CROSS-REFERENCE TO RELATED APPLICATIONS
TECHNICAL FIELD
[0002] The present application relates generally to the field of cutting devices for cutting
patterns in sheet material.
BACKGROUND
[0003] Cutting devices may be used to cut a desired shape in sheet material. However, it
may be difficult to consistently cut the desired shape with scissors or another similar
hand-held tool. A rotary blade and a template may also be used, but the rotary blade
may be difficult to maneuver within the desired pattern. A user may be required to
adjust the rotary blade at least once before the cut is completed due to the desired
shape. The rotary blade may also wander into the template as the cut is performed,
damaging the template and/or the blade itself.
SUMMARY
[0004] One embodiment relates to an apparatus for cutting a pattern in a sheet material.
The apparatus includes a template comprising a channel having a predetermined shape,
and a cutting device. The cutting device includes a base having one or more projections
configured to interact with the channel, a handle coupled to the base and moveable
relative to the base between a first position and a second position, and a retractable
rotary blade coupled to the handle, the retractable rotary blade moveable between
a retracted position when the handle is in the first position and an extended position
from the base in line with the one or more projections when the handle is in the second
position, the retractable rotary blade configured to cut a pattern according to the
predetermined shape when the cutting device is tracked along the channel while both
the handle is in the second position and the one or more projections are positioned
within the channel.
[0005] Another embodiment relates to an apparatus for cutting a pattern in a sheet material.
The apparatus includes a template comprising a channel having a predetermined shape,
and a cutting device. The cutting device includes a base having one or more projections
configured to interact with the channel, a handle coupled to the base, the handle
rotatable relative to the base about a vertical axis provided by the base, the handle
moveable along the vertical axis relative to the base between a first position and
a second position, and a removable blade cartridge coupled to the handle, the blade
cartridge including a rotary blade moveable with the blade cartridge between a retracted
position when the handle is in the first position and an extended position from the
base in line with the one or more projections when the handle is in the second position,
the rotary blade configured to cut a pattern according to the predetermined shape
when the cutting device is tracked along the channel while both the handle is in the
second position and the one or more projections are positioned within the channel.
[0006] Yet another embodiment relates to an apparatus for cutting a pattern in a sheet material.
The apparatus includes a template, including a bottom surface, a channel formed through
the template and having a predetermined shape, and a stop coupled to the bottom surface,
the stop raised relative to the bottom surface and configured to align a sheet of
material to be cut. The apparatus also includes a cutting device, including a base
having one or more projections configured to interact with the channel, a handle coupled
to the base, the handle rotatable relative to the base about a vertical axis provided
by the base, the handle moveable along the vertical axis relative to the base between
a first position and a second position, and a retractable rotary blade coupled to
the handle, the retractable rotary blade moveable between a retracted position when
the handle is in the first position and an extended position from the base in line
with the one or more projections when the handle is in the second position, the retractable
rotary blade configured to cut a pattern according to the predetermined shape when
the cutting device is tracked along the channel while the handle is in the second
position and the one or more projections are positioned within the channel.
[0007] The foregoing is a summary and thus by necessity contains simplifications, generalizations,
and omissions of detail. Consequently, those skilled in the art will appreciate that
the summary is illustrative only and is not intended to be in any way limiting. Other
aspects, inventive features, and advantages of the devices and/or processes described
herein, as defined solely by the claims, will become apparent in the detailed description
set forth herein and taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008]
FIG. 1 is a top perspective view of an apparatus for cutting a pattern in a sheet
material, the apparatus including a cutting device and a cutting template, in accordance
with an exemplary embodiment.
FIG. 2 is a top perspective view of a cutting device for the cutting apparatus of
FIG. 1, the cutting device having a retractable blade shown in the retracted position,
in accordance with an exemplary embodiment.
FIG. 3 is a bottom perspective view of the cutting device of FIG. 2 with the retractable
blade in the retracted position.
FIG. 4 is a front plan view of the cutting device of FIG. 2 with the retractable blade
in the retracted position.
FIG. 5 is a front plan view of the cutting device of FIG. 2 with the retractable blade
in the extended position.
FIG. 6 is a top perspective view of the cutting device of FIG. 2 with the retractable
blade in the extended position.
