Ergonomic utility knife/box cutter and method of making

A utility knife comprising:

• an ergonomically-shaped handle portion defining a longitudinal cavity at a forward end, a top surface and an aft recess substantially adjacent said top surface,
• a channel member received in said cavity, said channel member integrally including a plate-like guide/guard portion forwardly of said handle portion,
• a blade carder member received in said channel member for receiving a cutting blade defining a cutting edge, the blade being received such that said cutting edge faces substantially away from said top surface,
• a lock to retain said blade carrier in a selected position relative said handle portion, and
• a spare blade holder member pivotally received into said aft recess.

A utility knife comprising:

• an ergonomically-shaped handle portion defining a longitudinal cavity at a forward end, a top surface, an aft recess substantially adjacent said top surface and a partition wall separating said cavity and said aft recess, said partition wall including an aperture extending longitudinally therethrough,
• a channel member received in said cavity, said channel member having a tang protruding through said aperture into said aft recess,
• a blade carrier member received in said channel member for receiving a cutting blade defining a cutting edge, the blade being received such that said cutting edge faces substantially away from said top surface,
• a lock to retain said blade carrier in a selected position relative said handle portion, and
• a spare blade holder member pivotally received into said aft recess.

A utility knife/box cutter comprising:

• an elongate bulbular ergonomic handle portion having an exterior surface, said handle portion defining a forwardly-extending elongate longitudinal cavity separated by a perforate partition wall from a rearward upwardly-opening recess;
• a spare blade holder member pivotally received into said rearward recess and movable between a closed blade-retaining position and an open blade-releasing position in which a forward portion of the spare blade holder member is pivoted upwardly out of said recess and free of the remainder of the handle portion, in said closed position of said spare blade holder member the latter defining a part of the exterior surface of said handle portion;
• a channel member received into said forward cavity, said channel member including a tab extending through a perforation of the partition wall into said rearward recess, said channel member defining a pair of longitudinal grooves and a pair of longitudinal edge surfaces each of which are engaged by a respective longitudinal rib defined by said handle portion within said forward cavity to support the channel member in opposition to cutting forces on the knife;
• a blade carrier member slidably received into said channel member for longitudinal movement relative said handle portion, said blade carrier member is itself channel shaped to receive therein an all purpose blade defining a cutting edge, said cutting edge facing downwardly when said blade is received in said blade carrier member, and said blade carrier is somewhat tray-shaped to prevent accidental dropping of said blade when the blade carrier is moved outwardly of the channel member to a blade changing position;
• and
• said channel member also defines an integral plate-like guide and blade guard outwardly of the handle portion, said plate-like blade guard shielding said blade outwardly of said handle portion and is angulated toward but short of intersection with the blade.

A method of providing a utility knife/box cutter, said method including the steps of:

• providing an ergonomic elongate handle portion forwardly defining a longitudinal cavity, and aft recess, and a partition wall separating said cavity from said recess;
• inserting a channel member into said cavity with a tang portion of said channel member extending through an aperture of said partition wall to captively retain said channel member within said cavity;
• and
• slidably disposing a channel-shaped tray-like cutter blade carrier member within said channel member for longitudinal movement to expose an end part of a cutting blade carried therein externally and forwardly of said handle portion.

A utility knife comprising:

• an ergonomically-shaped handle portion defining a longitudinal cavity at a forward end, a top surface and an aft recess substantially adjacent said top surface,
• a channel member received in said cavity, said channel member including an elongate longitudinal slot with a number of semi-circular enlargements spaced therealong,
• a blade carrier member received in said channel member for receiving a cutting blade defining a cutting edge, the blade being received such that said cutting edge faces substantially away from said top surface, said blade carrier member being of generally tray-like shape and including a web with upper and lower wall portions extending perpendicularly thereto, a tab at its forward end preventing forward dropping of a cutting blade therefrom, means, including a button member secured to said blade carrier member, at its aft end defining the aft end of a tray into which a cutting blade will lay, and an integral spring arm portion extending aft from the remainder thereof, said spring arm portion carrying said button member and yieldably urging an enlarged collar portion thereof outwardly into said slot enlargements to prevent longitudinal movement of said blade carder member, and thereby to define a lock for said blade carrier member, and
• a spare blade holder member pivotally received into said aft recess.