includes a lever <NUM> that is configured to engage with a tang <NUM> of the blade <NUM> to facilitate selective retention of the blade <NUM> within the blade holder <NUM> (e.g., by engaging with one or more notches on the tang <NUM> of the blade <NUM>). The lever <NUM> can include or cooperate with a biasing member (e.g., a spring) to engage and disengage with the tang <NUM> of the blade <NUM> to allow for easy replacement of the blade <NUM>. Additional or alternative blade retention components are within the scope of the present disclosure.

In the example of <FIG>, the blade holder <NUM> comprises a sliding rack <NUM> (e.g., formed into a sidewall of the blade holder <NUM>) that is configured to engage with a pinion gear <NUM>. <FIG> illustrates the pinion gear <NUM> as position-able within the housing <NUM> by a fastener <NUM>, which fastens the pinion gear <NUM> to the actuator <NUM> from within the housing <NUM> (other types of securing means may be used). The pinion gear <NUM> may be positioned within a small clearance between the first and second scales <NUM>, <NUM> of the housing <NUM>. The pinion gear <NUM> may engage with the actuator <NUM> through an elongate opening <NUM> of the first scale <NUM> (e.g., via the fastener <NUM>). When arranged within the housing <NUM>, the pinion gear <NUM> may be configured to rotate about a first axis I1, that extends through the center of one or more sets of teeth of the pinion gear.

The pinion gear <NUM> engages with both the sliding rack <NUM> and a fixed rack <NUM> via one or more sets of teeth. For example, the pinion gear <NUM> may include a first set of teeth <NUM> and a second set of teeth <NUM>, where the first set of teeth is configured to engage with the fixed rack <NUM> and the second set of teeth is configured to engage with the sliding rack <NUM> (see <FIG>).

<FIG> illustrates the pinion gear <NUM> as located adjacent to the blade holder <NUM>, allowing the pinion gear <NUM> to engage with the sliding rack <NUM> of the blade holder <NUM> from a side of the blade holder <NUM>. The adjacent arrangement of the pinion gear <NUM> and the blade holder <NUM> may reduce the overall length of the knife <NUM> between the open end <NUM> and closed end <NUM>.

<FIG> depicts a sidewall or scale <NUM> of the housing <NUM> in relation to the pinion gear <NUM> and actuator <NUM> (with various other features of the knife <NUM> not shown for clarity). <FIG> shows the pinion gear <NUM> configured to engage with a mating post <NUM> (e.g., via the fastener <NUM>) of the actuator <NUM> along the first axis I1. When the actuator <NUM> is linearly translated (e.g., responsive to forces applied by a user's hand), the pinion gear <NUM> linearly translates along with the actuator while rotating about the first axis I1 via the interaction between teeth of the pinion gear <NUM> and the fixed rack <NUM> of the housing <NUM> (e.g., of sidewall or scale <NUM>). The pinion gear <NUM> and first axis I1 can thus linearly translate (while rotating) between the open end <NUM> and closed end <NUM> of the housing <NUM>. Stated differently, the actuator <NUM> advances the pinion gear <NUM> while engaged with the fixed rack <NUM>, which causes the pinion gear <NUM> to rotate as it advances or retracts. When the pinion gear <NUM> is further engaged with the sliding rack <NUM> (see, e.g., <FIG>), the sliding rack <NUM> is advanced or retracted (along with the blade holder <NUM> and the blade <NUM>) by both the linear translation and rotation of the pinion gear <NUM>. Such functionality may enable the blade holder <NUM> and the blade <NUM> to translate a greater linear distance than the linear distance traversed by the actuator <NUM> (and pinion gear <NUM>). Such functionality may additionally enable the blade holder <NUM> and the blade <NUM> to linearly translate at a greater rate than a linear translation rate associated with the actuator <NUM> (and pinion gear <NUM>).

<FIG> illustrates that the actuator <NUM> may also comprise a second post <NUM> configured to extend into a portion (e.g., a narrowed portion) of the elongate opening <NUM> of the housing <NUM>. The engagement between the second post <NUM> and the elongate opening <NUM> may prevent rotation of the actuator <NUM>.

