Cutter with sliding gear

Abstract

A utility knife includes a blade, a housing for storing the blade, an actuator, and a pinion for deploying the blade. The pinion includes one or more sets of teeth that mesh with a fixed rack of the housing and a sliding rack of the blade holder. The pinion is also coupled to the actuator, which is configured to linearly translate the pinion. As the pinion translates linearly between the front and rear ends of the housing, it rotates due to its meshing with the fixed rack. Further meshing between the pinion and the sliding rack causes the sliding rack to advance in the same linear direction as the pinion, a distance greater than the linear distance the pinion traverses, thereby advancing or retracting the blade attached to the blade holder.

Description

Technical Field

[0001] This disclosure relates to cutting tools, such as utility knives, which include means for safely and quickly unfolding the blade from the handle and retracting the blade into the handle. Background Technology

[0002] Cutting tools, such as utility knives, are used in a variety of applications related to manufacturing, packaging, transportation, and construction to cut or remove material from objects or workpieces. Cutting tools and knives containing cutting edges typically include devices for securing and protecting the cutting edges during storage and transport. Utility knives are generally classified according to the type and manner in which the blade is deployed. These types include fixed-blade utility knives, folding utility knives, and telescopic utility knives.

[0003] Fixed-blade utility knives are characterized by blades that are fixed in position relative to their respective handles. The cutting edge can be fixed in an exposed position relative to the handle. Fixed-blade utility knives typically include a separate sheath, scabbard, or operating guard to cover the fixed blade when not in use.

[0004] Folding utility knives are characterized by the fact that when the blade is in the closed position, it is at least partially stored within the handle and can be rotated out from one side of the handle to enter an exposed and open position. These knives typically include a lever or mechanism to hold or lock the blade in the open position. When the blade is in the open position, a groove in the handle is usually exposed (e.g., a groove in which the blade is at least partially located when closed, from which it rotates to the open position). Undesirable material and / or debris may enter this groove and prevent the knife from properly returning to the closed position. Because the blade typically rotates out from one side of the handle, the user often cannot fully grip the handle of a folding utility knife when the blade is unfolded or retracted, resulting in a loose or unsafe grip during unfolding / retraction. This can lead to undesirable consequences such as injury.

[0005] Telescopic or out-of-the-fly (OTF) utility knives are generally considered safer and easier to operate because the blade extends and retracts from the front of the handle. Most telescopic utility knives utilize an actuator that advances and retracts the blade holder. However, for traditional telescopic utility knives, the actuator or sliding button travels a distance equal to (or greater than) the blade travels, as is the case with snap-on utility knives. To allow the actuator to travel its full travel (especially with larger utility knives), the user frequently repositions their grip on the knife handle during blade extension or retraction, which can be dangerous and / or cause user fatigue. Additionally, holding the handle with one hand and using the other to extend the actuator's travel can disrupt workflow. While some telescopic utility knives may be spring-loaded to facilitate rapid blade extension, spring-loaded utility knives are illegal in many countries.

[0006] Therefore, there is a need to provide improved practical cutting tools. Summary of the Invention

[0007] The subject matter claimed herein is not limited to embodiments that address any drawbacks or that operate only in environments such as those described above. Rather, this background is provided merely to illustrate an exemplary technical field in which some of the embodiments described herein can be implemented.

[0008] This disclosure achieves an improvement over existing utility tools by providing an improved pinion mechanism for securely deploying the blade. The utility tool advances and rotates a pinion on a fixed rack and an opposing movable or sliding rack to allow the blade to deploy and retract. The pinion is mounted on an actuator and rotates about an axis that translates linearly with the actuator along the housing. Advancing the pinion when it meshes with the fixed rack causes it to rotate during this advance. The pinion further meshes with the opposing movable rack, which is advanced in the same direction as the pinion's translation by the movement and rotation of the pinion.

[0009] The use of a pinion for blade deployment and retraction, as described herein, offers several advantages over existing utility knife deployment mechanisms. For example, using a pinion allows for an actuator stroke shorter than the blade stroke required for deployment or retraction. This functionality allows the user to easily actuate the actuator with a single finger over the entire stroke while maintaining a full grip on the utility knife handle. Maintaining a full grip on the handle during blade deployment and / or retraction improves user safety, increases user efficiency, and / or reduces user fatigue and / or strain when using the utility knife. Furthermore, the pinion-driven utility knife of this disclosure enables rapid blade deployment and / or retraction while avoiding reliance on spring loading or other biasing components, thus allowing the utility knife of this disclosure to be used in countries where spring-loaded knives are prohibited.

[0010] In one embodiment, the utility knife includes a blade, a blade holder, a housing, a pinion, and an actuator. The actuator is accessible from the outside of the knife's shank or housing and is configured to be operated by the user's thumb or fingers. In some cases, the actuator may extend a significant portion of the housing's length to allow for operation of the blade's unfolding and retraction from multiple grip positions (the advantageously larger length of the actuator can be achieved through the shorter actuator travel distance required for unfolding / retracting the utility blade, as provided by the principles described herein).

[0011] In one embodiment, the blade holder provides mounting and guidance for the blade. The blade holder operates within an internal channel or space formed by the housing. The blade holder includes a sliding rack driven by the displacement and rotation of a pinion. The blade holder may include one or more components separate from the blade, configured to selectively receive and hold the blade (e.g., to allow various types of blades to be mounted onto the blade holder).

[0012] In one embodiment, the cutter housing includes first and second sidewalls (or first and second trim pieces) and a spacer. The spacer provides space or passage for the blade, blade holder, and / or pinion to function between the first and second sidewalls. The spacer includes a fixed rack that induces rotation of the pinion when it is advanced or retracted by an actuator. The spacer can provide space or passage for receiving the blade holder and allows the blade holder to slide between an extended position and a retracted position.

