|HAO WAKATIAKIT TELUT HITAM DANUT

US009764485B1

(12) United States Patent (10 ) Patent No.: US 9 , 764 ,485 B1

Hawk et al. (45) Date of Patent: Sep . 19 , 2017
(54) OUT THE FRONT, AUTOMATIC KNIFE 4 ,823 ,463 A * 4 /1989 Lemaire ... ....... B26B 1/08
30 / 162
(71) Applicant: Hawk Designs Inc ., Idaho City, ID 5,139,507 A * 8/1992 Dolgin ............... A61B 17 /3211
30 /151
(US ) 5,371,948 A * 12/1994 Liffiton ................... B26B 5 /001
(72 ) Inventors: Grant Woodrow Hawk , Idaho City, ID 30 / 162
(US); Gavin Dan Hawk , Idaho City , ID 5 ,511,311 A * 4/1996 Collins ............... B26B 29 /025
224 / 232
(US ) 6 ,059,792 A * 5/2000 Josephberg ......... A61F 9/ 00763
604 /22
( 73 ) Assignee : HAWK DESIGNS INC , Idaho City , ID 6 ,085 ,423 A * 7/2000 Marifone ....... ....... B26B 1 /08
(US) 30 / 151
8 ,671,578 B1 * 3/2014 Frazer . . . . . . . . . . . B26B 1/08
( * ) Notice : Subject to any disclaimer, the term of this 30 / 151
patent is extended or adjusted under 35 8, 939,054 B2 * 1/2015 Hawk B26B 1/04
U . S . C . 154 (b ) by 0 days. 30 / 151
9 ,056 ,398 B2 * 6 / 2015 Liao ...... . B26B 1/ 08
9 ,375 ,854 B2 * 6 / 2016 Chu B26B 1/08
( 21) Appl. No.: 15 /297,000 9 , 498 ,889 B1 * 11/ 2016 Hawk ........ B26B 1/ 08
ã 2004 /0261272 A1 * 12/2004 Moser . ..... B26B 1/ 04
(22 ) Filed : Oct. 18 , 2016 30 / 160
Related U .S . Application Data (Continued )
(63 ) Continuation -in -part of application No. 15 /098, 068,
filed on Apr. 13, 2016 , now Pat. No. 9 ,498 ,889 . Primary Examiner — Sean Michalski
(60 ) Provisional application No. 62/ 148 ,127 , filed on Apr. (74 ) Attorney, Agent, or Firm — Parsons Behle &
15 , 2015 . Latimer

(51) Int. CI. (57) ABSTRACT

B26B 1/ 08 ( 2006 . 01)
B26B 1/ 10 ( 2006 .01) A knife include a handle , button ,blade with an integral tang,
(52 ) U .S . CI. locking mechanism within the tang, and thrust mechanism .
CPC . B26B 1/ 08 (2013 .01); B26B 1/ 10 (2013 .01 ) The blade moves between closed and open positions . The
(58 ) Field of Classification Search button may axially slide along the handle . When the blade is
??? ................ B26B 1 /08 ; B26B 1/ 10 in the closed position and locked , movement of the button
USPC ................................... 30 / 151, 162, 160, 335 towards the first handle end releases the locking mechanism
See application file for complete search history. and the thrust mechanism moves the blade to the open
position . A knife includes a stop pin connected to a tang of
(56 ) References Cited a blade and a stop plate positioned within a knife handle . The
U . S . PATENT DOCUMENTS stop plate has two angled surfaces. The stop pin mates with
both angled surfaces and the blade is constrained from
472 ,104 A * 4/1892 Bultzingslowen ..... B26B 1/ 08 movement in two planes .
24/40
845 ,792 A * 3/ 1907 Jenkins .............. B26B 1 /08
30 / 162 18 Claims, 17 Drawing Sheets
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 US 9 ,764,485 B1
Page 2

(56) References Cited

U . S . PATENT DOCUMENTS
2006 /0130340 A1* 6 /2006 Berns ...................... B26B 5 /003
30 / 162
2006 /0207102 A1 * 9/2006 Bezold ............. B26B 1/ 08
30 / 162
2007/0107233 Al* 5/2007 Polei ....................... B26B 5 /003
30 / 162
2007/0175045 A1* 8/ 2007 McHenry ................ B26B 1/08
30 / 162
2014 /0013605 A1 * 1/ 2014 Wu ............... B26B 5 /003
30 / 162
2014 /0101943 Al * 4 /2014 Chu .......... . . . . . . B26B 1/08
30 / 162
2014 /0208596 A1* 7 / 2014 Constantine .............. B26B 1/08
30 / 162
* cited by examiner
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 US 9 , 764,485 B1
OUT THE FRONT, AUTOMATIC KNIFE c ) The force required to both propel the blade to a reliable
lockup and to overcome the counter force of a spring
CROSS -REFERENCE TO RELATED loaded lock is limited to the force available from
APPLICATION operator input. Generally speaking , the closer a design
5 approaches reliability , themore difficult it is to activate
This application is a continuation - in -part of U .S . appli and thus may be perceived as less desirable .
cation Ser. No. 15 /098 ,068, entitled “ Double Action , Out d ) The complex nature of the mechanical mission most
The Front, Automatic Knife ,” filed Apr. 13 , 2016 , which often results in small , difficult to manufacture , preci
claims the benefit of U . S . Provisional Patent Application sion parts , tending to push costs above the level of
Ser. No. 62 / 148 , 127 filed on Apr. 15 , 2015 and entitled 10 economic feasibility .