<FIG> provides a detailed view of a stepped pinion gear <NUM> engaged with the fixed rack <NUM> of the housing <NUM> and the sliding rack <NUM> of the blade holder <NUM>. In the example of <FIG>, the pinion gear <NUM> comprises a first set of teeth <NUM> and a second set of teeth <NUM>. The first set of teeth <NUM> is configured to engage with the fixed rack <NUM>, and the second set of teeth <NUM> is configured to engage with the sliding rack <NUM>. The stepped pinion gear <NUM> has a first diameter D1 associated with the first set of the teeth <NUM> and a second diameter D2 associated with the second set of teeth <NUM>. The second diameter D2 of the second set of teeth <NUM> is greater than the first diameter D1 of the first set of teeth <NUM>. In one embodiment, the first set of teeth <NUM> and second set of teeth <NUM> are integrated into the same pinion gear <NUM> and share the first axis I1 during actuation and operation of the blade <NUM>. Alternatively, the first set of teeth <NUM> and second set of teeth <NUM> may be formed on separate gears and be positioned adjacent to each other to form the pinion gear <NUM> (e.g., still sharing the first axis I1).

<FIG> depicts detailed operation of the pinion gear <NUM> with a first set of teeth <NUM> and a second set of teeth <NUM>. The difference between the first diameter D1 and second diameter D2 can contribute to an increased distance traveled by the blade <NUM> (e.g., relative to the distance traveled by the pinion gear <NUM> and/or actuator <NUM> to facilitate movement of the blade <NUM>). As the pinion gear <NUM> is displaced by a first distance X1, the actuator <NUM> is displaced by the same first distance X1. The first set of teeth <NUM> of the pinion gear <NUM> is rotated by engagement with the fixed rack <NUM> and has an arc length of rotation that is equal to the first distance X1. The second set of teeth <NUM> of the pinion gear <NUM> is rotated (during translation) by an arc length that is greater than the first distance X1 (e.g., in view of the difference in diameter between the first set of teeth <NUM> and the second set of teeth <NUM>). The sliding rack <NUM> is simultaneously displaced in the same direction as the actuator <NUM> and the pinion gear <NUM> via the interaction of the second set of teeth <NUM> and the sliding rack <NUM>, either toward the open end <NUM> or toward the closed end <NUM>. The sliding rack <NUM> is advanced by the second distance X2 that is greater than the first distance X1.

In an example embodiment, the first set of teeth <NUM> of the pinion gear <NUM> has a first diameter D1 equal to <NUM> (<NUM> inches) and the second set of teeth <NUM> of the pinion gear <NUM> has a second diameter D2 equal to <NUM> (<NUM> inches). The difference in diameters D1 and D2 results in an increase ratio of blade travel distance X2 (or second distance X2) to actuator travel distance X1 (or first distance X1) that is greater than <NUM>:<NUM>, i.e., <NUM>. Other diameters of first and second sets of teeth <NUM>, <NUM> may be used on the stepped pinion gear <NUM> to reduce or increase the desired travel ratio. In an alternative embodiment, a stepped pinion gear <NUM> may have a first set of teeth <NUM> with a first diameter D1 equal to <NUM> (<NUM> inches) and a second set of teeth <NUM> with a second diameter D2 equal to <NUM> (<NUM> inches) for an overall ratio of blade travel distance of X2 to actuator travel distance X1 equal to <NUM>:<NUM>. The knife <NUM> may include one or more additional or intermediate gears that are driven by the pinion gear <NUM> to further increase the blade travel distance X2 (e.g., relative to actuation distance of the actuator <NUM>). One or more of the sets of teeth <NUM>, <NUM> could be replaced by a lever or levers. At least one of or both sliding rack <NUM> and fixed rack <NUM> may comprise segments of a diametral gear that provides a curved path of actuation or curved path of deployment as desired. In these cases, the associated path or channel <NUM> for the actuator <NUM> or housing <NUM> may be curved also.

<FIG> illustrate side views of the knife <NUM>, with certain internal features of the knife shown in dashed lines for clarity. As shown in <FIG>, the knife <NUM> comprises a retention system that includes magnets <NUM>, <NUM>, <NUM> as detent features. <FIG> shows the knife <NUM> in the extended position, whereas <FIG> shows the knife <NUM> in the retracted position (<FIG> shows the blade travel distance X2 that the blade <NUM> and blade holder <NUM> may traverse between the extended position of <FIG> and the retracted position of <FIG>).