[0013] In one embodiment, the pinion is configured to rotate and translate linearly through a channel in the housing to facilitate the unfolding of the blade. The pinion may include one or more sets of teeth. One or more sets of teeth of the pinion mesh with both a fixed rack and a sliding rack. The pinion can be connected to the actuator via a mating post. The pinion can be positioned within the gap space between the first and second sidewalls and can be connected to the mating post via fasteners.

[0014] In one alternative embodiment, the utility tool includes a blade, a blade holder, a housing, a pinion with a stepped structure (e.g., having multiple sets of teeth, each set including different diameters), and an actuator. The blade is configured to interact with a desired workpiece and may have one or more cutting edges. The blade includes a shank that may have one or more notches or recesses to engage with the blade holder.

[0015] In one embodiment, the blade holder provides a support for the blade and is configured to engage with the shank of the blade (e.g., through a notch or recess in the shank). The blade holder operates within an internal channel formed by the housing. The blade holder includes a sliding rack driven by the displacement and rotation of a pinion. The blade holder has a lever configured to selectively engage and disengage with the shank of the blade to allow for blade replacement. This lever may have a biasing element, such as a spring or elastic element, to facilitate the connection between the shank and the blade holder. In one embodiment, the blade holder includes a magnet configured to bias the blade and / or the blade holder into various states (e.g., closed / retracted state, open / expanded state, etc.).

[0016] In one embodiment, the cutter housing includes first and second sidewalls or trimmers that provide space or passageways for the blade, blade holder, and pinion so that they function between the first and second trimmers. The first trimmer includes a fixed rack that induces rotation of the pinion as it is advanced by an actuator. The first trimmer includes an elongated opening to facilitate engagement between the actuator and the pinion. This elongated opening forms a path or track for the actuator, allowing it to move between the open and closed ends of the cutter.

[0017] In one embodiment, the pinion has a first set of teeth with a first diameter and a second set of teeth with a second diameter. The second diameter is larger than the first diameter. The first set of teeth is configured to mesh with a fixed rack, while the second set of teeth is configured to mesh with a sliding rack. In one embodiment, the pinion is located next to the insert holder (while still allowing the pinion and insert holder to translate along the length of the utility tool at different rates) to reduce the overall length of the tool housing. The stepped pinion is configured to allow the insert travel distance to be greater than or equal to the actuator travel distance (e.g., allowing longer inserts to have shorter actuator travel). Furthermore, the stepped pinion configuration (i.e., the pinion has more than one set of teeth) allows the insert to extend at a speed or rate greater than the actuator displacement speed or rate. The stepped pinion may include one or more intermediate gears driven by the pinion to further increase the distance and speed of the insert travel relative to the actuator travel distance and speed.

[0018] In one embodiment, the utility knife has a non-locking retention system to provide blade retention in both the extended and retracted blade positions. The utility knife provides resistance to actuator movement until the desired force is reached, thus providing quick extension and retraction. In some embodiments, the retention system further provides enhanced safety by allowing automatic retraction of the blade should the blade inadvertently become embedded in an object or surface. The non-locking retention system may include (i) a braking mechanism between the blade holder, the blade, and / or the actuator and (ii) a component of the housing. In one embodiment, the braking feature is provided by magnets on the blade holder or the blade and corresponding first and second magnets (e.g., first and second opposing magnets) at different locations on the housing. The magnets may be positioned such that: (i) when the blade holder is translated to the retracted position, the magnets of the blade holder are forced toward the first opposing magnet of the housing; (ii) when the blade holder is translated to the extended position, the magnets of the blade holder are forced toward the second opposing magnet of the housing. The configuration of the magnets may generate a bias for the extended and retracted blade configurations. During purposeful use, the blade remains in an extended position when a user, holding the handle and maintaining force on the actuator, applies force to the blade (e.g., while working with the blade). If an accident occurs while the blade is in the extended position, such as the knife falling, the user's force on the actuator will cease to exist, and the minimum force applied to the blade (e.g., by the ground or even the user's shoe) will overcome the attraction between the blade clip magnet and the second opposing magnet, causing the blade to retract and potentially preventing injury from a blade locked in the extended position during such an event. The magnet's construction can additionally or alternatively facilitate the rapid extension and / or retraction of the blade. For example, to extend the blade, the user can apply force to the actuator, which is initially counteracted by the attraction between the blade clip magnet and the first opposing magnet. This creates a buildup of potential energy, which is released when the user's applied force overcomes the attraction, causing the blade to rapidly advance into the extended position, resulting in a "snap" opening effect. Without loss of generality, the same principle applies to facilitating the rapid retraction of the blade.

[0019] In one embodiment, the utility knife includes a blade with integrated operating features. For example, an actuator may form a significant portion of the housing, such that a portion of the housing unfolds or retracts relative to another portion of the housing upon contact with the user's hand. The actuator may extend along a significant length of the housing between an open end (through which the blade passes during unfolding / retraction) and a closed end. The actuator may be operated by the user's thumb and / or fingers, and therefore may include an anatomically appropriate grip form to allow for multiple grip positions.

[0020] In one embodiment, the blade includes a shank with a sliding rack, such that the sliding rack is integrally formed with the blade. Such an embodiment can omit the blade clip. The sliding rack is configured to mesh with a pinion. The housing is formed of a first and a second trim, which form channels for the blade so that the cutting edge of the blade can be stored. The pinion meshes with both the sliding and fixed racks via one or more sets of teeth. The pinion meshes with an actuator through an elongated opening in the first trim and is configured to rotate about a first axis.