“ Double Action , Out The Front, Automatic Knife ,” the Other disadvantages exist. The many design issues have
contents of which are hereby incorporated by reference in resulted in known OTF knives that may be of a clunky,
their entireties. disproportionate , unwieldy configuration , difficult to
manipulate , under -powered to the point of unreliability, and
FIELD OF THE DISCLOSURE 15 terminating in a lock up that ' s both weak and wobbly . As a
consequence , known OTF knives are generally considered
The embodiments described below are an improvement to to possess more theatrical value than practical value .
the type of automatic opening knife that propels the blade
outof the front of the handle, in a linear direction . Generally SUMMARY
referred to as an out-the - front automatic or OTF . 20
The present disclosure is directed to an OTF knife that
BACKGROUND overcomes some of the problems and disadvantages dis
cussed above.
Out-the- front automatic knives are of two principles One embodiment of a knife comprises a handle , button ,
types. Double action and single action . Both share the 25 blade , locking mechanism , and thrust mechanism . The
common features of a handle enclosure that contains a blade handle has a first end and a second end . The button may be
in a closed position . Automatic opening is achieved by connected to the handle and be configured to axially slide
activating a trigger mechanism , which releases the stored along a surface of the handle. The blade has an integral tang .
energy of a compressed spring. Thereby propelling the blade The blade and tang are configured to move between a closed
along a linear path , out the front of the handle , to an open 30 position wherein the blade and tang are positioned within the
and locked position . handle and an open position wherein the blade extends from
Single action versions are limited to releasing the spring the first end of the handle. The locking mechanism is
loaded blade by a trigger mechanism , thereby allowing the positioned within the tang. When the blade is in the closed
blade to fly forward to lock -up. Single action mechanisms position and selectively locked , actuation of the button
rely upon a secondary operation to close and reload the blade 35 selectively releases the locking mechanism and the thrust
against spring pressure, in preparation for the next firing. mechanism moves the blade to the open position , the blade
Double action , out-the- front automatic knives perform then being selectively locked in the open position by the
both the automatic opening of the blade and the automatic locking mechanism . The actuation may be movement of the
closing of the blade with a single sliding button , activated by button towards the first end of the handle . In a double action
the user. The single sliding button being pushed in the 40 knife , when the blade is in the open position and selectively
direction desired for the blade to travel performs two pri- locked by the locking mechanism , movement of the button
mary functions; the first portion of the button travel results towards the second end of the handle selectively releases the
in the loading of a main spring in preparation for releasing locking mechanism and the thrust mechanism moves the
the blade and the last portion of button travel serves to blade to the closed position , the blade then being selectively
trigger the release . 45 locked by the locking mechanism .
Designers of out-the - front, double action , automatic The locking mechanism may include a lock bar, rocker
knives face a wide array of difficult mechanical challenges. bar, and ball. The lock bar has a control pin and a cavity . The
Among these challenges are: lock bar is configured to axially move within a cavity in the
a ) The limitations of available space to house the mecha - tang. The rocker bar has a control pin . A portion of the rocker
nism required to perform the primary functions as set 50 bar is connected to the lock bar and the rocker bar is
forth above . Users of out-the- front automatic knives configured to pivot about an axis within a cavity in the tang.
place great importance on what is generally referred to Rotational movement of the rocker bar axially moves the
as “ blade to handle ratio ” . In other words, the smaller lock bar. When the locking mechanism is unlocked , the ball
the handle in relation to the blade , the more desirable is positioned within the cavity of the lock bar. When the
the design . 55 lockingmechanism is locked , the ball is positioned between
b ) Because the blade must be essentially set free to fly tothe lock bar and a dowel pin connected to the handle . The
its destination , within the loosely defined limits of ball may not be positioned within the cavity of the lock bar
linear guides, to either a locked open or locked closed when the locking mechanism is locked . The knife may be
position , means that the locking method must account configured to attach to the muzzle end of a firearm .