FIG. 7 is a bottom perspective view of the cutting device of FIG. 2 with the retractable
blade in the extended position.
FIG. 8 is a cross-sectional view of the cutting device of FIG. 3, taken along line
8-8.
FIG. 9 is a perspective cross-sectional view of the cutting device of FIG. 3, taken
along line 9-9.
FIG. 10 is a top perspective view of a removable blade cartridge for the cutting device
of FIG. 2, in accordance with an exemplary embodiment.
FIG. 11 is a top perspective view of a cutting template for the cutting apparatus
of FIG. 1, in accordance with an exemplary embodiment.
FIG. 12 is a bottom plan view of the template of FIG. 11.
FIG. 13 is a front plan view of the template of FIG. 11.
FIG. 14 is a cross-sectional view of the template of FIG. 11, taken along line 14-14.
DETAILED DESCRIPTION
[0009] Referring generally to the Figures, an apparatus for cutting a circular pattern in
a sheet material and components thereof are shown according to an exemplary embodiment.
[0010] Referring to FIG. 1, a cutting apparatus 10 is shown according to an exemplary embodiment.
The apparatus 10 shown in FIG. 1 is configured to facilitate making circular cuts
in a sheet of material (e.g., a sheet of fabric). However, in other embodiments the
apparatus 10 may be configured to cut another desired (i.e., non-circular) shape in
a sheet of material, including other symmetrical shapes such as an oval, hexagon,
rectangle, triangle, and the like. The apparatus 10 includes a cutting device 12 (e.g.,
carriage, cutting tool, etc.) and a cutting template 14 (e.g., board). The cutting
template 14 includes a flat top surface 16, a raised outer edge 18 bordering rear
and side portions of the top surface 16, and a plurality of channels 20 (e.g., grooves,
guides, etc.) formed in the top surface 16 and through the template 14. Each of the
channels 20 is configured to receive the cutting device 12. The channels 20 are configured
to guide the cutting device 12 around the circumference of the channel's 20 predetermined
radius to make a circular cut. For instance, a material to be cut may be folded in
half and placed underneath the template 14. The cutting device 12 may then be placed
into one of the channels 20. The selected channel 20 is configured to guide the movement
of the cutting device 12 from one end of the channel 20 to the other. The movement
of the cutting device 12 causes a semi-circular cut through both halves of the sheet
material when a blade 34 (shown in FIG. 3) of the device 12 is extended, causing a
wholly circular pattern to be cut within the material. In other embodiments in which
the apparatus 10 is configured to cut a non-circular shape in the sheet of material,
the channels 20 may be configured (e.g., shaped) accordingly.
[0011] Referring to FIGS. 2-7, the cutting device 12 of the apparatus 10 is shown according
to an exemplary embodiment. The cutting device 12 is configured to move between a
first position (i.e., a retracted position) in which the blade 34 (e.g., rotary blade)
is retracted within the device 12 (shown in FIGS. 2-4), and a second position (i.e.,
a cutting, extended, or exposed position) in which the blade 34 is projected from
the device 12 to make a cut (shown in FIGS. 5-7). The cutting device 12 includes a
base 22, a handle 24 rotatably coupled to the base 22, and a blade cartridge 36 housing
the blade 34. The handle 24 is configured to be manipulated (e.g., held, received,
operated, moved, etc.) by an operator of the apparatus 10, including to move the device
12 within the channel 20 when the cutting device 12 is in the second position. The
handle 24 is freely rotatable relative to the base 22 and about a vertical axis provided
by the base 22, including as a cut is being performed within one of the channels 20.
The rotatable handle 24 allows a user of the apparatus 10 to maintain a comfortable
hand position and/or grip on the handle 24 as the user tracks the device 12 within
the channels 20 in the template 14.
[0012] Referring still generally to FIGS. 2-7, the handle 24 includes a body 70 having a
skirt 76 and a flange 72. The body 70, including the skirt 76 and the flange 72, may
be a single piece. The body 70 has an annular shape, having an opening formed therethrough
that is configured to receive at least a portion of the base 22 (see FIG. 8). The
handle 24 also includes a cap 26 removably coupled to and covering an open top end
of the body 70. For instance, the cap 26 and a portion of the body 70 may each include
corresponding threads configured to mate the cap 26 with the body 70. The handle 24
is sized and shaped to enable a user of the apparatus 10 to grip the handle 24 while
tracking the device 12 within the channels 20 of the template 14 when the device 12
is in the second position. The skirt 76, for instance, has a smaller maximum diameter
than the cap 26 or the flange 72, enabling a user to grip the handle 24 more easily
at the skirt 76. The skirt 76 is V-shaped, decreasing in diameter from a top end of
the skirt 76 (i.e., at or near the cap 26) to the lower end of the skirt 76 (i.e.,
at the flange 72).