[0021] In one embodiment, the pinion and the first axis translate linearly between the open and closed ends of the housing while the pinion rotates. An actuator advances the pinion when it meshes with a fixed rack, causing the pinion to rotate as it advances. The pinion also meshes with a sliding rack, which advances due to the movement and rotation of the pinion. A first set of teeth on the pinion is configured to mesh with the fixed rack, and a second set of teeth on the pinion is configured to mesh with the sliding rack. In one embodiment, the first and second sets of teeth are integrated into the same pinion and share the first axis during drive and operation of the blade. Alternatively, the first and second sets of teeth may be formed on separate gears positioned adjacent to each other to form the pinion (thus sharing the first axis).

[0022] In one embodiment, the shank of the utility knife includes a magnet (e.g., combined with a fixed rack) that forms part of a blade holding system (e.g., an unlocked blade holding system). For example, the magnet may interact with first and second opposing magnets associated with the knife housing to bias the blade to an extended or retracted state. This can provide several safety advantages (e.g., allowing small forces or contact pressures to cause blade retraction in unintended blade events if the user stops holding force on the actuator), and / or facilitate rapid blade extension and / or retraction.

[0023] By reading the following description, the appended claims, and referring to the accompanying drawings, it will become clear how these and other aspects of the disclosed utility tool, the operation and function of the elements of the related structures, and the economy of the combination and manufacture of the components, all of which form part of this specification.

[0024] To provide an overview of the disclosed utility tool, certain aspects, advantages, and novel features of the utility tool have been described herein. It should be understood that not all of these advantages are necessarily achieved according to any particular embodiment of the utility tool. Therefore, the utility tool may be embodied or implemented in a manner that realizes or optimizes one or more advantages taught herein, without necessarily realizing other advantages taught or suggested herein. Attached Figure Description

[0025] The embodiments of this disclosure will now be described with reference to examples shown in the accompanying drawings. These drawings are intended to be illustrative and not limiting. Although the disclosure has been generally described in the context of these embodiments, it should be understood that the scope of the disclosure is not limited to these specific embodiments. The contents of the drawings are not necessarily drawn to scale.

[0026] Figure 1A This is a left-side view of an exemplary utility knife according to various embodiments of the present disclosure, showing the handle and the blade in the unfolded position.

[0027] Figure 1B Various embodiments according to this disclosure Figure 1A The left-side view of the utility knife shown illustrates the shank with the blade in the retracted position.

[0028] Figure 2 Various embodiments according to this disclosure Figure 1A and 1B An exploded perspective view of the utility knife shown.

[0029] Figure 3 This is an exploded perspective view of the sidewall of the tool holder and the corresponding actuator according to various embodiments of the present disclosure.

[0030] Figure 4 This is a detailed view of a stepped pinion according to various embodiments of the present disclosure.

[0031] Figure 5A This is a partially cut-away plan view of a utility knife with the blade in the unfolded position according to various embodiments of the present disclosure.

[0032] Figure 5B When the blade is in the retracted position according to various embodiments of this disclosure Figure 5A A partially cut plan view of the utility tool shown.

[0033] Figure 6A This is a partially cut-away plan view of a utility knife with the blade in the unfolded position according to various embodiments of the present disclosure.

[0034] Figure 6B When the blade is in the retracted position according to various embodiments of this disclosure Figure 6A A partially cut plan view of the utility tool shown.

[0035] Figure 7 This is a left-side view of an exemplary utility knife according to various embodiments of the present disclosure, showing the handle and the blade in the unfolded position.

[0036] Figure 8 Various embodiments according to this disclosure Figure 7An exploded perspective view of the utility knife shown.

[0037] Figure 9A This is a left-side view of an exemplary utility knife according to various embodiments of the present disclosure, showing the handle and the blade in the unfolded position.

[0038] Figure 9B Various embodiments according to this disclosure Figure 9A The left-side view of the utility knife shown illustrates the shank with the blade in the retracted position.

[0039] Figure 10 Various embodiments according to this disclosure Figure 9A and 9B An exploded perspective view of the utility knife shown.

[0040] Figure 11 Various embodiments according to this disclosure Figure 9A and 9B The partial cutaway plan view of the utility knife shown illustrates the blade in the retracted position.

[0041] Figures 12A to 12F Side plan views of various embodiments of the blade construction of a utility knife used according to various embodiments of the present disclosure are shown. Detailed Implementation

[0042] Different embodiments of the present disclosure can be better understood from the following description and with reference to the accompanying drawings, in which similar reference numerals refer to similar elements.

[0043] Some illustrative embodiments are described below and in the accompanying drawings, but various modifications and alternative structures can be made to this disclosure. However, it is to be understood that this disclosure is not limited to the specific embodiments disclosed. This disclosure covers all modifications, alternative structures, combinations, and equivalents that fall within the spirit and scope of this disclosure.

[0044] Figure 1A and 1B An exemplary embodiment of a utility knife 100 is shown. The utility knife 100 includes a blade 102 that extends and retracts through an opening 120 of a housing 110. The knife 100 includes an actuator 130 located on an outer surface 142 of the housing 110 and configured to extend and retract the blade 102. When the actuator 130 moves toward the opening 120 of the housing 110, the blade 102 extends through the opening 120 of the housing 110. When the actuator 130 moves away from the opening 120 of the housing 110, the blade 102 retracts through the opening 120 of the housing 110.

[0045] In some embodiments, the actuator 130 forms a significant portion of the housing 110 such that actuation of the actuator is equivalent to actuation of a portion of the housing 110 relative to another portion of the housing 110 through engagement with a user's hand. In some embodiments, the actuator 130 extends a significant length through the housing 110 between the open end 120 and the closed end 118. For example, the actuator 130 may have a length greater than the stroke distance associated with the actuator to facilitate the deployment and / or retraction of the blade 102. In some embodiments, the length of the actuator is between 50% and 75% of the total length of the housing. For example, if the length of the housing is 12.7 cm (5 inches), the length of the actuator may be between 6.35 cm (2.5 inches) and 9.525 cm (3.75 inches). In some embodiments, the length of the actuator is between 75% and 95% of the total length of the housing. For example, if the length of the housing is 12.7 cm (5 inches), the length of the actuator can be between 9.525 cm (3.75 inches) and 12.065 cm (4.75 inches). In some embodiments, the length of the actuator is within a range in which the endpoints are selected from any two of the aforementioned numerical ranges. The actuator 130 is configured to be operated by a user's thumb or fingers, and therefore may include an anatomically appropriate grip form to allow for multiple grip positions.

