US3191460A - Method of making a knife - Google Patents

Method of making a knife Download PDF

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US3191460A
US3191460A US121781A US12178161A US3191460A US 3191460 A US3191460 A US 3191460A US 121781 A US121781 A US 121781A US 12178161 A US12178161 A US 12178161A US 3191460 A US3191460 A US 3191460A
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handle
tang
knife
synthetic resin
blade
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US121781A
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Joseph N Christian
Howard A Jones
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Oneida LLC
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Oneida LLC
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    • BPERFORMING OPERATIONS; TRANSPORTING
    • B26HAND CUTTING TOOLS; CUTTING; SEVERING
    • B26BHAND-HELD CUTTING TOOLS NOT OTHERWISE PROVIDED FOR
    • B26B3/00Hand knives with fixed blades
    • B26B3/02Table-knives

Definitions

  • Knives of this type have customarily been manufactured by placing so-called Sauerei'sen cement in the handle, inserting the blade tang into the handle and then placing the blade and handle in a holding fixture .and baking to set the cement.
  • the cement once set cannot be softened, is difiicult to clean off, is abrasive in character and porous. It is also unsuited to high speed automatic production methods, due to its irreversible setting action.
  • a further object is to provide a method for filling the knife handle which is suitable for high speed mass production manufacture and insures against looseness and objectionable voids.
  • FIG. 1 is an exploded isometric showing a knife and hollow handle for producing .a knife according to the method of the invention
  • FIG. 2 is an isometric of the completed knife
  • FIG. 3 is a section on the line 33 of FIG. 2;
  • FIG. 4 is a section on the line 4-4 of FIG. 2;
  • FIGS. 5 and 6 are outline views, showing different configurations of the handle which may be utilized in the knife of the invention.
  • FIG. 7 is a schematic view illustrating the cycle for producing .a knife accord-ing to the method of the invention.
  • the primary difiiculty in the formation of a knife by means of a synthetic resin filling the hollow handle and surrounding the blade tang has been that the suitable resins from the standpoint of rapid production cycle, low cost and suitable mechanical properties are typified by polystyrenes of various types which have considerable mold shrinkage as well as shrinkage after molding, and the coefiicient of thermal expansion may be rela tively high as compared with most metals.
  • the mold shrinkage may approximate .004 in./ in. (the usual range being from about .002-.006 in./in.).
  • the shrinkage involved in setting tends to open up pockets at unpredictable locations and typically art the joint between blade and handle, thus creating the possibility of the entrance of water and food particles and bacterial action of an unsanitary character, as Well as causing a weakening of the joint. Additional shrinkage occurring after molding may reach a magnitude of .001 in./in.
  • the blade 1 has a bolster 2 for abutting against the handle and a tang 3 which is of tapered form, being wide at its tip and narrowing gradually as it approaches the bolster or butt end of the blade.
  • the handle 4 may be formed of stainless steel, brass or other metals and may have a generally trapezoidal shape as shown in FIGS. 1 and 2, the contracted end adjacent the bolster being sufiiciently large as to admit the enlarged end of the tang 3.
  • the handle may also have other outlines as indicated in FIGS. 5 and 6, the selection of particular contours being made from considerations of design and aesthetic appeal and not affecting in any substantial way the molding and holding action.
  • the longitudinal shrinkage (parallel to the tang axis) will far exceed the transverse shrinkage (at right angles to the tang axis).
  • the longitudinal shrinkage involves movement of plastic along the tang and this fact is utilized to counteract and even reyerse the effect of transverse shrinkage around the tang.
  • the plastic grips around the enlarged end of the tapered tang and longitudinal shrinkage from this point on can only have the effect of forcing the plastic around the tang toward the knife bolster.