The blade holder <NUM> comprises a magnet <NUM>, and the housing <NUM> of the knife <NUM> comprises a first opposing magnet <NUM> that is positioned toward (or proximate to) the closed end <NUM> of the housing <NUM> and a second opposing magnet <NUM> that is positioned toward (or proximate to) the open end <NUM> of the housing <NUM>. The first opposing magnet <NUM> is configured to interact with the magnet <NUM> to create a bias toward a retracted position (without rigidly locking the knife in the retracted position), as indicated in <FIG> by the arrow extending from magnet <NUM> toward magnet <NUM>. The second opposing magnet <NUM> is configured to interact with the magnet <NUM> to create a bias toward an extended position (without rigidly locking the knife in the extended position), as indicated in <FIG> by the arrow extending from magnet <NUM> toward magnet <NUM>. The detent (magnet) features provide a non-locking blade extension and retraction system.

To operate the knife <NUM>, a user applies force to the actuator <NUM>. The force is stored in the user's finger and then rapidly released when the force applied by the user exceeds the attractive forces of the magnets <NUM> and <NUM> (or the attractive forces of the magnets <NUM> and <NUM>). This allows the blade <NUM> to snap open or closed in a rapid manner.

During intentional use with the blade <NUM> in the extended position (where reactionary forces are exerted on the blade <NUM> through use of the blade <NUM>), the user can maintain the extended positioning of the blade <NUM> by exerting or maintaining force on the actuator <NUM>. When no force is maintained on the actuator <NUM>, the blade <NUM> is able to advantageously (and safely) retract through the open end <NUM> in response minimal contact pressure to the blade <NUM> and/or edge <NUM> thereof. The blade <NUM> is configured to be replaceable and may be removed from the blade holder <NUM> via lever <NUM>.

In some implementations, for magnetizable blades, the magnet <NUM> of the blade holder <NUM> can advantageously provide the additional functionality of further securing the blade <NUM> to the blade holder <NUM> to reduce free play (or undesired rattling or other movement) of the blade <NUM> while the blade <NUM> is secured to the blade holder <NUM>.

Although the example of <FIG> focuses, in at least some respects, on utilizing oppositely polarized magnets on the blade holder and the housing, other types of detents may be used. For example, a combination of one or more magnets and one or more magnetizable components may be utilized, such as a magnet on the blade holder (or blade itself) in combination with ferromagnetic inserts on the housing (with other portions of the housing being substantially non-magnetizable). An opposite arrangement may be utilized in accordance with the present disclosure (e.g., magnets on the housing and a ferromagnetic insert on the blade holder or blade). Furthermore, one will appreciate, in view of the present disclosure, that other types of detent features in addition to or as an alternative to magnets may be utilized. For example, detent features may additionally or alternatively include one or more spring biasing features configured to engage with opposing detent feature(s) such as a ball detent.

Furthermore, although the present disclosure focuses, in at least some respects, on implementing non-locking retention systems with detent features, locking retention systems may be implemented in accordance with the principles described herein. For example, detent features may comprise one or more locking features to secure the blade in the extended or retracted position. Such locking features may become automatically locked (e.g., operating automatically when the blade is moved into the extended or retracted position) and/or manually actuated (e.g., to facilitate unlocking) by a user via a lock actuator.

<FIG> depicts an example utility knife <NUM> that features a blade <NUM> with at least some integrated operative features. The utility knife <NUM> comprises a housing <NUM> and a blade <NUM> featuring an edge <NUM>. The knife <NUM> comprises an actuator <NUM> that is externally located on the housing <NUM> and configured to cause extension and retraction of the blade <NUM>. The blade <NUM> extends through the open end <NUM> of the housing <NUM> as the actuator <NUM> moves toward the open end <NUM> of the housing <NUM>. The blade <NUM> retracts through the open end <NUM> of the housing <NUM> as the actuator <NUM> moves toward the closed end <NUM> of the housing <NUM>. In some embodiments, the actuator <NUM> extends a significant length of the housing <NUM> between the open end <NUM> and a closed end <NUM>. The actuator <NUM> is configured to be operated by a thumb or finger(s) of a user and, as such, may include anatomically appropriate grip formations to allow for multiple grip positions.