[0046] Reference Figure 2 An exemplary embodiment of the utility knife 100 includes a blade 102 and a blade holder 104. The housing 110 may be formed by a first sidewall or trim 112 and a second sidewall or trim 114, which form a channel 116 for the blade 102 and the blade holder 104. The blade holder 104 is longitudinally movable within the channel 116 to facilitate (i) the extension of the cutting edge 141 of the blade 102 through the open end 120, and (ii) the retraction of the cutting edge 141 of the blade into the channel 116 (e.g., to allow the cutting edge 141 of the blade 102 to be stored when not in use). The knife 100 may have a tail cap 136 forming the rear portion of the channel 116. The tail cap 136 may include a pocket clip 138, such as... Figure 2 As shown, it can be arranged on the side of the cutter 100 excluding the actuator 130 to avoid interfering with the unfolding or retraction of the cutter.

[0047] The blade holder 104 includes a support 106 for receiving a blade 102. The blade holder 104 may include various components / features for retaining the blade 102 within the blade holder 104 and for facilitating the selective withdrawal of the blade 102 from the blade holder 104. Figure 2In this example, the blade holder 104 includes a lever 144 configured to engage with the shank 140 of the blade 102 to facilitate selective retention of the blade 102 within the blade holder 104 (e.g., by engaging with one or more notches on the shank 140 of the blade 102). The lever 144 may include or cooperate with a biasing element (e.g., a spring) to engage and disengage with the shank 140 of the blade 102 to allow easy replacement of the blade 102. Additional or alternative blade holding components are also within the scope of this disclosure.

[0048] exist Figure 2 In one example, the blade holder 104 includes a sliding rack 108 (e.g., formed within the sidewall of the blade holder 104) configured to mesh with a pinion 124. Figure 2 The pinion 124 is shown to be positioned within the housing 110 by a fastener 125, which secures the pinion 124 from the housing 110 to the actuator 130 (other types of securing means may also be used). The pinion 124 may be disposed within a small gap between the first and second trims 112, 114 of the housing 110. The pinion 124 may pass through an elongated opening 134 in the first trim 112 and engage with the actuator 130, for example, by the fastener 125. When arranged within the housing 110, the pinion 124 may be configured to rotate about a first axis I1, which extends through the center of one or more sets of teeth of the pinion.

[0049] The pinion 124 meshes with both the sliding rack 108 and the fixed rack 122 via one or more sets of teeth. For example, the pinion 124 may include a first set of teeth 126 and a second set of teeth 128, wherein the first set of teeth is configured to mesh with the fixed rack 122, and the second set of teeth is configured to mesh with the sliding rack 108 (see...). Figure 4 ).

[0050] Figure 2 The pinion 124 is shown located near the insert holder 104, allowing the pinion 124 to mesh with the sliding rack 108 of the insert holder 104 from one side of the insert holder 104. The adjacent arrangement of the pinion 124 and the insert holder 104 reduces the total length of the tool 100 between the open end 120 and the closed end 118.

[0051] Figure 3 The relationship between the sidewall or trim 112 of the housing 110 and the pinion 124 and actuator 130 is shown (various other features of the cutter 100 are not shown for clarity). Figure 3The diagram shows a pinion 124 configured to engage (e.g., via fastener 125) with a mating post 132 of an actuator 130 along a first axis I1. When the actuator 130 translates linearly (e.g., in response to a force applied by a user's hand), the pinion 124 translates linearly with the actuator, while simultaneously rotating about the first axis I1 through the interaction between the teeth of the pinion 124 and a fixed rack 122 of the housing 110 (e.g., sidewall or trim 112). Therefore, the pinion 124 and the first axis I1 can translate (and rotate) linearly between the open end 120 and the closed end 118 of the housing 110. In other words, the actuator 130 advances the pinion 124 when engaged with the fixed rack 122, causing the pinion 124 to rotate as it advances or retracts. When the pinion 124 further engages with a sliding rack 108 (e.g., see...) Figures 4 to 5B The sliding rack 108 is advanced or retracted (together with the blade holder 104 and the blade 102) by the linear translation and rotation of the pinion 124. This function allows the linear translation distance of the blade holder 104 and the blade 102 to be greater than the linear distance traversed by the actuator 130 (and the pinion 124). This function also allows the blade holder 104 and the blade 102 to perform linear translation at a rate greater than the linear translation rate associated with the actuator 130 (and the pinion 124).

[0052] Figure 3 The actuator 130 is shown to further include a second post 133 configured to extend into a portion (e.g., a reduced portion) of an elongated opening 134 in the housing 110. The engagement between the second post 133 and the elongated opening 134 prevents rotation of the actuator 130.

[0053] Figure 4 A detailed view is provided of the stepped pinion 124 that meshes with the fixed rack 122 of the housing 110 and the sliding rack 108 of the blade holder 104. Figure 4 In this example, the pinion 124 includes a first set of teeth 126 and a second set of teeth 128. The first set of teeth 126 is configured to mesh with a fixed rack 122, and the second set of teeth 128 is configured to mesh with a sliding rack 108. The stepped pinion 124 has a first diameter D1 associated with the first set of teeth 126 and a second diameter D2 associated with the second set of teeth 128. The second diameter D2 of the second set of teeth 128 is larger than the first diameter D1 of the first set of teeth 126. In one embodiment, the first set of teeth 126 and the second set of teeth 128 are integrated into the same pinion 124 and share a first axis I1 during the actuation and operation of the blade 102. Alternatively, the first set of teeth 126 and the second set of teeth 128 may be formed on separate gears and arranged adjacent to each other to form the pinion 124 (e.g., still sharing the first axis I1).