for restricting all six degrees of freedom inherent in a 60 The knife may include an upper unlocking control hook
free floating blade . The lack of a solid lock up is a key and a lower unlocking control hook . The knife may include
defect, common to known out-the- front automatic an upper locking control hook and a lower locking control
(OTF ) knives , which results in an undesirable amount hook . Actuation of the button controls movement of the
ofmovement or play in the open " locked ” blade. For at upper and lower unlocking control hooks. When the blade is
least this reason , knives of this category , although 65 in the locked open position , movement of the upper unlock
providing fascinating entertainment, are seldom taken ing control hook towards the second end of the handle
seriously . engages the control pin on the rocker bar to pivot the rocker
 US 9, 764, 485 B1
bar to move the lock bar towards the first end of the handle One embodiment of a knife comprises a handle , blade,
to permit the ball to move into the cavity on the lock bar to locking mechanism , and thrust mechanism , and switch . The
selectively release the blade from the locked open position . blade has a tang and is configured to axially slide within the
When the blade is in the locked closed position , movement handle between an open position with at least a portion of
of the lower unlocking control hook towards the first end of 5 the blade extending from the handle and a closed position
the handle engages the control pin on the locking barmoving with the blade within the handle . The thrust mechanism is
the locking bar towards the first end of the handle to permit configured to actuate the blade from the closed position to
the open position . In a double action knife , the thrust
the ball to move into the cavity on the lock bar to selectively mechanism
release the blade from the locked closed position . is configured to actuate the blade between the
The thrust mechanism may include a shuttle plate con nism is within and
10 open position the closed position . The locking mecha
nected to the button . The shuttle plate may include a first has a lock position and of
the tang the blade . The locking mechanism
an unlock position . The lock position
end , a second end , a lower profile , and an upper profile. The
lower profile is configured to engage the lower unlocking restricts movement of the blade with respect to the handle
and the unlock position permits movement of the blade with
control hook . When the blade is in the locked closed4 15 respect to the handle . The same locking mechanism is
position , movement of the shuttle plate engages and moves configured to selectively lock the blade in the open position
the lower unlocking control hook . The upper profile is and closed position . The switch has a first position and a
configured to engage the upper unlocking control hook . second position . Movement of the switch from the first
When the blade is in the locked open position ,movement of position to the second position selectively actuates the
the shuttle plate engages and moves the upper unlocking 20 locking mechanism from the lock position to the unlock
control hook . position and the thrust mechanism moves the blade from the
The thrustmechanism may include an upper thrust block closed position to the open position . In a double action knife ,
positioned at the first end of the shuttle plate , a lower thrust movement of the switch from the second position to the first
block positioned at the second end of the shuttle plate , and position selectively actuates the locking mechanism from
a plurality of springs positioned between the upper thrust 25 the lock position to the unlock position and the thrust
block and the lower thrust block . Movement of the shuttle mechanism moves the blade from the open position to the
plate when the blade is in the locked closed position may closed position .
increase the distance between the upper thrust block and the Movement of the blade between the open position and the
lower thrust block . closed position may actuate the locking mechanism from the
The tang of the blade may include a drive pin . When the 30 unlock position to the lock position . The knife may be
blade is in the locked open position , the drive pin engages configured to attach to the muzzle end of a firearm . The knife
the upper thrust block . When the blade is in the locked may include a stop pin connected to the tang and a stop plate
closed position , the drive pin engages the lower thrust block . positioned within the handle . The stop plate has a plurality
The knife may include a stop pin connected to the tang and of angled surfaces. The stop pin engages the plurality of
a stop plate positioned within the handle . The stop plate has 35 angled surfaces when the blade is in the open position . The
a first angled surface and a second angled surface . The stop engagement of the stop pin with the plurality of angled
pin is configured to mate with both the first angled surface surfaces restricts movement of the blade in at least two
and the second angled surface . When the stop pin mates with planes.
both the first and second angled surfaces the blade is The locking mechanism may include a ball positioned in
constrained from movement in two planes. 40 a ball pocket of the tang of the blade . The ball extends
One embodiment of a knife comprises a handle , a button , beyond a surface of the tang and contacts a portion of the
a thrust mechanism , a blade , a stop pin , and a stop plate . The handle to restrict movement of the blade with respect to the
button may be the surface of the handle . The button may be handle when the locking mechanism is in the lock position .
movable between an open position and a closed position . The locking mechanism may include a lock bar configured
The blade has an integral tang connected to the thrust 45 to axially move along the tang. The lock bar has a recess
mechanism and the button . When the button is actuated , the configured to receive the ball when the locking mechanism
thrust mechanism moves the blade from being positioned is in the unlock position and a ramp adjacent the recess. The
entirely within the handle to a position extending from an ramp is shaped to guide the ball from the recess to the ball
end of the handle . The button may be actuated by moving pocket with axialmovement of the tang. The locking mecha
from the closed position to the open position . In a double 50 nism may include a rocker bar pivotally connected to the
action knife , when the button is moved from the open tang of the blade . The rocker bar is configured to engage the
position to the closed position , the thrust mechanism moves lock bar and convert rotationalmotion of the rocker bar into
the blade from a position extending from the end of the axial motion of the lock bar.
