Patent ID: 12257729

DETAILED DESCRIPTION OF THE INVENTION

Reference will now be made in detail to present embodiments of the invention, one or more examples of which are illustrated in the accompanying drawings. The detailed description uses numerical and letter designations to refer to features in the drawings. Like or similar designations in the drawings and description have been used to refer to like or similar parts of the invention. Each example is provided by way of explanation of the invention, not limitation of the invention. In fact, it will be apparent to those skilled in the art that modifications and variations can be made in the present invention without departing from the scope or spirit thereof. For instance, features illustrated or described as part of one embodiment may be used on another embodiment to yield a still further embodiment. Thus, it is intended that the present invention covers such modifications and variations as come within the scope of the appended claims and their equivalents.

Embodiments of the present invention include a pocket knife that reduces or eliminates movement or play between the blade and the chassis when the blade is in the deployed position. For convention of reference in describing the embodiments shown in the figures, the term “front” shall refer to the end of the pocket knife from which a blade deploys; the term “rear” shall refer to the end of the pocket knife that is opposite from the front; the term “forward” shall refer to the direction toward the front of the pocket knife; the term “rearward” shall refer to the direction away from the front of the pocket knife; the term “top” shall refer to the side of the pocket knife that houses an actuator for operating the pocket knife; the term “bottom” shall refer to the side of the pocket knife that is opposite from the top; and the terms “left” and “right” shall refer to the opposing sides of the pocket knife that are adjacent to and generally perpendicular to the top and bottom. As used herein, the term “longitudinal” shall refer to the direction between the front and rear of the pocket knife, and the term “axial” shall refer to the direction perpendicular to the longitudinal direction.

FIGS.1and2provide perspective views of a pocket knife10according to one embodiment of the present invention in retracted and deployed positions, respectively, andFIG.3provides an axial cross-section of the pocket knife10shown inFIG.2taken along3-3. As shown inFIGS.1-3, the pocket knife10generally includes a chassis12, a blade14, and an actuator16.

The chassis12provides a frame for supporting the various components associated with the pocket knife10and may be molded, pressed, or machined from plastics, metals, polymers, or any material or combination of materials having the desired strength and durability. The chassis12generally includes a first or left scale18opposed to a second or right scale20, and when assembled together, the first and second scales18,20produce a cavity26(shown inFIG.3) inside the chassis12.

The blade14generally has one or more cutting edges28and can move between retracted and deployed positions. In the retracted position, as shown inFIGS.1,13, and14, the cutting edge28is inside of the cavity26or between the first and second scales18,20to shield the cutting edge28from inadvertent contact that might damage the blade14or cause harm to personnel or objects. In the deployed position, as shown inFIGS.2,15, and16, at least a portion of the cutting edge28is outside of the cavity26of the chassis12to allow use of the cutting edge28as desired.

For the embodiments shown inFIGS.1-3, the actuator16is in sliding contact with the top of the chassis12and controls the operation of the pocket knife10. The actuator16has a shut or rear position, shown inFIGS.1,13, and16, that moves the blade14to the retracted position and an open or front position, shown inFIGS.2,14, and15, that moves the blade14to the deployed position.

FIG.4provides an exploded view of the pocket knife10shown inFIGS.1-3according to one embodiment of the present invention. As shown inFIG.4, the rear portion of the blade14generally includes a tang30, and the tang30of the blade14may include an aperture31and a notch34longitudinally separated from a rear surface36of the blade14. The aperture31is sized and shaped to receive a stop pin32which will be described in more detail with respect toFIGS.5-8. In particular embodiments, the stop pin32may be simply a projection from the tang30, while in other embodiments, as shown inFIG.4, the stop pin32may be a separate part threaded or press-fit into the aperture31in the tang30. The notch34may be on one or both sides of the tang30. The purpose and operation of the stop pin32, notch34, and rear surface36will be described in more detail with respect to operation of the blade14between the retracted and deployed positions as shown inFIGS.13-16.