[0054] Figure 5A and 5B The detailed operation of a pinion 124 with a first set of teeth 126 and a second set of teeth 128 is illustrated. The difference between a first diameter D1 and a second diameter D2 contributes to an increase in the travel distance of the blade 102 (e.g., the distance traveled relative to the pinion 124 and / or the actuator 130 to facilitate the movement of the blade 102). When the pinion 124 is displaced by a first distance X1, the actuator 130 is also displaced by the same first distance X1. The first set of teeth 126 of the pinion 124 rotates by meshing with a fixed rack 122, with a rotation arc length equal to the first distance X1. The second set of teeth 128 of the pinion 124 rotates (during translation) with an arc length greater than the first distance X1 (e.g., due to the diameter difference between the first set of teeth 126 and the second set of teeth 128). The sliding rack 108 is simultaneously displaced in the same direction as the actuator 130 and the pinion 124 by the interaction of the second set of teeth 128 and the sliding rack 108, either toward the open end 120 or toward the closed end 118. The sliding rack 108 is pushed a second distance X2 that is greater than the first distance X1.

[0055] In one exemplary embodiment, the first set of teeth 126 of the pinion 124 has a first diameter D1 equal to 9.525 mm (0.375 inches), and the second set of teeth 128 of the pinion 124 has a second diameter D2 equal to 12.7 mm (0.5 inches). The difference between diameters D1 and D2 results in an increased ratio of the blade travel distance X2 (or the second distance X2) to the actuator travel distance X1 (or the first distance X1), which is greater than 2:1, i.e., 2.33. Different diameters of the first set of teeth 126 and the second set of teeth 128 can be used on the stepped pinion 124 to reduce or increase the desired travel ratio. In another embodiment, the stepped pinion 124 may have a first set of teeth 126 with a first diameter D1 equal to 9.525 mm (0.375 inches) and a second set of teeth 128 with a second diameter D2 equal to 19.05 mm (0.75 inches) so that the overall ratio of the blade travel distance X2 to the actuator travel distance X1 is equal to 3:1. The cutting tool 100 may include one or more additional or intermediate gears driven by a pinion 124 to further increase the blade travel distance X2 (e.g., the actuation distance relative to the actuator 130). One or more sets of teeth 126, 128 may be replaced by one or more levers. At least one or both of the sliding rack 108 and the fixed rack 122 may include segments of a diameter gear, which may provide a curved actuation path or a curved unfolding path as desired. In these cases, the associated path or channel 116 of the actuator 130 or housing 110 may also be curved.

[0056] Figure 6A and 6BA side view of the cutting tool 100 is shown; for clarity, some internal features of the tool are indicated by dashed lines. For example... Figure 6A and 6B As shown, the tool 100 includes a holding system having magnets 146, 148, 150 as a braking feature. Figure 6A The image shows the cutter 100 in the extended position, while... Figure 6B This shows the cutter 100 in the retracted position. Figure 6A The blade travels a distance X2, meaning the blade 102 and the blade holder 104 can travel at a distance of X2. Figure 6A The unfolding position and Figure 6B (The distance traversed between the retraction positions).

[0057] The blade holder 104 includes a magnet 146, and the housing 110 of the tool 100 includes a first opposing magnet 148 positioned toward (or near) a closed end 118 of the housing 110 and a second opposing magnet 150 positioned toward (or near) an open end 120 of the housing 110. The first opposing magnet 148 is configured to interact with the magnet 146 to generate a bias toward a retracted position (instead of rigidly locking the tool in the retracted position), such as... Figure 6B The arrow extending from magnet 146 to magnet 148 is shown in the diagram. The second opposing magnet 150 is configured to interact with magnet 146 to generate a bias towards the deployed position (instead of rigidly locking the tool in the deployed position), as shown in the diagram. Figure 6A The arrow extending from magnet 146 to magnet 150 is shown in the diagram. The braking (magnet) feature provides an unlocked blade deployment and retraction system.

[0058] To operate the blade 100, the user applies force to the actuator 130. This force is stored in the user's finger and then released rapidly when the force applied by the user exceeds the attractive force of magnets 146 and 148 (or magnets 146 and 150). This allows the blade 102 to open or close rapidly.

[0059] During conscious use of the blade 102 in the deployed position (while applying a reaction force to the blade 102 using the blade 102), the user can maintain the deployed position of the blade 102 by applying or holding a force on the actuator 130. When there is no holding force on the actuator 130, the blade 102 can be advantageously (and safely) retracted through the open end 120 in response to minimal contact pressure on the blade 102 and / or its cutting edge 141. The blade 102 is configured to be replaceable and can be removed from the blade holder 104 via the lever 144.

[0060] In some embodiments, for magnetizable blades, the magnet 146 of the blade holder 104 may advantageously provide additional functionality to further secure the blade 102 to the blade holder 104, thereby reducing free movement (or unwanted jitter or other movement) of the blade 102 when it is secured to the blade holder 104.