  • This longitudinal shrinkage movement counteracts the transverse shrinkage around the tang and to a suificient extent so that the material adjacent the bolster and for a considerable way down the tang may actual-1y be expanded and, hence, be under compression as it sets.
  • thermoplastic synthetic resin machines fall basically into three categories: injection molding machines, which inject heated thermoplastic into a die cavity under extremely high pressures (10,000 to 20,000 p.s.i.); extruding machines which produce sheet tubing, etc. by extruding heated thermoplastic through a suitably shaped dieand calender rollers which mechanically work thermoplastic masses to produce a sheet.
  • a typical index time may be one second and a typical filling time 1.4 second, for anoverall cycle of 2.4 seconds, corresponding to a production of fifteen hundred pieces per hour, utilizing generally standard indexing equipment.
  • the indicated operations at the various stations all take place at each indexing movement and as will be apparent to those skilled in the art, the time intervals involved are entirely suitable with relation to the characteristics of the thermoplastic resin which is used.
  • the hanv tang With respect to the filling operation at station 1, as soon 7 as the indexing movement has been completed, the hanv tang, so that the insertion of the tang displaces synthetic previous equipment or technique for filling a hollow handle with thermoplastic synthetic resin in a manner so as to permit a suitable molding cycle.
  • the filling of the handle by discharging melted plastic in a measured amount from a spout is not suitable, due to entrapment of air in a cycle of any rapidity and a lack of control over the thermoplastic material in slower cycles.
  • the present invention provides a handle filling methotd of novel character consistent with a satisfactorily rapid cycle.
  • thermoplastic resin is deposited in a handle by a nozzle located, to begin with, close to the bottom of the handle (as, for example, a quarter inch therefrom) and the nozzle and handle are then moved apart at a regulated speed, corresponding to the rate of filling of the handle so that entrapment of air (which would result from too great separation between the nozzle and surface of the liquid plastic) is avoided, while at the same time undue hydraulic pressure (which would result from the immersion of the nozzle below the surface of the liquid plastic) is also avoided.
  • the nozzle may be supplied by otherwise standard injection molding equipment but it will be observed that it operates against substantially atmospheric pressure as compared with the extremely high pressures encountered in injection moldmg.
  • a typical operating cycle is shown in a schematic manner in FIG. 7 of the drawing, and may involve the use of an index table of usual type having eight positions and rotating through at each step, at intervals such as about two or three seconds and corresponding to a production rate of about fifteen hundred pieces per hour.
  • an index table of usual type having eight positions and rotating through at each step, at intervals such as about two or three seconds and corresponding to a production rate of about fifteen hundred pieces per hour.
  • the cycle may be, as follows:
  • the blade is loaded in a suitable holder at station 7, passes through an idle station 8 to station 1 where itis filled with the thermoplastic, thence to station 2 where the blade is inserted, thence to station 3 where the handle is resin and squeezes it out between handle and bolster, finally cutting it off as bolster and handle engage. After chilling, the extruded plastic at this point is readily broken off and no finishing operation is ordinarily required.
  • Method of forming hollow handled cutlery which comprises injecting melted thermoplastic synthetic resin having substantial mold shrinkage through a nozzle into the handlecommencing at a point close to the bottom of the handle and moving upwardly so as to keepthe nozzle substantially at the level of the synthetic resin as the handle is filled, inserting the end of the tapered tang of a knife blade, which tang is thicker at its said end, in the handle so as to displace some of the synthetic resin therefrom and bring the bolster of the blade against the upper edge of the hollow handle so as substantially to close off the space within the handle, and then setting the synthetic resin so as to contract the same longitudinally of the handle and compress the same around the tang, thereby eliminating transverse mold shrinkage around the tang.
  • the said resin is polystyrene.