As shown most clearly inFIG.4, one or more springs38, front and rear operators40,42, front and rear locks44,46, and a slider48may be located inside the cavity26of the chassis12. The springs38connect the front operator40to the rear operator42. Although the front and rear operators40,42shown inFIG.4are identical, they may not be identical in particular embodiments, and the present invention is not limited to identical front and rear operators40,42unless recited in the claims. As will be explained in more detail with respect toFIGS.13-16, the front and rear operators40,42alternately engage with the stop pin32and the slider48to move the blade14between the retracted and deployed positions.

The front and rear locks44,46may be pivotally connected to the chassis12and biased radially inward in the cavity26by springs50. With the blade14in the retracted position, the rear lock46is in biased engagement with the notch34in the tang30to lock the blade14inside of the chassis12. Conversely, with the blade14in the deployed position, the front lock44is in biased engagement with the rear surface36of the tang30to lock at least a portion of the blade14outside of the chassis12.

The slider48has a bottom side52opposed to a top side54with a front sloped surface56and a rear sloped surface58on either of the bottom or top sides52,54. In the particular embodiment shown inFIG.4, the front and rear sloped surfaces56,58are located or defined on the bottom side52of the slider48to engage with the front and rear locks44,46as the slider48moves longitudinally in the cavity26. In alternate embodiments, the front and rear sloped surfaces56,58may be located or defined on opposite sides52,54of the slider48to correspond to the positions of the associated front and rear locks44,46, and the present invention is not limited to the specific location of the front and rear sloped surfaces56,58unless specifically recited in the claims.

A tab60may extend from whichever side of the slider48is closest to the actuator16so that the tab60engages with the actuator16and the actuator16and the slider48move together. In the particular embodiment shown inFIG.4, for example, the tab60extends from the top side54of the slider48. In this manner, forward and rearward movement of the actuator16moves the slider48the same direction and distance.

The slider48has a rear position that moves the blade14to the retracted position and a front position that moves the blade14to the deployed position. Specifically, with the slider48in the front position and the blade14locked in the deployed position, as the slider48moves to the rear position, the slider48engages with the rear operator42to increase tension in the springs38. Rearward movement of the slider48causes the front sloped surface56to engage with the front lock44to pivot the front lock44outward, disengaging the front lock44from the rear surface36of the tang30to allow the springs38to pull the front operator40against the stop pin32in the tang30to move the blade14to the retracted position. When the blade14reaches the retracted position, the spring50pushes the rear lock46pivotally into biased engagement with the notch34in the tang30to lock the blade14in the retracted position inside of the chassis12. Conversely, with the slider48in the rear position and the blade14locked in the retracted position, as the slider48moves to the front position, the slider48engages with the front operator40to increase tension in the springs38. Forward movement of the slider48causes the rear sloped surface58to engage with the rear lock46to pivot the rear lock46outward, disengaging the rear lock46from the notch34in the tang30of the blade14to allow the springs38to pull the rear operator42against the stop pin32in the tang30to move the blade14to the deployed position. When the blade14reaches the deployed position, the spring50pushes the front lock44pivotally into biased engagement with the rear surface36of the tang30to lock the blade14in the deployed position with at least a portion of the blade14outside of the chassis12.

When the blade14is in the deployed position, the front lock44is in biased engagement with the rear surface of the tang40to prevent the blade14from leaving the deployed position. However, the manufacturing tolerances and designed clearances between the various components that provide the single or double action functionality result in slight longitudinal and/or axial movement or play between the blade14and the chassis12when the blade14is locked in the deployed position. This slight movement or play reduces the precision and usefulness of the pocket knife10compared to a folding or fixed blade knife. Therefore, embodiments of the present invention include a means for preventing movement of the blade14with respect to the chassis12when the blade14is in the deployed position. The function of the means is to prevent movement of the blade14with respect to the chassis12when the blade14is in the deployed position. The structure for performing this function is an end66of the stop pin32that extends a predetermined distance68from the blade14to engage with an insert80inside the chassis12when the blade14is in the deployed position to prevent movement of the blade14with respect to the chassis12. In particular embodiments, the stop pin32may be simply a projection from the tang30, while in other embodiments, the stop pin32may be a separate part threaded or press-fit into the aperture31in the tang30of the blade14. In other particular embodiments, an insert surface82defined by the insert80may be arcuate or curved and may have an insert surface hardness that is greater than the surface hardness of the chassis12. Moreover, the end66of the stop pin32may be tapered, and the insert surface82defined by the insert80may be angled to match the tapered end of the stop pin32.