handle to being positioned within the handle . The stop pin is The knife may include an upper locking control hook , an
connected to the tang. The stop plate is positioned within the 55 upper unlocking control hook , a lower locking control hook ,
handle and has a first angled surface and a second angled and a lower unlocking control hook . The switch may control
surface. The stop pin is configured to mate with both the first movement of the upper unlocking control hook and the
angled surface and the second angled surface when the blade lower unlocking control hook . The upper locking control
is in the position extending from the end of the handle . When hook is positioned to engage a portion of the lock bar when
the stop pin mates with both the first and second angled 60 the blade slides from the closed position to the open posi
surfaces, the blade is constrained from movement in two tion . The lower locking control hook is positioned to engage
planes . a portion of the rocker bar when the blade slides from the
The first angled surface may be substantially at 24 degrees open position to the closed position . When the blade is in the
with respect to a direction of travel of the stop pin and a open position , movement of the upper unlocking control
horizontal axis of the blade . The second angled surface may 65 hook engages a portion of the rocker bar. When the blade is
be substantially at 45 degrees with respect to an axis of the in the closed position , movement of the lower unlocking
stop pin and the horizontal axis of the blade . control hook engages a portion of the lock bar.
 US 9, 764, 485 B1
The thrust mechanism may include a shuttle plate con FIG . 31 is a bottom plan view of the blade and tang with
nected to the switch . The shuttle plate may include a first lock mechanism installed , as it approaches the locked closed
end , a second end , a lower profile configured to engage the position .
lower unlocking control hook , and an upper profile config FIG . 32 is a bottom plan view of the blade and tang in the
ured to engage the upper unlocking control hook . The thrust 5 locked closed position .
mechanism may include an upper thrust block positioned at FIG . 33 is a bottom plan view of the blade and tang
the first end of the shuttle plate, a lower thrust block positioned
posit within the center section .
positioned at the second end of the shuttle plate , and at least plateFIGin. 34place
is a top plan view of the bottom cover with a stop
.
one spring positioned between the upper thrust block and the
lower thrust block .Movement of the shuttle plate when the 10 FIG . 35 is a cross section view as indicated in FIG . 33.
FIG . 36 is a cross section view as indicated in FIG . 34 .
blade is in the open or closed position increases the distance FIG . 37 is a combined cross section of FIGS. 35 and 36 .
between the upper thrust block and the lower thrust block . FIG . 38 is a top plan view of a stop plate .
The tang of the blade may include a drive pin configured to
FIG . 39 is a cross section view as indicated in FIG . 38.
selectively engage the upper thrust block and lower thrust 15 FIG . 40 is a bottom plan view of a shuttle plate .
block . FIG . 41 is an edge view of the shuttle plate .
BRIEF DESCRIPTION OF THE DRAWINGS FIGS. 42 , 43, and 44 are cross sectional views of the
shuttle plate of FIG . 40.
FIG . 45a shows a plan view of a thrust block .
The disclosure may be better understood by reference to 20 FIG . 45b shows a side view of a thrust block .
the following detailed description when taken in conjunction FIG . 45c shows an end view of a thrust block .
with the following drawings. FIG . 46 is a plan view of the thrust block , spring anchor
FIG . 1 is a top plan view of an OTF knife , according to screws, main springs and guide pin before sub -assembly .
one embodiment of the present disclosure , showing a blade FIG . 47a is an end view of thrust block , spring anchor
in the closed position . 25 screws, main springs and guide pin after sub - assembly .
FIG . 2 is a top plan view of the knife showing the blade FIG . 47b is a side view of thrust block , spring anchor
in an open position . screws, main springs and guide pin after sub -assembly.
FIG . 3 is a side view of the knife showing the blade in an FIG . 48 is a cross sectional view of the sub -assembly of
open position and the orientation of top and bottom as used FIG . 47 .
hereinafter. 30 FIG . 49 is a bottom plan view of the shuttle plate
FIG . 4 shows a bottom plan view of the center section of assembly with thrust blocks and main springs installed .
the knife of FIG . 3 FIG . 50 is a short axis cross sectional view of FIG . 49 .
FIG . 5 shows a top plan view of the same center section FIG . 51 is a long axis cross section of FIG . 49.
as shown in FIG . 4 FIG . 52a is a top plan view of a shuttle plate assembly .
FIGS. 6 , 7 , and 8 are cross sectional views of the 35 FIG . 52b is an end view of a shuttle plate assembly .
corresponding cross sections as indicated in FIG . 4 FIG . 53a is a partial top plan view of blade and tang .
FIG . 9 is a bottom view of the top handle cover of FIGS. FIG . 53b is an end view of blade and tang .
1 through 3 FIG . 54 is a partial top plan view of shuttle plate assem
FIG . 10 is a top view of the top handle cover. bly .