[0013] In addition to being rotatable, the handle 24 is configured to move axially relative
to the base 22, along the vertical axis provided by the base 22. When a downward (e.g.,
compressive) force is applied to the handle 24 while the device 12 is in the first
position (shown in FIG. 4), the blade 34 of the cutting device 12 is moved from the
retracted position to the cutting position (as shown in FIG. 5). For instance, a manual
force may be applied by the user at the cap 26. Downward movement of the handle 24
forces the blade cartridge 36 downward in the same direction as the handle 24, causing
the blade 34 of the blade cartridge 36 to extend to the cutting position (as shown
in FIGS. 5 and 7). When the blade 34 is extended, the cutting device 12 may be used
to cut a desired pattern within a sheet of material. The handle 24 is spring-loaded
to return the device 12 (e.g., the blade 34) to the first position when the force
is removed.
[0014] Still referring generally to FIGS. 2-7, the base 22 has an annular disc shape, having
an opening 32 formed through the center of the base 22 to allow the blade 34 to extend
out from the base 22 to make a cut. The base 22 includes projections 30 (e.g., guides)
configured to interface with the channels 20 of the template 14, guiding movement
of the cutting device 12 within the channels 20 when the cutting device 12 is in the
cutting position. The projections 30 are intended to guide the blade 34 within the
channels 20, being positioned in line with the cutting path of the rotary blade 34.
The projections 30 may have a width approximately equal to the width of the channels
20 to prevent the blade 34 from wandering into the sides of the channels 20. By aligning
(e.g., centering) the blade 34 within the channels 20, the projections 30 may prevent
damage to the template 14 and/or the blade 34. The projections 30 include chamfers
60 in the illustrated embodiment. The chamfers 60 are intended to interface with complementary
features of the channels 20 to align the projections 30 (i.e., the cutting device
12) within the channels 20. The chamfers 60 may aid in aligning (e.g., centering)
the blade 34 within the corresponding channel 20 when the blade 34 is in the extended
position within the channel 20. In other embodiments, the projections 30 and the channels
20 may have other complementary shapes configured to align the projections 30 (and
the blade 34) within the channels 20. The base 22 also includes a flat bottom surface
74 configured to interface with the top surface 16 of the template 14 when the projections
30 are positioned within one of the channels 20. Tabs 28 are positioned opposite each
other on a top side of the base 22. The tabs 28 are intended to assist the user in
moving the cutting device 12 within the channels 20 by providing an indication of
the direction of the blade 34 when the blade 34 is not visible (e.g., is positioned
within one of the channels 20).
[0015] Referring now to FIGS. 8 and 9, the cutting device 12 is shown in further detail
and according to an exemplary embodiment. FIG. 8 shows a cross-sectional view of the
cutting device 12 when the cutting device 12 is between the first and second positions
(i.e., with the blade 34 partially extended). FIG. 9 shows a cross-sectional view
of the cutting device in the first position, but with the cap 26 removed. The blade
cartridge 36 is positioned within the cutting device 12. In an exemplary embodiment,
the blade cartridge 36 is a single unit configured to be removed and replaced when
the blade 34 requires replacement. The blade cartridge 36 provides a case for the
blade 34 so that a user of the cutting device 12 may remove the blade 34 without touching
the blade 34. The blade cartridge 36 includes a tab 38 having an annular flange 40,
as well as a housing 42 configured to store the blade 34. When the cutting device
12 is in the first (i.e., resting) position (as shown in FIG. 9), the tab 38 extends
vertically above the body 70 into an area that is typically covered by the cap 26.
The cap 26 includes a pocket 80 that is sized and shaped to accommodate the tab 38
when the cap 26 is coupled to the body 70 (as shown in FIG. 8). The tab 38 is configured
to be grasped by a user of the cutting device 12 to remove and replace the blade cartridge
36, and thus the blade 34. For instance, the cap 26 may be removed (as shown in FIG.