Description

June 29, 1965 J. N. CHRISTIAN ETAL 3,191,460
I METHOD OF MAKING A KNIFE Filed July '7. 1961 2 Sheets-Sheet l INVENTORS JOfEPH M (HAP/5774M kWh 4Z0 4. MA/E5 %%TORNEY June 29, 1965 Filed July 7. 1961 J. N. CHRISTIAN ETAL 3,191,460
METHOD OF MAKING A KNIFE 2 Sheets-Sheet 2 IMF/1V6 NOZZlf INVENTORS /0.5E/// 1V- (WAVE/VAN HOWJKD 4. JOA/FS United States Patent 3,191,460 METHOD OF MAKING A KNIFE Joseph N. Christian and Howard A. Jones, Oneida, N. Y., assignors to Oneida Ltd., Oneida, N.Y., a corporation of New York Filed July 7, 1961, Ser. No. 121,781 3 Claims. (Cl. 76-104) This invention relates to the manufacture of knives.
More particularly, the invention is concerned with knives of the hollow handled type and with the securing of the knife blade to the handle. Knives of this type have customarily been manufactured by placing so-called Sauerei'sen cement in the handle, inserting the blade tang into the handle and then placing the blade and handle in a holding fixture .and baking to set the cement. The cement once set cannot be softened, is difiicult to clean off, is abrasive in character and porous. It is also unsuited to high speed automatic production methods, due to its irreversible setting action.
It is an object of the present invention to provide an improved tang holding material and method of assembly of the knife and handle, eliminating the deficiencies above mentioned.
. While attempts have been made to utilize thermoplastic materials such as various synthetic resins as part or all of the filling and holding material for securing the tang within the handle of a knife, these efforts have met with only limited success, due to difiiculties experienced in properly filling the handle with the synthetic resin, and also due to casting stresses and voids created by shrinkage during the setting process.
It is an object of the present invention to provide a structure of tang and handle which eliminates the creation of voids .and other difiic-ulties due to contraction upon setting.
A further object is to provide a method for filling the knife handle which is suitable for high speed mass production manufacture and insures against looseness and objectionable voids. t
A knife construction and method of manufacturing the same will now first be described withreference to the accompany-ing drawing and the features forming the invention will then be more particularly pointed out in the appended claims.
In the drawing:
FIG. 1 is an exploded isometric showing a knife and hollow handle for producing .a knife according to the method of the invention;
FIG. 2 is an isometric of the completed knife;
FIG. 3 is a section on the line 33 of FIG. 2;
FIG. 4 is a section on the line 4-4 of FIG. 2;
FIGS. 5 and 6 .are outline views, showing different configurations of the handle which may be utilized in the knife of the invention; and
FIG. 7 is a schematic view illustrating the cycle for producing .a knife accord-ing to the method of the invention.
Apart from certain manufacturing problems which will be mentioned latter, the primary difiiculty in the formation of a knife by means of a synthetic resin filling the hollow handle and surrounding the blade tang has been that the suitable resins from the standpoint of rapid production cycle, low cost and suitable mechanical properties are typified by polystyrenes of various types which have considerable mold shrinkage as well as shrinkage after molding, and the coefiicient of thermal expansion may be rela tively high as compared with most metals.
The mold shrinkage may approximate .004 in./ in. (the usual range being from about .002-.006 in./in.). In consequence, when the handle and blade having a tang of usual configuration are assembled together and the 3,191,460 Patented June 29, 1965 "ice space within the handle around the tang and elsewhere is filled with molten polystyrene and then the polystyrene is allowed to set, the shrinkage involved in setting tends to open up pockets at unpredictable locations and typically art the joint between blade and handle, thus creating the possibility of the entrance of water and food particles and bacterial action of an unsanitary character, as Well as causing a weakening of the joint. Additional shrinkage occurring after molding may reach a magnitude of .001 in./in. *or somewhat more, aggravating any faulty condition due to molding and in addition a composite plasticmetal structure is subjected to stresses resulting from the fact that the coeificient of thermal expansion of the plastic may be approximately double that of the metal. Under these conditions, the holding action of the synthetic resin between tang and handle may be of a localized and imperfect character and the local failure or cracking of the plastic which occurs in an unpredictable manner after the lapse of an unpredictable time may result in a loose handle with progressive increase of this looseness with continued use. For these reasons, prior to the present invention it has not been found practical to produce a polystyrene or similar synthetic resin to fill a hollow knife handle in a satisfactory manner.