[0061] although Figure 6A and 6B Examples of braking mechanisms focus, at least in some respects, on the use of magnets of opposite polarity on the blade holder and the housing, but other types of brakes may also be used. For example, a combination of one or more magnets and one or more magnetizable components may be used, such as a magnet on the blade holder (or the blade itself) combined with a ferromagnetic insert on the housing (the rest of the housing being substantially non-magnetizable). According to this disclosure, the opposite arrangement may also be used (e.g., a magnet on the housing and a ferromagnetic insert on the blade holder or the blade). Furthermore, as can be appreciated from the content of this disclosure, other types of braking features may also be utilized as an addition to or alternative to the magnets. For example, the braking feature may additionally or alternatively include one or more spring-biased features configured to engage with an opposing braking feature (such as a brake ball).

[0062] Furthermore, although this disclosure focuses at least in some respects on implementation as a non-locking retaining system with braking features, it can also be implemented as a locking retaining system according to the principles described herein. For example, the braking feature may include one or more locking features to ensure the blade is in the extended or retracted position. This locking function may lock automatically (e.g., automatically when the blade is moved to the extended or retracted position) and / or be manually driven by the user via a locking actuator (e.g., for easy unlocking).

[0063] Figure 7 An exemplary utility knife 200 is shown, comprising a blade 202 having at least some integrated operating features. The utility knife 200 includes a housing 210 and a blade 202 having a cutting edge 204. The knife 200 includes an actuator 230 located outside the housing 210 and configured to cause the blade 202 to extend and retract. When the actuator 230 moves toward an open end 220 of the housing 210, the blade 202 extends through the open end 220 of the housing 210. When the actuator 230 moves toward a closed end 218 of the housing 210, the blade 202 retracts through the open end 220 of the housing 210. In some embodiments, the actuator 230 extends a length between the open end 220 and the closed end 218 corresponding to a substantial portion of the length of the housing 210. The actuator 230 is configured to be operated by a user's thumb or fingers, and therefore may include an anatomically suitable grip form to allow for multiple grip positions.

[0064] Reference Figure 8This exemplary embodiment of the utility knife 200 includes a blade 202 and a housing 210. The housing 210 may be formed of a first trim 212 and a second trim 214 (held together by fasteners 242), which forms a channel 216 for the blade 202 so that the cutting edge 204 of the blade 202 can be stored. The blade 202 includes a shank 206 and a sliding rack 208 (integrated with the shank 206 of the blade 202), the sliding rack being configured to mesh with a pinion 224. The pinion 224 is located within the housing 210 by fasteners 225. The pinion 224 meshes with the sliding rack 208 and a fixed rack 222 (of the housing 210, particularly of the trim 212), and may include one or more sets of teeth (e.g., a first set of teeth 226 and a second set of teeth 228). The sliding rack 208 is configured to be opposite to the fixed rack 222 of the cutter 200 (e.g., the teeth of the sliding rack 208 are substantially oriented opposite to the teeth of the fixed rack 222). The pinion 224 meshes with the actuator 230 through an elongated opening 234 in the first trim 212 and forms a first axis I1. The first trim 212 also has a groove 232 in which the actuator 230 can translate along the first trim 212.

[0065] Pinion 224 rotates about a first axis I1 while simultaneously translating linearly between the open end 220 and the closed end 218 of housing 210. When pinion 224 meshes with fixed rack 222, actuator 230 advances (or retracts) pinion 224, causing pinion 224 to rotate during advancement (or retraction). Pinion 224 further meshes with the opposing sliding rack 208, being advanced (or retracted) by the advance and rotation of pinion 224. A first set of teeth 226 is configured to mesh with fixed rack 222, and a second set of teeth 228 is configured to mesh with sliding rack 208.

[0066] Similar to a reference Figure 6A and 6B The aforementioned holding system discussed may include a holding system for the tool 200 that includes a magnet 236 and ferromagnetic inserts 238 and 240 as braking features. Figure 8 The magnet 236 shown is not mounted on the blade holder (e.g., as...). Figure 6A and 6B (Similar to magnet 146 in the example), but instead it is disposed on the shank 206 of the blade 202. Ferromagnetic inserts 238 and 240 are disposed in the non-magnetic trim 214. Magnet 236 and inserts 238 and 240 facilitate the unlocked blade deployment and retraction function, similar to the reference. Figure 6A and 6B The functions described are achieved by magnets 146, 148, and 150.

[0067] Figure 9A and 9BAn exemplary embodiment of a utility knife 300 is shown. The utility knife 300 includes a blade 302 that can be extended and retracted through an open end 322 of a housing 310. The knife 300 includes an actuator 334 located outside the housing 310 and configured to extend and retract the blade 302. When the actuator 334 moves toward the open end 322 of the housing 310, the blade 302 extends through the open end 322 of the housing 310. When the actuator 334 moves toward the closed end 320 of the housing 310, the blade 302 retracts through the open end 322 of the housing 310. In some embodiments, the actuator 334 extends along a greater length of the housing 310 between the open end 322 and the closed end 320. The actuator 334 is configured to be operable by a user's thumb or fingers, and therefore may include an anatomically suitable grip form 332 to allow for multiple grip positions.

[0068] Reference Figure 10 and 11 An exemplary embodiment of the utility knife 300 includes a blade 302, a blade holder 304, and a housing 310. The housing 310 may be formed by a first trim or sidewall 312, a second trim or sidewall 314, and a partition 316, which forms a channel 318 for the blade 302 and the blade holder 304 so that the blade 302 can be securely stored within the channel 318 (the partition 316 may, in some cases, be considered part of the knife housing according to this disclosure). The blade holder 304 includes a support 306 for the blade 302 and a sliding rack 308 configured to engage with a pinion 328.