9) to reveal the tab 38. In an exemplary embodiment, the tab 38 is positioned parallel
to and on the same two-dimensional plane as the rotary blade 34.
[0016] Still referring to FIGS. 8 and 9, the base 22 includes a skirt 46 configured to receive
the blade cartridge 36. The cutting device 12 includes a spring 44 or other form of
biasing member positioned between the flange 40 of the blade cartridge 36 and the
skirt 46. The spring 44 is configured to push against both the flange 40 and the skirt
46, driving apart the blade cartridge 36 and the base 22 (i.e., the skirt 46) in absence
of an oppositional force (i.e., a force applied by a user of the device 12 to cut).
The spring 44 is configured to return the device 12 to the first (i.e., retracted)
position after the cut has been made. The flange 40 is captured within a pocket 78
formed by the body 70 and the cap 26, such that the body 70 and the cap 26 (i.e.,
the handle 24) are also driven upward by the force of the spring 44. The skirt 46
forms an annular outer rib 48 positioned at or near a top end of the skirt 46. An
inner surface of the handle 24 includes a shelf 58. The rib 48 is configured to provide
a stop for the shelf 58 (i.e., for the handle 24) against the force of the spring
44, preventing the handle 24 and/or the blade cartridge 36 from being de-coupled from
the base 22 by the force of the spring 44 by interfacing with the shelf 58 (as shown
in FIG. 9).
[0017] When a downward force is applied to the handle 24, the blade cartridge 36, and thus
the blade 34, are shifted similarly to expose the blade 34. The cap 26 includes a
projection 50 configured to engage the tab 38 of the blade cartridge 36 when the handle
24 is depressed. The cap 26 also includes interfaces 82 configured to engage the flange
40, and interfaces 84 configured to engage the body 70, moving the cartridge 36 and
the body 70 along with the cap 26. The cap 26 is configured to mate with a lip 52
formed by the body 70.
[0018] Referring to FIG. 10, the blade cartridge 36 is shown according to an exemplary embodiment.
As described previously, the cartridge 36 includes the cylindrical (e.g., annular)
housing 42 configured to house the blade 34. The housing 42 includes a track 54 configured
to provide a guide for the blade 34, preventing the blade 34 from twisting or moving
from side to side. The track 54 may also match with corresponding components of the
base 22 to align the blade cartridge 36 relative to the base 22. Similarly, the blade
cartridge 36 includes a guide 56 configured to match with a corresponding feature
of the base 22 to align the blade cartridge 36 relative to the base 22. In an exemplary
embodiment, the blade cartridge 36 is "keyed" (e.g., interlocked, mated, etc.) to
the base 22 such that the blade 34 cuts tangent to the circular pattern.
[0019] Referring to FIGS. 11-14, the template 14 of the cutting apparatus 10 is shown according
to an exemplary embodiment. As shown in FIGS. 11 and 12, the plurality of channels
20 are semi-circular in shape, with each of the plurality of channels 20 providing
a different predetermined circular cutting radius. The predetermined cutting radii
associated with each of the channels 20 corresponds to the radius of the circular
material pattern that will be produced using a selected channel 20. The channels 20
are arranged on the template 14 according to their cutting radius, in ascending order
from a front portion of the template 14 to a rear portion of the template 14 (i.e.,
at or near the rear raised edge 18). In an exemplary embodiment, the cutting radii
range from a minimum radius of approximately 5.08 centimeters (2 inches) to a maximum
diameter of approximately 15.24 centimeters (6 inches). In other embodiments, the
radii of the channels 20 may be larger or smaller, depending on the particular application.
In some embodiments, for instance, the template 14 may be manipulatable by an operator
of the apparatus 10 to create a custom channel having an operator-determined cutting
radius. As noted previously, in other embodiments the apparatus 10 may be configured
to cut another desired (i.e., non-circular) shape in a sheet of material. In such
embodiments, the channels 20 may be configured according to the desired shape. For
instance, in embodiments in which the desired cutting shape is an oval, the channels
20 may each be semi-ovular in shape.