In a preferred construction according to the present invention, the blade 1 has a bolster 2 for abutting against the handle and a tang 3 which is of tapered form, being wide at its tip and narrowing gradually as it approaches the bolster or butt end of the blade. The handle 4 may be formed of stainless steel, brass or other metals and may have a generally trapezoidal shape as shown in FIGS. 1 and 2, the contracted end adjacent the bolster being sufiiciently large as to admit the enlarged end of the tang 3. The handle may also have other outlines as indicated in FIGS. 5 and 6, the selection of particular contours being made from considerations of design and aesthetic appeal and not affecting in any substantial way the molding and holding action.
While the synthetic resin as a whole will have a mold shrinkage of the order of .004 in./in. as above stated, it has been found possible by utilizing a tang of the type indicated in conjunction with a suitable hollow handle and appropriate manufacturing technique, to produce a knife in which the mold shrinkage around the tang is eliminated and to go even further and to produce an actual expansion of the synthetic resin as it sets, in the space around the tang immediately adjacent the bolster. In this way, all looseness of holding which might progressively increase in use and finally render the knife useless as well as all unsanitary open spaces adjacent the bolster are completely eliminated. Thus, when a knife of the type shown in FIGS. 1 and 6 is cut through so as to permit removing the hollow handle and the examination of the surface of the polystyrene within it, it may be found that some looseness will exist adjacent the butt end of the handle as Well as a certain amount of pitting and checking of the plastic in this area, while in the area at the narrow part of the handle surrounding the tang and adjacent the bolster, the synthetic resin will have the characteristic shiny molded finish, indicating its having been forced under pressure against the metal of the hollow handle as it set. It will be noted that the net shrinkage at any section plane through the handle such as the plane of FIG. 3 is the net effect of the local mold shrinkage of the plastic within that plane, as increased by flow of material out of this plane or counteracted by flow of material into this plane.
As is apparent from the geometry of the situation, the longitudinal shrinkage (parallel to the tang axis) will far exceed the transverse shrinkage (at right angles to the tang axis). The longitudinal shrinkage involves movement of plastic along the tang and this fact is utilized to counteract and even reyerse the effect of transverse shrinkage around the tang. As will be apparent, as soon as the plastic has sufliciently set, it grips around the enlarged end of the tapered tang and longitudinal shrinkage from this point on can only have the effect of forcing the plastic around the tang toward the knife bolster. This longitudinal shrinkage movement counteracts the transverse shrinkage around the tang and to a suificient extent so that the material adjacent the bolster and for a considerable way down the tang may actual-1y be expanded and, hence, be under compression as it sets.
Prior techniques utilized in attempts to manufacture cutlery and similar articles of the type to which the present invention is directed have met with limited success or no success whatever, due to the'absence of suitable techniques for relating assembly operations in a manner so as to obtain proper interaction between the synthetic resin and the handle and blade components and the absence of suitable techniques for obtaining a practical molding cycle. Thermoplastic synthetic resin machines fall basically into three categories: injection molding machines, which inject heated thermoplastic into a die cavity under extremely high pressures (10,000 to 20,000 p.s.i.); extruding machines which produce sheet tubing, etc. by extruding heated thermoplastic through a suitably shaped dieand calender rollers