Referring to <FIG>, the example embodiment of the utility knife <NUM> comprises a blade <NUM> and a housing <NUM>. The housing <NUM> may be formed of a first scale <NUM> and second scale <NUM> (held together by fasteners <NUM>) that form a channel <NUM> for the blade <NUM> so that the cutting edge <NUM> of the blade <NUM> may be stored. The blade <NUM> comprises a tang <NUM> and a sliding rack <NUM> (integrally formed with the tang <NUM> of the blade <NUM>) that is configured to engage with a pinion gear <NUM>. The pinion gear <NUM> is positioned within the housing <NUM> by a fastener <NUM>. The pinion gear <NUM> engages with both the sliding rack <NUM> and a fixed rack <NUM> (of the housing <NUM>, in particular of the scale <NUM>) and may contain one or more sets of teeth (e.g., a first set of teeth <NUM> and a second set of teeth <NUM>). The sliding rack <NUM> is configured to oppose the fixed rack <NUM> of the knife <NUM> (e.g., with the teeth of the sliding rack <NUM> being oriented substantially opposite to the teeth of the fixed rack <NUM>). The pinion gear <NUM> engages with the actuator <NUM> through an elongate opening <NUM> of the first scale <NUM> and forms a first axis I1. The first scale <NUM> additionally features a groove <NUM> within which the actuator <NUM> may translate along the first scale <NUM>.

The pinion gear <NUM> rotates about the first axis I1 while linearly translating between the open end <NUM> and closed end <NUM> of the housing <NUM>. The actuator <NUM> advances (or retracts) the pinion gear <NUM> while the pinion gear <NUM> is engaged with the fixed rack <NUM>, which causes the pinion gear <NUM> to rotate as it advances (or retracts). The pinion gear <NUM> is further engaged with the opposing sliding rack <NUM>, is advanced (or retracted) by both the travel and rotation of the pinion gear <NUM>. The first set of teeth <NUM> is configured to engage with the fixed rack <NUM> and the second set of teeth <NUM> is configured to engage with the sliding rack <NUM>.

Similar to the retention system discussed hereinabove with reference to <FIG>, the knife <NUM> may comprise a retention system that includes magnet <NUM>, and ferromagnetic inserts <NUM>, <NUM> as detent features. Rather than being positioned on a blade holder (e.g., as magnet <NUM> in the example of <FIG>), the magnet <NUM> of <FIG> is positioned on the tang <NUM> of the blade <NUM>. The ferromagnetic inserts <NUM> and <NUM> are positioned in a non-magnetic scale <NUM>. The magnet <NUM> and inserts <NUM> and <NUM> may facilitate non-lock blade extension and retraction functionality that is similar to that described as facilitated by magnets <NUM>, <NUM>, and <NUM> with reference to <FIG>.

<FIG> depict an example embodiment of a utility knife <NUM>. The utility knife <NUM> comprises a blade <NUM> that extends and retracts through an open end <NUM> of a housing <NUM>. The knife <NUM> comprises an actuator <NUM> that is externally located to the housing <NUM> and configured to extend and retract the blade <NUM>. The blade <NUM> extends through the open end <NUM> of the housing <NUM> as the actuator <NUM> moves toward the open end <NUM> of the housing <NUM>. The blade <NUM> retracts through the open end <NUM> of the housing <NUM> as the actuator <NUM> moves toward the closed end <NUM> of the housing <NUM>. In some embodiments, the actuator <NUM> extends along a significant length of the housing <NUM> between the open end <NUM> and a closed end <NUM>. The actuator <NUM> is configured to be operated by a thumb or finger(s) of a user and, as such, may include anatomically appropriate grip formations <NUM> to allow for multiple grip positions.

Referring to <FIG>, the example embodiment of the utility knife <NUM> comprises a blade <NUM>, blade holder <NUM>, and housing <NUM>. The housing <NUM> may be formed of a first scale or sidewall <NUM>, second scale or sidewall <NUM>, and spacer <NUM> that forms a channel <NUM> for the blade <NUM> and blade holder <NUM> so that the blade <NUM> may be stored safely within the channel <NUM> (the spacer <NUM> may, in some instances, be regarded as part of a housing of a knife in accordance with the present disclosure). The blade holder <NUM> comprises a mount <NUM> for the blade <NUM> and a sliding rack <NUM> that is configured to engage with a pinion gear <NUM>.