[0020] Referring particularly to FIGS. 12-14, the template 14 includes a stop 64 formed
on a bottom surface 62 of the template 14. The stop 64 is formed across a length of
the bottom surface 62. The stop 64 is raised relative to the bottom surface 62 in
order to provide alignment for a sheet of fabric to be cut by the cutting device 12.
The stop 64 extends across the length of the template 14 and across each of the channels
20. However, the channels 20 are continuous and formed entirely through the template
14. Thus, as shown in FIG. 13, the stop 64 may be formed from a plurality of stop
strips positioned between each of the channels 20. In an exemplary embodiment, the
stop 64 is positioned across the diameter of each of the plurality of channels 20,
such that the portion of each of the channels 20 that is positioned above the stop
64 (according to the orientation of FIG. 12) has a semi-circular shape. Thus, if a
sheet of material is folded in half and the material's fold line is aligned with the
stop 64, the cutting device 12 is configured to make a circular shape within the material
through any of the channels 20.
[0021] Referring to FIGS. 13 and 14, the raised edge 18 is formed around a rear end and
the sides of the template 14. The raised edge 18 is configured to provide a handle
for an operator to manipulate the template 14. For instance, the raised edge 18 includes
ledges 66 (shown in FIG. 13) at each side of the template 14 for lifting the template
14. The raised edge 18 also includes a ledge 68 at a rear edge of the template 14.
The ledges 66 and 68 may be one continuous ledge formed at the top of the raised edge
18.
[0022] The construction and arrangement of the elements of the apparatus as shown in the
exemplary embodiments are illustrative only. Although only a few embodiments of the
present disclosure have been described in detail, those skilled in the art who review
this disclosure will readily appreciate that many modifications are possible (e.g.,
variations in sizes, dimensions, structures, shapes and proportions of the various
elements, values of parameters, mounting arrangements, use of materials, colors, orientations,
etc.) without materially departing from the novel teachings and advantages of the
subject matter recited. For example, elements shown as integrally formed may be constructed
of multiple parts or elements. The elements and assemblies may be constructed from
any of a wide variety of materials that provide sufficient strength or durability,
in any of a wide variety of colors, textures, and combinations. Additionally, in the
subject description, the word "exemplary" is used to mean serving as an example, instance,
or illustration. Any embodiment or design described herein as "exemplary" is not necessarily
to be construed as preferred or advantageous over other embodiments or designs. Rather,
use of the word "exemplary" is intended to present concepts in a concrete manner.
Accordingly, all such modifications are intended to be included within the scope of
the present disclosure. Other substitutions, modifications, changes, and omissions
may be made in the design, operating conditions, and arrangement of the preferred
and other exemplary embodiments without departing from the scope of the appended claims.
[0023] It should be noted that references to "front," "back," "rear," "upward," "downward,"
"inner," "outer," "right," and "left" in this description are merely used to identify
the various elements as they are oriented in the FIGURES. These terms are not meant
to limit the element which they describe, as the various elements may be oriented
differently in various applications.
[0024] It should further be noted that for purposes of this disclosure, the term "coupled"
means the joining of two members directly or indirectly to one another. Such joining
may be stationary in nature or moveable in nature and/or such joining may allow for
the flow of fluids, electricity, electrical signals, or other types of signals or
communication between the two members. Such joining may be achieved with the two members
or the two members and any additional intermediate members being integrally formed
as a single unitary body with one another or with the two members or the two members
and any additional intermediate members being attached to one another. Such joining
may be permanent in nature or alternatively may be removable or releasable in nature.
[0025] The order or sequence of any process or method steps may be varied or re-sequenced
according to alternative embodiments. Any means-plus-function clause is intended to
cover the structures described herein as performing the recited function and not only
structural equivalents but also equivalent structures. Other substitutions, modifications,
changes and omissions may be made in the design, operating configuration, and arrangement
of the preferred and other exemplary embodiments without departing from the scope
of the appended claims.
1. An apparatus, comprising:
a template comprising a channel having a predetermined shape; and
a cutting device, including:
a base having one or more projections configured to interact with the channel;
a handle coupled to the base and moveable relative to the base between a first position
and a second position; and
a retractable rotary blade coupled to the handle, the retractable rotary blade moveable
between a retracted position when the handle is in the first position and an extended
position from the base in line with the one or more projections when the handle is
in the second position, the retractable rotary blade configured to cut a pattern according
to the predetermined shape when the cutting device is tracked along the channel while
both the handle is in the second position and the one or more projections are positioned
within the channel.