FIG.5provides a perspective view of the stop pin32shown inFIG.4according to one embodiment of the present invention, andFIG.6provides a side cross-section view of the stop pin32shown inFIG.5taken along6-6. As shown inFIGS.5and6, the stop pin32may include threads62between a first end64opposed to a second end66. The threads62of the stop pin32allow the stop pin32to be threadingly engaged with complementary threads in the aperture31in the tang30of the blade14. When installed in the aperture31in the tang30, the first end64of the stop pin32extends above the tang30of the blade14for engagement with the front or rear operators40,42when retracting or deploying the blade14, respectively, as previously described. As shown inFIG.6, the second end66of the stop pin32may be tapered. When installed in the aperture31in the tang30, the second end66of the stop pin32extends a predetermined distance68from the tang30of the blade14to wedge against the insert80when the blade14is in the deployed position.

FIG.7provides a left plan view of the stop pin32installed in the aperture31in the tang30of the blade14, andFIG.8provides a cross-section view of the tang30of the blade14shown inFIG.7taken along8-8. As shown inFIGS.7and8, the threads62of the stop pin32provide threaded engagement with complementary threads in the aperture31in the tang30of the blade14. As shown most clearly inFIG.8, the first end64of the stop pin32extends above the tang30of the blade14for engagement with the front or rear operators40,42when retracting or deploying the blade14, respectively, as previously described, and the second end66of the stop pin32extends the predetermined distance68from the tang30of the blade14to wedge against the insert80when the blade14is in the deployed position.

In particular embodiments, the predetermined distance68that the second end66of the stop pin32extends from the blade14may be adjustable to optimize the engagement between the second end66of the stop pin32and the insert80. As shown inFIGS.5-8, for example, embodiments of the present invention may further include a means for adjusting the predetermined distance68that the second end66of the stop pin32extends from the blade14. The function of the means is to adjust the predetermined distance68that the second end66of the stop pin32extends from the blade14. The structure for performing this function is the threads62of the stop pin32that allow rotation of the stop pin32in the aperture31to raise or lower the stop pin32in the aperture31of the tang30. In particular embodiments, a surface feature70in the first or second ends64,66of the stop pin32may facilitate precise rotation of the stop pin32in the aperture31to finely adjust the predetermined distance68that the second end66of the stop pin32extends from the blade14. The surface feature70may be any shape or size to fit a tool used to rotate the stop pin32in the aperture31. Alternately or in addition, as shown inFIG.7, one or more set screws72may be threadingly engaged with the blade14to extend into the aperture31and against the stop pin32to prevent the stop pin32from rotating in the aperture31and lock the second end66of the stop pin32at the predetermined distance68from the blade14.

FIG.9provides a top perspective view of an insert80according to one embodiment of the present invention, andFIG.10provides a top plan view of the insert80shown inFIG.9. The insert80may be molded, pressed, or machined from metals, polymers, or any material or combination of materials having the desired hardness, strength, and durability. The purpose of the insert80is to engage with the second end66of the stop pin32when the blade14is in the deployed position to prevent movement of the blade14with respect to the chassis12. As shown inFIGS.9and10, the insert80defines an insert surface82and may include one or more tabs84that extend from the insert80. In particular embodiments, the insert surface82defined by the insert80may be curved or angled to match the tapered second end66of the stop pin32to wedge the components together to more securely prevent movement of the blade14with respect to the chassis12when the blade is in the deployed position. Alternately or in addition, in particular embodiments, the insert80may include a threaded surface86for fixedly attaching the insert80to the chassis12.

FIG.11provides a top plan view of the right scale20shown inFIG.4with the insert80shown inFIGS.9and10installed in the right scale20, andFIG.12provides a bottom plan view of the right scale20and insert80shown inFIG.11. Although the insert80is shown at the front of the chassis12, the insert80may be placed at other locations inside the chassis12, and embodiments of the present invention are not limited to a particular location of the insert80unless specifically recited in the claims. As shown inFIGS.11and12, the right scale20of the chassis12may define a chassis surface90and one or more recesses92in the chassis12.