The pinion gear <NUM> is positioned within the housing <NUM> between the sliding rack <NUM> of the blade holder <NUM> and a fixed rack <NUM> of the spacer <NUM>. The fixed rack <NUM> of the spacer <NUM> may be arranged on an internal surface <NUM> of the spacer <NUM>. The pinion gear <NUM> may be positioned within a small clearance between the first and second sidewalls <NUM>, <NUM>. The pinion gear <NUM> engages with both the sliding rack <NUM> and the fixed rack <NUM>. The pinion gear <NUM> engages with the actuator via a post <NUM> of the actuator <NUM> through an elongate opening <NUM> of the first sidewall <NUM>. The pinion gear <NUM> is configured to rotate about a first axis I1 when connected to the actuator <NUM>. The actuator <NUM> may also feature a second post <NUM> that is configured to translate along and through a second elongate opening <NUM> (e.g., to prevent rotation of the actuator <NUM>). The knife <NUM> may feature a pocket clip <NUM>. In the example of <FIG>, the pocket clip <NUM> is that located on an external surface <NUM> of the second sidewall <NUM>.

<FIG> depicts detailed operation of the pinion gear <NUM>. In the illustrated embodiment, the pinion gear <NUM> comprises a single set of teeth that engages with both the sliding rack <NUM> and fixed rack <NUM>. In some implementations, utilizing a single set of teeth for the pinion gear <NUM> may enable a thinner knife construction. To extend the blade <NUM>, a user slides the actuator <NUM> toward the open end <NUM>. As the actuator <NUM> travels a first distance X1, the actuator <NUM> advances the pinion gear <NUM> by the same first distance X1. The pinion gear <NUM> is also rotated by its engagement with the fixed rack <NUM>, and the arc length of the rotation of the pinion gear <NUM> at the pitch diameter of the pinion gear <NUM> is equal to the first distance X1. The sliding rack <NUM> is advanced in the same direction toward the open end <NUM> and is advanced by a distance composed of the translational first distance X1 and also the rotational arc length that the pinion gear <NUM> rotates (which is equal to the first distance X1), resulting in a total distance traveled X2 (which, in the illustrated embodiment, is twice the first distance X1). Retraction of the blade <NUM> follows the reverse process as a user slides the actuator <NUM> away toward the closed end <NUM>.

One will appreciate, in view of the present disclosure, that the particular shapes, forms, relative sizes, and/or other granular aspects of the components or features of the embodiments described herein and shown in the Figures are provided by way of example only and are not limiting of the principles described herein. For instance, the blades shown and described hereinabove are not limiting of the principles described herein, and various types of blades may be implemented in knives/knife systems of the present disclosure. For instance, <FIG> provide various example knife configurations/forms that may be utilized in implementations of the present disclosure. <FIG> depicts a side plan view of a blade <NUM> having a Wharncliffe configuration. <FIG> depicts a side plan view of a blade <NUM> having a square end configuration. <FIG> depicts a side plan view of a blade <NUM> having a straight edge utility blade configuration. <FIG> depicts a side plan view of a blade <NUM> having a Tanto configuration. <FIG> depicts a side plan view of a blade <NUM> having a Karambit configuration. <FIG> depicts a side plan view of a blade <NUM> having a spear point configuration.

Furthermore, the features and/or components of one embodiment, example, or Figure discussed, shown, or suggested hereinabove may be combined with features and/or components of other embodiments, examples, or Figures discussed, shown, or suggested herein to provide embodiments, examples, or implementation variations that are not explicitly verbally or visually described or shown herein.

Other configurations of knives, blades, and housings can be used to incorporate a pinion gear configured to rotate and linearly translate to facilitate deployment of the blade as described herein. These and other alternatives will readily occur to the skilled artisan in view of the present disclosure and are encompassed within the subject matter of the present disclosure.

In light of the disclosure herein, one example embodiment of a utility knife may include a blade and a pinion gear configured to (i) rotate and (ii) linearly translate to facilitate deployment of the blade.

In some embodiments, the utility knife can also include a blade holder comprising a mount for the blade and further comprising a sliding rack.

In some embodiments, the utility knife can also include a housing comprising a channel for receiving the blade and the blade holder, the channel extending from a closed end of the housing to an open end of the housing, wherein the housing comprises a fixed rack.

In some embodiments, the utility knife can also include an actuator, wherein the pinion gear comprises one or more sets of teeth configured to engage with the sliding rack of the blade holder and the fixed rack of the housing and wherein the actuator is configured to engage with the pinion gear to permit blade deployment and blade retraction through the open end of the housing.

In some embodiments, the pinion gear comprises a first set of teeth having a first diameter and a second set of teeth having a second diameter, the first set of teeth configured to engage the fixed rack and the second set of teeth configured to engage the sliding rack.

In some embodiments, displacement of the actuator between the closed and open ends of the housing by a first distance causes displacement of the blade by a second distance that is greater than the first distance.