[0069] A pinion 328 is disposed within the housing 110, located between the sliding rack 308 of the blade holder 304 and the fixed rack 324 of the partition 316. The fixed rack 324 of the partition 316 may be arranged on the inner surface 326 of the partition 316. The pinion 328 may be disposed within a small gap between the first sidewall 312 and the second sidewall 314. The pinion 328 meshes with both the sliding rack 308 and the fixed rack 324. The pinion 328 passes through an elongated opening 338 in the first sidewall 312 and engages with the actuator 334 via a post 336. The pinion 328 is configured to rotate about a first axis I1 when engaged with the actuator 334. The actuator 334 may also have a second post 337 configured to translate along and through a second elongated opening 339 (e.g., to prevent rotation of the actuator 334). The tool 300 may have a pocket clip 330. Figure 10 In the example, the pocket clip 330 is located on the outer surface 344 of the second sidewall 314.

[0070] Figure 11The detailed operation of pinion 328 is illustrated. In the illustrated embodiment, pinion 328 includes a single set of teeth that meshes with both sliding rack 308 and fixed rack 324. In some embodiments, the single set of teeth of pinion 328 can allow for a thinner cutter structure. To extend the blade 302, the user slides actuator 334 toward the open end 322. As actuator 334 moves a first distance X1, it advances pinion 328 by the same first distance X1. Pinion 328 also rotates due to its meshing with fixed rack 324, the arc length of which pinion 328 rotates at its pitch diameter equal to the first distance X1. Sliding rack 308 advances toward the open end 322 in the same direction, and the distance advanced consists of the first translational distance X1 and the arc length of rotation of pinion 328 (equal to the first distance X1), resulting in a total movement distance X2 (twice the first distance X1 in the illustrated embodiment). When the user slides the actuator 334 toward the closed end 320, the retraction of the blade 302 follows the reverse process.

[0071] Based on this disclosure, it will be understood that the specific shapes, forms, relative dimensions, and / or other granular aspects of the components or features of the embodiments described herein and illustrated are provided by way of example only and do not limit the principles described herein. For example, the inserts shown and described herein are not intended to limit the principles described herein, and various types of inserts can be implemented in the cutting tools / tool ​​systems disclosed herein. For example, Figures 12A to 12F Various exemplary tool constructions / forms that may be employed in embodiments of this disclosure are provided. Figure 12A A side plan view of the blade 402 with Warncliffe construction is shown. Figure 12B A side plan view of the blade 404 with a square end configuration is shown. Figure 12C A side plan view of a blade 406 with a straight-edged practical blade construction is shown. Figure 12D A side plan view of the blade 408 with a Tanto construction is shown. Figure 12E A side plan view of the blade 410 with a calanbit configuration is shown. Figure 12F A side plan view of the blade 412 with a spearhead configuration is shown.

[0072] Furthermore, features and / or components of one embodiment, example, or figure discussed, shown, or suggested herein may be combined with features and / or components of other embodiments, examples, or figures discussed, shown, or suggested herein to provide embodiments, examples, or variations of implementation not expressly described or shown herein.

[0073] Other configurations of the cutting tool, blade, and housing can be used to incorporate a small gear configured for rotation and linear translation to facilitate the unfolding of the blade described herein. These and other alternatives will readily conceive of those skilled in the art based on the content of this disclosure, all of which are embodied in the subject matter of this disclosure.

[0074] According to this disclosure, an exemplary embodiment of a utility knife may include a blade and a pinion configured to rotate and translate linearly to facilitate the unfolding of the blade.

[0075] In some embodiments, the utility knife may also include a blade holder, which includes a support for the blade, and a sliding rack.

[0076] In some embodiments, the utility knife may also include a housing that includes a channel for receiving a blade and a blade holder, the channel extending from a closed end of the housing to an open end of the housing, wherein the housing includes a retaining rack.

[0077] In some embodiments, the utility knife may further include an actuator, wherein the pinion includes one or more sets of teeth configured to engage with a sliding rack of the blade holder and a fixed rack of the housing, and the actuator is configured to engage with the pinion to allow the blade to unfold and retract through an open end of the housing.

[0078] In some embodiments, the pinion includes a first set of teeth having a first diameter and a second set of teeth having a second diameter, the first set of teeth being configured to mesh with a fixed rack and the second set of teeth being configured to mesh with a sliding rack.

[0079] In some embodiments, displacement of the actuator at a first distance between the closed end and the open end of the housing results in displacement of the blade at a second distance greater than the first distance.

[0080] In some embodiments, the blade holder includes a magnet, and the housing includes a first opposing magnet near the closed end of the housing and a second opposing magnet near the open end of the housing.

[0081] In some embodiments, the magnet and the first opposing magnet generate a first bias voltage toward the blade retraction, while the magnet and the second opposing magnet generate a second bias voltage toward the blade unfolding.

[0082] In some embodiments, the blade may be selectively removed from the housing.

[0083] In some embodiments, the actuator is configured to actuate along the outer surface of a first trim piece of the housing between the closed end and the open end of the housing.

[0084] In another embodiment, the utility knife includes: a blade including a cutting edge and a shank, the shank including a sliding rack; a housing including a channel for receiving the blade and its shank, the channel extending from a closed end of the housing to an open end of the housing, wherein the housing includes a fixed rack; a pinion including one or more sets of teeth and configured to mesh with the sliding rack of the blade shank and the fixed rack of the housing; and an actuator configured to mesh with the pinion to allow the blade to unfold and retract through the open end of the housing.

[0085] In some embodiments, the pinion includes a first set of teeth having a first pitch diameter and a second set of teeth having a second pitch diameter, the first set of teeth being configured to mesh with a fixed rack and the second set of teeth being configured to mesh with a sliding rack.

[0086] In some embodiments, the displacement of the actuator at a first distance between the closed end and the open end of the housing simultaneously causes the blade at the open end to be displaced by a second distance greater than the first distance.

[0087] In some embodiments, the shank includes a magnet, and the housing includes a first opposing magnet near the closed end of the housing and a second opposing magnet near the open end of the housing.

[0088] In some embodiments, the magnet and the first opposing magnet generate a first bias voltage for blade retraction, while the magnet and the second opposing magnet generate a second bias voltage for blade deployment.