The chassis surface92may have a chassis surface hardness, and the insert surface82may have an insert surface hardness that is greater than the chassis surface hardness. The increased surface hardness of the insert surface82compared to the chassis surface90reduces wear of the insert surface82during repeated engagement between the second end66of the stop pin32and the insert surface82as the blade14is locked in the deployed position. One of ordinary skill in the art will appreciate that the hardness of the chassis surface92and the insert surface82may be measured in several different ways, such as scratch hardness, indentation hardness, and rebound hardness. Scratch hardness is the measure of how resistant a sample is to fracture or permanent plastic deformation due to friction from a sharp object. Indentation hardness measures the resistance of a sample to material deformation due to a constant compression load from a sharp object. Rebound hardness, also known as dynamic hardness, measures the height of the “bounce” of a diamond-tipped hammer dropped from a fixed height onto a material. This type of hardness is related to elasticity. Embodiments of the present invention are not limited to any particular hardness measurement unless recited in the claims.

As shown in phantom inFIGS.11and12, the tabs84extend from the insert80into the recesses92defined by the chassis12to retain the insert80in position. Alternately or in addition, the insert80may be fixedly connected to the chassis12using adhesive, staking, or a screw threaded into the threads86in the insert80.

Operation of the pocket knife10between the retracted and deployed positions will now be described with respect toFIGS.13-16. As shown inFIG.13, the actuator16is in the shut position, and the slider48is in the rear position with the blade14retracted inside the cavity26. With the blade14in the retracted position, the rear operator42is engaged with first end64of the stop pin32in the tang30, and the rear lock46is engaged with the notch34in the tang30to retain the blade14in the retracted position.

To deploy the blade14, the actuator16is moved forward to the open position as shown inFIG.14, and the engagement between the tab60and the actuator16causes the slider48to move forward with the actuator16. As the slider48initially moves forward, the rear lock46remains engaged with the notch34in the tang30to prevent the blade14from moving, and the front of the slider48engages with the front operator40to move the front operator40forward and increase tension in the springs38between the front and rear operators40,42. Eventually, the rear sloped surface58of the slider48disengages the rear lock46from the notch34to release the blade14, as shown inFIG.14.

When the rear lock46disengages from the notch34, the tension in the springs38pulls the rear operator42against the first end64of the stop pin32in the tang30to eject the blade14out of the cavity26to the deployed position, as shown inFIG.15. The blade14moves out of the cavity26until the first end64of the stop pin32contacts the front operator40to prevent further travel of the blade14out of the cavity26. As shown inFIG.15, the actuator16is in the open position with the blade14deployed outside of the cavity26. In the deployed position, the front operator40is engaged with the first end64of the stop pin32, and the front lock44is engaged with the rear surface36of the tang30to hold the blade14in the deployed position. In addition, the tapered second end66of the stop pin32is wedged against the insert surface82of the insert80to prevent movement of the blade14with respect to the chassis12.

To retract the blade14, the actuator16is moved rearward to the shut position as shown inFIG.16, and the engagement between the tab60and the actuator16causes the slider48to move rearward with the actuator16. As the slider48initially moves rearward, the front lock44remains engaged with the rear surface36of the tang30to prevent the blade14from moving, and the rear of the slider48engages with the rear operator42to move the rear operator42rearward and increase tension in the springs38between the front and rear operators40,42. Eventually, the front sloped surface56of the slider48disengages the front lock44from the rear surface36of the tang30to release the blade14, as shown inFIG.16.

When the front lock44disengages from the rear surface36of the tang30, the tension in the springs38pulls the front operator40against the first end64of the stop pin32in the tang30to pull the blade14into the cavity26to the retracted position, as shown inFIG.13. The blade14moves into the cavity26until the first end64of the stop pin32contacts the rear operator42, and the rear lock46again engages with the notch34in the tang30to retain the blade14in the retracted position.

This written description uses examples to disclose the invention, including the best mode, and also to enable any person skilled in the art to practice the invention, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the invention is defined by the claims and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they include structural elements that do not differ from the literal language of the claims or if they include equivalent structural elements with insubstantial differences from the literal language of the claims.