In some embodiments, the blade holder comprises a magnet and the housing comprises a first opposing magnet proximate to the closed end of the housing and a second opposing magnet proximate to the open end of the housing.

In some embodiments, the magnet and the first opposing magnet create a first bias toward blade retraction, and wherein the magnet and the second opposing magnet create a second bias toward blade deployment.

In some embodiments, the blade is selectively removable from the housing.

In some embodiments, the actuator is configured to actuate between the closed and open ends of the housing and along an external surface of a first scale of the housing.

In another embodiment, a utility knife includes a blade comprising a cutting edge and a tang, the tang comprising a sliding rack; a housing comprising a channel for receiving the blade and the tang thereof, the channel extending from a closed end of the housing to an open end of the housing, wherein the housing comprises a fixed rack; a pinion gear comprising one or more sets of teeth and configured to engage with the sliding rack of the tang of the blade and the fixed rack of the housing; and an actuator configured to engage with the pinion gear to permit blade deployment and blade retraction through the open end of the housing.

In some embodiments, the pinion gear comprises a first pitch diameter having a first set of teeth and a second pitch diameter having a second set of teeth, the first set of teeth configured to engage the fixed rack and the second set of teeth configured to engage the sliding rack.

In some embodiments, displacement of the actuator between the closed and open ends of the housing by a first distance simultaneously displaces the blade at the open end by a second distance that is greater than the first distance.

In some embodiments, the tang comprises a magnet and the housing comprises a first opposing magnet proximate to the closed end of the housing and a second opposing magnet proximate to the open end of the housing.

In some embodiments, the magnet and the first opposing magnet create a first bias for blade retraction, and wherein the magnet and the second opposing magnet create a second bias for blade deployment.

In some embodiments, the actuator extends between the closed and open ends of the housing and along an external surface of the housing.

In yet another embodiment, a utility knife includes a blade; a blade holder comprising a mount for the blade and further comprising a sliding rack; a housing comprising a first sidewall, a second sidewall, and a spacer, the spacer being positioned between the first and second sidewalls and forming a channel for receiving the blade holder and the blade, the channel extending from a closed end of the housing to an open end of the housing, wherein the spacer comprises a fixed rack on an internal surface of the spacer; a pinion gear comprising one or more sets of teeth and configured to engage with the sliding rack of the blade holder and the fixed rack of the spacer; and an actuator configured to engage with the pinion gear to permit blade deployment and blade retraction through the open end of the housing.

In some embodiments, the pinion gear comprises a first diameter having a first set of teeth and a second diameter having a second set of teeth.

In some embodiments, the first set of teeth engage the fixed rack, and wherein the second set of teeth engage the sliding rack.

In some embodiments, displacement of the actuator between the closed and open ends of the housing by a first distance simultaneously displaces the blade by a second distance that is greater than the first distance.

In some embodiments, the utility knife can also include the blade holder comprises a magnet and the housing comprises a first opposing magnet proximate to the closed end of the housing and a second opposing magnet proximate to the open end of the housing, and wherein the magnet and the first opposing magnet create a first bias for blade retraction, and wherein the magnet and the second opposing magnet create a second bias for blade deployment.

Claim 1:
A utility knife (<NUM>), comprising:
a blade (<NUM>) comprising a cutting edge (<NUM>) and a tang (<NUM>), the tang (<NUM>) comprising a sliding rack (<NUM>);
a housing (<NUM>) comprising a channel (<NUM>) for receiving the blade (<NUM>) and the tang (<NUM>) thereof, the channel (<NUM>) extending to an open end (<NUM>) of the housing (<NUM>);
a fixed rack (<NUM>) associated with the housing (<NUM>), the fixed rack (<NUM>) being maintained in a fixed position relative to the housing (<NUM>);
a pinion gear (<NUM>) comprising one or more sets of teeth (<NUM>, <NUM>) and configured to engage with the sliding rack (<NUM>) of the tang (<NUM>) of the blade (<NUM>) and the fixed rack (<NUM>) associated with the housing (<NUM>); and
an actuator (<NUM>) connected to the pinion gear (<NUM>) such that the pinion gear (<NUM>) engages the actuator (<NUM>), the sliding rack (<NUM>), and the fixed rack (<NUM>), the actuator (<NUM>) being configured to move the pinion gear (<NUM>) to permit blade deployment and blade retraction through the open end (<NUM>) of the housing (<NUM>).