2. The apparatus of claim 1, wherein the handle is freely rotatable relative to the base
about a vertical axis provided by the base, the handle moveable along the vertical
axis relative to the base between the first position and the second position.
3. The apparatus of claim 1 or 2, further comprising a biasing member biasing the handle
in the first position, and wherein the handle is moveable to the second position in
response to a force applied to the handle in the direction of the base.
4. The apparatus of claim 3, further comprising a blade cartridge housing the retractable
rotary blade, wherein the biasing member is a spring positioned between the blade
cartridge and the base, the spring biasing the retractable rotary blade in the retracted
position.
5. The apparatus of any preceding claim, wherein the one or more projections include
two projections, and wherein the blade extends between the two projections when the
handle is in the second position.
6. The apparatus of any preceding claim, wherein the one or more projections and the
channel include complementary chamfers configured to interface with each other, thereby
aligning the one or more projections within the channel, the one or more projections
guiding the retractable rotary blade within the channel when the handle is in the
second position.
7. The apparatus of any preceding claim, wherein the channel has a semi-circular shape
having a predetermined radius, and wherein the retractable rotary blade is configured
to cut a circular pattern having the predetermined radius when the cutting device
is tracked along the channel while both the handle is in the second position and the
one or more projections are positioned within the channel.
8. The apparatus of any preceding claim, wherein the one or more projections project
from a bottom surface of the base, and wherein the retractable rotary blade extends
a further distance from the bottom surface than the one or more projections when the
handle is in the second position.
9. The apparatus of claim 1, wherein:
the handle is rotatable relative to the base about a vertical axis provided by the
base, the handle moveable along the vertical axis relative to the base between the
first position and the second position; and further comprising
a removable blade cartridge coupled to the handle, the blade cartridge including the
rotary blade moveable with the blade cartridge between the retracted position when
the handle is in the first position and the extended position from the base in line
with the one or more projections when the handle is in the second position.
10. The apparatus of claim 9, wherein the removable blade cartridge includes a guide aligning
the removable blade cartridge with the base such that the rotary blade cuts in a direction
that is tangential to the pattern and/or wherein the removable blade cartridge further
comprises a flange captured between the cap and the body of the handle.
11. The apparatus of claim 9 or 10, wherein the removable blade cartridge is moveable
with the handle relative to the base between the first position and the second position,
wherein the cutting device further comprises a biasing member biasing the removable
blade cartridge in the first position, and wherein the removable blade cartridge is
moveable to the second position in response to a force applied to the handle in the
direction of the base.
12. The apparatus of claim 9, 10 or 11, wherein the handle comprises a body and a cap
removably coupled to the body, and wherein the cap is removable so as to provide access
to the removable blade cartridge and, optionally or preferably, wherein the removable
blade cartridge further comprises a tab that is graspable by a user of the cutting
device to remove the removable blade cartridge from the cutting device, and wherein
the tab is accessible when the cap is de-coupled from the body and, optionally or
preferably, wherein the cap comprises a pocket that is sized and shaped to accommodate
the tab, and wherein the cap further comprises a projection within the pocket that
engages the tab when the handle is moved to the second position, causing the rotary
blade to extend from the base.
13. The apparatus of claim 1, wherein:
the template includes a bottom surface and the channel is formed through the template,
and further comprising a stop coupled to the bottom surface, the stop raised relative
to the bottom surface and configured to align a sheet of material to be cut; and wherein
the handle of the cutting device is rotatable relative to the base about a vertical
axis provided by the base, the handle moveable along the vertical axis relative to
the base between the first position and the second position.
14. The apparatus of claim 13, wherein the stop includes a plurality of strips having
the channel positioned in between, and, optionally or preferably, wherein the stop
is positioned across the diameter of the channel, such that a portion of the channel
on one side of the stop has a semi-circular shape.
15. The apparatus of claim 13 or 14, wherein the template further comprises a top surface
opposite the bottom surface, and a raised outer edge bordering rear and side portions
of the top surface and, optionally or preferably, wherein the raised outer edge includes
a continuous upper ledge providing a lift point for the template.