[0089] In some embodiments, the actuator extends along the outer surface of the housing between the closed end and the open end of the housing.

[0090] In another embodiment, the utility knife includes: a blade; a blade holder including a support for the blade and further including a sliding rack; a housing including a first sidewall, a second sidewall, and a partition located 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 partition includes a fixed rack located on an inner surface of the partition; a pinion including one or more sets of teeth and configured to engage with the sliding rack of the blade holder and the fixed rack of the partition; and an actuator configured to engage with the pinion to allow the blade to unfold and retract through the open end of the housing.

[0091] In some embodiments, the pinion includes a first set of teeth having a first diameter and a second set of teeth having a second diameter.

[0092] In some embodiments, the first set of teeth engages the fixed rack, while the second set of teeth engages the sliding rack.

[0093] In some embodiments, the displacement of the actuator at a first distance between the closed end and the open end of the housing simultaneously causes the blade to produce a second distance displacement greater than the first distance.

[0094] In some embodiments, the utility knife may further include a blade holder with a magnet, and the housing includes a first opposing magnet near a closed end of the housing and a second opposing magnet near an open end of the housing, wherein the magnet and the first opposing magnet generate a first bias for blade retraction, and the magnet and the second opposing magnet generate a second bias for blade deployment.

[0095] In some embodiments, the actuator extends along the outer surface of the housing between the closed end and the open end of the housing.

[0096] It should be understood that while many features and advantages of the embodiments of this disclosure, as well as details of the structure and function of the embodiments, have been set forth in the foregoing description, this detailed description is merely illustrative and specific changes may be made within the scope of the principles of this disclosure, particularly in terms of structure and components, to suit the full range indicated by the broad general meaning of the terms expressed in the appended claims.

Claims

1. A utility knife comprising: a blade comprising a cutting edge and a tang, the tang comprising a first opening extending therethrough and a sliding rack formed on a surface of the first opening; a housing comprising a channel for receiving the blade and tang, the channel extending to an open end of the housing, the housing further comprising a second opening extending through one wall of the housing, the surface of the second opening extending through the wall having a fixed rack formed thereon, the fixed rack being held in a fixed position relative to the housing; a pinion gear configured to mesh with the sliding rack of the tang of the blade and the fixed rack associated with the housing, the pinion gear comprising a first set of teeth having a first pitch diameter and a second set of teeth having a second pitch diameter, the first set of teeth being disposed at least partially within the second opening and configured to mesh with the fixed rack, the second set of teeth being configured to mesh with the sliding rack; an actuator connected to the pinion gear by a fastener extending through the second opening, the actuator configured to move the pinion gear to allow the blade to be deployed and retracted through the open end of the housing; and a first detent feature for retaining the blade in a retracted position and a second detent feature for retaining the blade in a deployed position, wherein the first detent feature comprises a first ferromagnetic insert proximate to a closed end of the housing and the second detent feature comprises a second ferromagnetic insert proximate to the open end of the housing, the tang of the blade comprising a magnet, wherein the magnet and the first ferromagnetic insert create a first bias for blade retraction and the magnet and the second ferromagnetic insert create a second bias for blade deployment, wherein the magnet and the first ferromagnetic insert are misaligned with each other when the blade is in the retracted position and the magnet and the second ferromagnetic insert are misaligned with each other when the blade is in the deployed position.

2. The utility knife of claim 1, wherein Displacement of the actuator relative to the first distance of the housing simultaneously causes displacement of the blade at the open end of a second distance greater than the first distance.

3. The utility knife of claim 1, wherein, The actuator moves along an outer surface of the housing in the same direction as the blade.

4. The utility knife of claim 1, wherein The actuator is configured to move the pinion gear along the fixed rack, thereby rotating the pinion gear about an axis.

5. The utility knife of claim 4, wherein, Rotation of the pinion gear causes the sliding rack to move linearly.

6. The utility knife of claim 1, wherein The housing has a closed end opposite the open end.

7. A utility knife comprising: a blade; a blade holder for retaining the blade, the blade holder comprising a sliding rack such that movement of the blade and the blade holder comprising the sliding rack are linked together; a housing comprising a channel for receiving the blade and a second opening extending through one wall of the housing, the surface of the second opening having a fixed rack formed thereon; a pinion gear configured to mesh with the sliding rack and the fixed rack, the pinion gear being rotatable about an axis and linearly translatable, at least a portion of the pinion gear extending into the second opening so as to mesh with the fixed rack; an actuator connected with the pinion by a fastener extending through the second opening, wherein movement of the actuator causes the pinion to rotate about the axis and translate linearly along the fixed rack; and a brake system including a magnet associated with the blade clamp and configured to facilitate securing the blade to the blade clamp, a first pair of opposing magnets associated with the housing and proximate a first end of the housing, and a second pair of opposing magnets associated with the housing and proximate a second end of the housing, wherein the first pair of opposing magnets is configured to interact with the magnet to create a bias toward a retracted position of the blade but not to lock the blade in the retracted position, and the second pair of opposing magnets is configured to interact with the magnet to create a bias toward a deployed position of the blade but not to lock the blade in the deployed position, wherein rotation of the pinion about the axis and linear translation of the pinion along the fixed rack causes the sliding rack and blade to move linearly in the same direction as the actuator but over a greater distance than the actuator, the pinion includes a first set of teeth having a first pitch diameter and a second set of teeth having a second pitch diameter, the first set of teeth configured to mesh with the fixed rack, and the second set of teeth configured to mesh with the sliding rack.

8. The utility knife of claim 7, wherein, the pinion meshes between the actuator and the sliding rack.

9. The utility knife of claim 7, wherein, the pinion meshes between the actuator and the fixed rack.

Images