which mechanically work thermoplastic masses to produce a sheet. There has been no chilled (as by a blast of cold air) and then to station 4 where it is discharged. The handle is inserted at station 5 and station 6 may be idle. A typical index time may be one second and a typical filling time 1.4 second, for anoverall cycle of 2.4 seconds, corresponding to a production of fifteen hundred pieces per hour, utilizing generally standard indexing equipment. As will be understood, the indicated operations at the various stations all take place at each indexing movement and as will be apparent to those skilled in the art, the time intervals involved are entirely suitable with relation to the characteristics of the thermoplastic resin which is used.
With respect to the filling operation at station 1, as soon 7 as the indexing movement has been completed, the hanv tang, so that the insertion of the tang displaces synthetic previous equipment or technique for filling a hollow handle with thermoplastic synthetic resin in a manner so as to permit a suitable molding cycle. The filling of the handle by discharging melted plastic in a measured amount from a spout is not suitable, due to entrapment of air in a cycle of any rapidity and a lack of control over the thermoplastic material in slower cycles. The present invention provides a handle filling methotd of novel character consistent with a satisfactorily rapid cycle.
In accordance with the invention, thermoplastic resin is deposited in a handle by a nozzle located, to begin with, close to the bottom of the handle (as, for example, a quarter inch therefrom) and the nozzle and handle are then moved apart at a regulated speed, corresponding to the rate of filling of the handle so that entrapment of air (which would result from too great separation between the nozzle and surface of the liquid plastic) is avoided, while at the same time undue hydraulic pressure (which would result from the immersion of the nozzle below the surface of the liquid plastic) is also avoided. The nozzle may be supplied by otherwise standard injection molding equipment but it will be observed that it operates against substantially atmospheric pressure as compared with the extremely high pressures encountered in injection moldmg.
A typical operating cycle is shown in a schematic manner in FIG. 7 of the drawing, and may involve the use of an index table of usual type having eight positions and rotating through at each step, at intervals such as about two or three seconds and corresponding to a production rate of about fifteen hundred pieces per hour. Using a typical eight position indexing table 10, having eight locations as shown, the cycle may be, as follows:
The blade is loaded in a suitable holder at station 7, passes through an idle station 8 to station 1 where itis filled with the thermoplastic, thence to station 2 where the blade is inserted, thence to station 3 where the handle is resin and squeezes it out between handle and bolster, finally cutting it off as bolster and handle engage. After chilling, the extruded plastic at this point is readily broken off and no finishing operation is ordinarily required.
What is claimed is:
1. Method of forming hollow handled cutlery which comprises injecting melted thermoplastic synthetic resin having substantial mold shrinkage through a nozzle into the handlecommencing at a point close to the bottom of the handle and moving upwardly so as to keepthe nozzle substantially at the level of the synthetic resin as the handle is filled, inserting the end of the tapered tang of a knife blade, which tang is thicker at its said end, in the handle so as to displace some of the synthetic resin therefrom and bring the bolster of the blade against the upper edge of the hollow handle so as substantially to close off the space within the handle, and then setting the synthetic resin so as to contract the same longitudinally of the handle and compress the same around the tang, thereby eliminating transverse mold shrinkage around the tang. 2. Method according to claim 1, in which the said resin is polystyrene.
3. Method according to claim 1, in which the said resin is polystyrene having about .004 in./in. mold shrinkage.
References Cited by the Examiner UNITED STATES PATENTS 6,482 5/49 Ropes 76-104 103,278 5/70 Bailey 30-343 1,030,321 6/12 Muller et al. 76-104 1,167,404 1/16 Hoch 76-104 2,072,581 3/37 Curtis 30-343 2,533,986 12/50 Atterbury 141-263 X I FOREIGN PATENTS 59,078 5/ 13 Austnia.
FRANK E. BAILEY, Primary Examiner.
EDWARD V. BENHAM, FRANK H. BRONAUGH,
Examiners.