FIGS. 11 , 12 , 13 , and 14 are cross sectional views of the 40 FIG . 55a is a cross sectional view of FIGS. 53 and 54
corresponding cross sections indicated in FIG . 9 . combined , with the blade in the locked open position .
FIG . 15 shows a top plan view of the bottom handle cover FIG . 55b is the same view of the same parts as FIG . 55a
of FIG . 3 but with the shuttle plate loaded against spring tension
FIG . 16 shows a bottom view of the bottom handle cover. preparatory to firing.
FIGS . 17 and 18 are cross sectional views of the corre - 45 FIG . 56 is a bottom plan view of top handle cover
sponding cross sections as indicated in FIG . 15 . containing shuttle plate assembly .
FIG . 19 is a side view of the blade and tang . FIG . 57 is a cross sectional view of FIG . 56 .
FIG . 20 is a bottom plan view of the blade and tang . FIG . 58 is top plan view of top handle cover showing
FIGS . 21 , 22 , and 23 are cross sectional views of the sliding button installed .
corresponding cross sections indicated in FIG . 20 . 50 FIG . 59 is a cross sectional view of FIG . 58 .
FIG . 24 is a cross sectional side view of the long axis of FIG . 60a shows a bottom plan view of control hook .
a blade and tang. FIG . 60b shows a right side , side view of the control hook
FIG . 25 is a bottom plan view of the blade and tang shown of FIG . 60a .
in FIG . 24 showing an assembled lock mechanism . FIG . 60c shows an end view of the control hook of FIG .
FIG . 26a is a side view of a lock bar. 55 60a .
FIG . 26b is an end view of a lock bar . FIG . 61a shows a bottom plan view of a de -locking
FIG . 26c is a bottom view of a lock bar. control hook .
FIG . 27a is a side view of a rocker bar. FIG . 61b shows a left side , side view of the de - locking
FIG . 27b is an end view of a rocker bar. control hook of FIG . 61a .
FIG . 27c is a bottom view of a rocker bar . 60 FIG . 610 shows an end view of the de- locking control
FIG . 28 is a cross section of the assembled lock mecha - hook of FIG . 61c.
nism as indicated in FIG . 25 . FIG . 62 shows a bottom plan view of the top cover with
FIG . 29 is a bottom plan view of the blade and tang with the shuttle plate and four control hooks installed , along with
lock mechanism installed , as the blade and tang approach the four control hook springs .
locked open position . 65 FIG . 63 shows the same view and same parts as FIG . 60
FIG . 30 is a bottom plan view of the blade and tang in the but with the shuttle plate at the opposite end of its travel.
locked open position . FIG . 64 is a cross sectional view of FIG . 63 .
 US 9, 764, 485 B1
FIG . 65 is a partial bottom plan view of top cover with FIGS. 9 through 14 illustrate the details of top handle
shuttle plate , control hooks , and control hook springs frame cover 6 . FIG . 9 is a bottom plan view of top handle
installed . frame cover 6 indicating the relative locations of internal
FIG . 66a is a cross sectional view as indicated in FIG . 65 . features. Control hook pockets 24 delineate the boundaries
FIG . 66b is the same cross section as FIG . 66a , but 5 of a cavity, providing for the control of a linear, forward and
reoriented to indicate alignment of assembly . rearward motion of control hooks 66a , 666, 68a, and 68b to
FIG . 67 is a partial top plan view of handle center section be shown in subsequentdrawings. Control hook spring stops
with blade installed . 26 are bosses , left standing in the control hook pockets 24 ,
FIG . 68 is a cross sectional view as indicated in FIG . 67 . to serve as spring abutments for control hook springs 96 , to
While the disclosure is susceptible to various modifica - 10 be shown later. The shuttle plate pocket 28 also captures and
tions and alternative forms, specific embodiments have been constrains to a linearmotion , the shuttle plate 80 , also shown
shown by way of example in the drawings and will be later.
described in detail herein . However, it should be understood FIG . 10 is a top plan view of top handle cover 6 showing
that the disclosure is not intended to be limited to the button slot 12 and fastener locations 16 and smooth bores to
particular forms disclosed . Rather, the intention is to cover 15 accept threaded inserts 18 .
all modifications, equivalents, and all alternatives falling FIGS. 11 through 14 are cross sectional views as indicated
within the scope of the disclosure as defined by the appended in FIG . 9 further illustrating internal features of top handle
claims. cover 6 .