Claims (1)

1. METHOD OF FORMING HOLLOW HANDLED CULTERY WHICH COMPRISES INJECTING MELTED THERMOPLASTIC SYNTHETIC RESIN HAVING SUBSTANTIAL MOLD SHRINKAGHE THROUGH A NOZZLE INTO THE HANDLE COMMENCING AT A POINT CLOSE TO THE BOTTOM OF THE HANDLE AND MOVING UPWARDLY SO AS TO KEEP THE NOZALE SUBSTANTIALLY AT THE LEVEL OF THE SYNTHETIC RESIN AS THE HANDLE IS FILLED, INSERTING THE END OF THE TAPERED TANG OF A KNIFE BLADE, WHICH TANG IS THICKER AT ITS SAID END, IN THE HANDLE SO AS TO DISPLACE SOME OF THE SYNTHETIC RESIN THEREFROM AND BRING THE BOLSTER OF THE BLADE AGAINST THE UPPER
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Cited By (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3387368A (en) * 1967-06-07 1968-06-11 William V. Scheck Knife with non-sticking blade
FR2595063A1 (en) * 1986-03-03 1987-09-04 Tarrerias Bonjean Cie Loop-shaped handle for a utensil such as a table article
US5614275A (en) * 1994-02-25 1997-03-25 Chan; Raymond C. L. High-relief, resiliently flexible, composite molded plastic product
US20060117575A1 (en) * 2004-12-03 2006-06-08 Calphalon Corporation Cutlery implement and block
US20060117576A1 (en) * 2004-12-03 2006-06-08 Calphalon Corporation Cutlery implement
US7866050B2 (en) * 2008-05-21 2011-01-11 Shu-Feng Yu Handheld tool structure
US20160270301A1 (en) * 2015-03-19 2016-09-22 Estwing Manufacturing Company, Inc. Machete

Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6482A (en) * 1849-05-29 David n
US103278A (en) * 1870-05-24 Improvement in handles for knives
US1030321A (en) * 1911-09-26 1912-06-25 Arthur Mueller Process of fixing the tangs of table-cutlery, tools, and the like in their handles.
AT59078B (en) * 1911-03-04 1913-05-10 Patent Besteck Werke G M B H Attachment of the interchangeable blade of knives, forks and the like. In the handle.
US1167404A (en) * 1913-08-04 1916-01-11 Otto Hoch Method of making handles for knives, forks, and tools.
US2072581A (en) * 1934-11-14 1937-03-02 Remington Arms Co Inc Cutlery
US2533986A (en) * 1944-09-22 1950-12-12 Precast Building Sections Inc Apparatus and method for filling molds

Patent Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6482A (en) * 1849-05-29 David n
US103278A (en) * 1870-05-24 Improvement in handles for knives
AT59078B (en) * 1911-03-04 1913-05-10 Patent Besteck Werke G M B H Attachment of the interchangeable blade of knives, forks and the like. In the handle.
US1030321A (en) * 1911-09-26 1912-06-25 Arthur Mueller Process of fixing the tangs of table-cutlery, tools, and the like in their handles.
US1167404A (en) * 1913-08-04 1916-01-11 Otto Hoch Method of making handles for knives, forks, and tools.
US2072581A (en) * 1934-11-14 1937-03-02 Remington Arms Co Inc Cutlery
US2533986A (en) * 1944-09-22 1950-12-12 Precast Building Sections Inc Apparatus and method for filling molds

Cited By (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3387368A (en) * 1967-06-07 1968-06-11 William V. Scheck Knife with non-sticking blade
FR2595063A1 (en) * 1986-03-03 1987-09-04 Tarrerias Bonjean Cie Loop-shaped handle for a utensil such as a table article
US5614275A (en) * 1994-02-25 1997-03-25 Chan; Raymond C. L. High-relief, resiliently flexible, composite molded plastic product
US20060117575A1 (en) * 2004-12-03 2006-06-08 Calphalon Corporation Cutlery implement and block
US20060117576A1 (en) * 2004-12-03 2006-06-08 Calphalon Corporation Cutlery implement
US7322113B2 (en) 2004-12-03 2008-01-29 Calphalon Corporation Cutlery implement and block
US7866050B2 (en) * 2008-05-21 2011-01-11 Shu-Feng Yu Handheld tool structure
US20160270301A1 (en) * 2015-03-19 2016-09-22 Estwing Manufacturing Company, Inc. Machete

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