FIGS. 15 through 18 illustrate the details of bottom handle
DETAILED DESCRIPTION 20 frame cover 8 . FIG . 15 is a top view of the bottom handle
frame cover 8 , indicating the relative locations of internal
One embodiment ofthe current disclosure is illustrated in features . The stop plate pocket 30 , shown in FIGS. 15 and
FIGS. 1 through 3 . FIG . 1 is a top plan view showing an 17 , provides a positive location for stop plate 70 , shown
OTF knife 1 with a blade 2 in a retracted , closed position . In later. The stop pin clearance groove 32, shown in FIGS. 15
FIG . 1 , a sliding button 10 is shown in a rearmost retracted 25 and 18 , allows for clearance of stop pin 48 (not shown in
position , relative to a sliding button slot 12 . A perimeter FIGS. 15 - 18 ), protruding from blade tang 34 , as blade 2 and
configuration is shown of a handle frame top cover 6 which integral blade tang 34 are propelled forward and back , upon
encompasses the internal mechanism and provide sufficient opening and closing ofOTF knife 1 . Blade 2 and blade tang
area to locate fasteners 14 . Fasteners secure the top handle 34 , along with stop pin 48 are shown later. FIG . 16 is a
cover 6 , a bottom handle cover 8 , and a handle frame center 30 bottom plan view of bottom handle frame cover 8 .
section 4 . The shape and configuration of the blade 2 , sliding FIGS. 19 through 23 illustrates various details of theblade
button 10 , sliding button slot 12 , handle frame 4 , and top 2 and integral tang 34 in regardsto the machining of pockets,
cover 6 is for illustrative purposes only and may be varied holes and slots to accommodate a locking mechanism . FIG .
within the scope of this disclosure as would be appreciated 20 is a top plan view of blade 2 and blade tang 34 , including
by one of ordinary skill in the art having the benefit of this 35 a locking ball 36 . Locking ball 36 is used to lock the blade
disclosure . 2 and integral blade tang 34 in both the forward locked open
FIG . 2 shows the OTF knife 1 with the blade 2 in the position and the rearward locked closed position . The lock
forward extended and locked position . The sliding button 10 ing ball 36 being subject to manipulation by a locking
is shown in the forward position relative to sliding button mechanism , to be disclosed in subsequent drawings , is
slot 12 . FIG . 3 shows a side view of the OTF knife 1 , 40 caused to travel in a limited linear path between the
illustrating the relative position of top handle cover 6 , unlocked position shown in FIG . 20 to an alternate locked
bottom handle cover 8 , and handle frame center section 4 . In position as shown in the cross sectional view of FIG . 22 in
the following drawings, all references to point of view will accordance with arrow (a ). Stop pin bore 38 positions and
coincide with FIGS. 1 , 2 , and 3, in regards to the top , side, secures stop pin 48 (not shown in FIGS . 19 - 23 ), which limits
and bottom views. Forward will indicate the direction that 45 the travel of blade 2 and integral blade tang 34 , at a
blade 2 emerges from handle assembly 4 , 6 , and 8 , while predetermined point upon reaching the open position of
rearward will indicate the direction that blade 2 travels in blade 2 . Control pin slot 40a , allows for forward and
retracting back into handle assembly 4 , 6 , and 8 . rearward travel of control pin 56 (not shown in FIGS.
FIGS. 4 through 8 illustrate the details of handle center 19 -23 ) . Control pin slot 406 , allows for the rotational travel
section 4 indicating the position of blade guide rails 22 50 of control pin 57 ( not shown in FIGS. 19 - 23 ), as described
which supports and guides blade 2 (not shown in FIGS. 4 - 8 ) below . Rocker pocket 42 is a pocket, machined into the
as blade 2 is propelled forward and rearward . Two dowel blade tang 34 , configured to position and allow limited
pins 20a and 20b are pressed into machined pockets cut into rotational movement of rocker bar 52 (not shown in FIGS.
center section 4 at the locations indicated . The dowel pins 19 - 23 ) . Rocker bar pivot point boss 44 is left standing upon
20a and 20b serve as stationary stops , against which a 55 themachining of rocker bar pocket 42 to provide a fixed axis
moving locking ball 36 , to be described later, comes into of rotation for rocker bar 52 (not shown in FIGS. 19 -23).
engagement, thereby locking blade 2 , in both the forward Lock bar pocket 46, is a pocket machined into blade tang 34 ,
extended position and the rearward retracted position . configured to position and allow limited forward and rear
FIG . 5 shows a top plan view of handle center section 4 . ward travel of lock bar 50 (not shown in FIGS . 19 - 23 ) .
Fastener holes 16 are configured to receive fasteners 14 60 FIGS. 24 through 28 illustrate the configuration and
(shown in FIG . 2 ) while a smooth bore to accept threaded arrangementof a locking mechanism . FIG . 26a shows a side
inserts are shown at 18 . It is appreciated that other types of view of a lock bar 50 . FIG . 26b shows an end view of the
fasteners may be used , such as, but not limited to , rivets, lock bar 50 . FIG . 26C shows a bottom view of lock bar 50 .
screws, welds , and pins. The lock bar 50 may include a pressed in control pin 56 that
FIGS. 6 through 8 are cross sectional views of handle 65 protrudes a predetermined distance from the top surface of
center section 4 as indicted in FIG . 4 showing the relative the lock bar 50 and remains flush to the bottom surface of
positions of dowel pins 20a and 20b and blade guide rails 22. lock bar 50 . Alternatively , control pin 56 may be integral to
 US 9, 764,485 B1
10
the lock bar 50 . Also shown is a lock bar ramp 54 positioned Control pin 57 is shown in FIGS. 25 , 27a -c , and 28 as
on the side of lock bar 50 , at the location indicated in FIG . installed in rocker bar 52 . FIG . 25 . shows how control pin
260. Lock bar ramp 54 is established at a slight angle slot 405 allows for the limited rotation of rocker bar 52 ,
( approximately 70 ) with respect to the controlled linear path along with its installed control pin 57 . Rocker bar 52 is
of lock bar 50 . As lock bar 50 moves from the forward 5 rotabably positioned on rocker pivot point boss 44 through
position to the rearmost position within lock bar pocket 46 , rocker bar pivot pointbore 58 . As rocker bar 52 rotates about
lock bar ramp 54 engages locking ball 36 , driving lock ball tothemoveaxis of rocker pivot point boss 44, control pin 57 is made
36 in the direction ofarrow (a ) of FIG . 28 , thereby achieving slot 40b . forward or rearward within the curved control pin
a locked condition by virtue of the engagement of lock ball
36 with dowel pin 20a (not shown ). As lock bar 50 moves 10 handle FIGS. 29 and 30 show a partial bottom plan view of
center section 4 , containing integral tang 34 , with the
from the rearward position to the forward position within
lock bar pocket 46 , lock bar ramp 54 relieves the wedging locking mechanism and control hooks 66a and 68a in place .
force and allows locking ball 36 to occupy the space 2 , and itsillustrates
FIG . 29
combined
a point in time during the travel of blade
assembly, slightly before forward open
provided by lock ball relief cavity 55 , thereby achieving a 15 lock
de -locked condition . A lock bar pocket 62 provides for a FIG . 30 illustrates the same blade 2 and its assembly as in
positive engagement with a rocker bar tongue 64 of a rocker FIG . 29 , in its final position of forward open lock up . It
bar 52, shown in FIGS . 27a - c . should be noted , that portions of the control hooks 68a and
FIGS . 27a -c shows a rocker bar 52 in three views; a side 66a are shown as dotted lines , to indicate their true location ,
view , an end view and a bottom plan view . The rocker bar 20 as being on the opposite side of handle center section 4 and
52 may include a pressed in control pin 57 that protrudes a integral tang 34 .
predetermined distance from the top surface of the rocker Because blade 2 , and its included locking mechanism , is
bar 52 while remaining flush with the bottom surface of propelled to both the open and closed positions, by a spring
rocker bar 52 . Alternatively, control pin 57 may be integral powered propulsion system , discussed herein , it may be
to the rocker bar 52 . A rocker tongue 64 provides a means 25 beneficial to minimize drag or friction as the blade 2 and its
for a positive engagement with the aforementioned lock bar entire assembly fly freely . In the present disclosure , how
pocket 62 of lock bar 50 , shown in FIGS. 26a - c . The ever, it might be beneficial that the spring loading of the ball
interface between the lock bar pocket 62 of lock bar 50 and does not take place until the last possible moment of its
rocker tongue 64 of rocker bar 52 is closely controlled along travel towards lock up . This result may be achieved by the
the long axis of lock bar 50, but provided with sufficient 30 method illustrated in FIGS. 29 and 30 , and explained below .
clearance along the short axis of lock bar 50 to allow for the In FIG . 29 it can be seen that at this point in time, when
arc of rotation of rocker bar tongue 64 of rocker bar 52 . blade 2 and its assembly are traveling forward in the
Additionally a rocker bar pivot point bore 58 , which may be direction of arrow (b ), the control pin 56 of lock bar 50 will
established by a hole bored through rocker bar 52, provides come into contact with control hook 68a. Because control
a fixed center of rotation when engaged with a rocker pivot 35 hook 68a is spring loaded (best shown in FIGS. 62 and 63 )
point boss 44 , shown in FIGS. 24 , 25 , and 28 . in the direction of arrow (d ), lock bar 50 will also be driven
FIG . 25 is a bottom plan view of blade 2 and integral tang in the direction of arrow (d ) as blade 2 is driven toward
34 , with the locking mechanism in place . Rocker bar pivot locked open . All ofwhich in turn will force lock ball 36 into
point bore 58 of rocker bar 52 is engaged with rocker pivot engagement with dowel pin 20a , by virtue of lock bar ramp
point boss 44 . Lock ball 36 is shown partly protruding from 40 54 , resulting in the locked open configuration as shown in
a pocket machined in integral tang 34 . The pocket may be FIG . 30 . As this transition to locked open takes place , rocker
machined by the use of a ball end cutter that starts a cut from bar 52 and its installed control pin 57 , is caused to rotate
a point within the lock bar pocket 46 and stops short of counter clockwise by virtue of the engagement between
breaking through the side surface of blade tang 34 , thereby rocker bar tongue 64 of rocker bar 52 and lock bar pocket 62
establishing a shoulder for the purpose of containing locking 45 of lock bar 50 . Rocker bar 52 rotates about a fixed center of
ball 36 . The lock bar 50 is constrained within integral tang rotation as established by rocker bar boss 44 . The exact end
34 by an elongated machined lock bar pocket 46 limiting point of travel of blade 2 and integral tang 34 is determined
travel of the lock bar 50 to a forward and rearward direction . by contact between stop pin 48 and stop plate 70 (not shown
Rocker tongue 64 of rocker bar 52 engages the rocker bar in FIGS . 29 and 30 ) .
pocket 62 of lock bar 50 . Lock bar 50 and rocking bar 52 are 50 It should be noted that in the locked open position as
shown in FIG . 25 in their mid -travel position . When lock bar illustrated in FIG . 30 , blade 2 may be unlocked by the
50 is moved to its full forward position the lock ball 36 is sliding of control hook 66a in the direction of arrow (j) to
free to occupy a ball relief cavity 55 of lock bar 50 . When engage control pin 57 , which will then rotate rocker bar 52
the lock bar 50 is moved to its full rearward position , lock in a clockwise direction . As a result of the rotation of rocker
bar ramp 54 forces lock ball 36 to protrude at least partially 55 bar 52, locking bar 50 will be forced in the direction of arrow
from integral tang 34 , resulting in a locked engagement with ( g ) via the engagement between lock bar pocket 62 and
a dowel pin 20a or 20b shown in FIGS. 4 , 6 , and 8 . Stop pin rocker bar tongue 64 , thereby allowing lock ball 36 to recede
48 is shown in FIGS. 24 , 25 and 28 . A drive pin extension back into lock ball relief cavity 55 , which in turn unlocks
60 of stop pin 48 is shown in FIGS. 24 and 28 . The drive pin blade 2 allowing it to respond to new input.
extension 60 provides a point of engagement for a thrust 60 FIGS. 31 and 32 illustrate the closed rearward locking
block 84 ( not shown in FIGS . 25 -28). Thrust block 84 is a sequence of blade 2 and its lock assembly. FIG . 31 shows
spring powered component that drives blade 2 and integral blade 2 in its final approach toward the locked closed
tang 34 toward open and closed . FIG . 24 shows stop pin 48 position as shown in FIG . 32 .
positioned in stop pin bore 38 (best shown in FIG . 20 ) with As shown in FIG . 31, as blade 2 nears the locked closed
the protrusion of drive pin extension 60 positioned above the 65 position , control pin 57 contacts control hook 68b which is
top surface of blade tang 34 to allow for contact with thrust spring loaded in the direction of arrow (n ) thereby rotating
block 84 . rocking bar 52 counter clockwise , which moves lock bar 50
 US 9 ,764 ,485 B1
11
in the direction of arrow (m ) via the engagement between the mating surfaces of the stop pin 48 as well as the angles
lock bar pocket 62 and rocker bar tongue 64 , forcing lock of the first and second angled surfaces may be varied from
ball 36 into engagement with dowel pin 205 by virtue of lock the configuration as shown in FIGS. 35 -38 and still provide
bar ramp 54, resulting in the locked closed position shown locking in two planes at once as would be appreciated by one
in FIG . 32 . In the locked closed position shown in FIG . 32 , 5 of ordinary skill in the art having the benefit of this disclo
blade 2 may be unlocked by the sliding of control hook 66b sure .
in the direction of arrow (p ) thereby allowing lock ball 36 to FIGS. 40 through 44 illustrate the details of a shuttle plate
recede back into lock ball relief cavity 55 (best seen in FIG . 80 . FIG .40 shows a bottom plan view of the shuttle plate 80 ,
26c), which in turn unlocks blade 2 allowing it to respond to indicating the location of two shuttle plate trip bosses 72a ,
new input. Stop pin 48 is not utilized in the closed position 10 and 72b , left standing for the purpose of actuating the
shown in FIG . 32 . Travel of blade 2 and blade tang 34 is de- locking control hooks 66a and 66b shown in FIGS. 29
stopped by its contact within the limits of handle center through 32 . Shuttle plate 80 is located within shuttle plate
section 4 , as defined by blade guide rail and pocket 22 (not pocket 28 ofhandle frame top cover 6 ( shown in FIGS. 9 and
shown in FIGS . 31 and 32 ). Further , travel of blade 2 and
blade tang bar
34 is52limited agement of
by the engagement of control
control pin 57
pinhook
57 1515 114 -:14 ), which constrains the movement ofshuttle plate 80 to
of rocker
of rocker bar 52 with
with spring loaded locking
spring loaded locking control
control hook a linear travel path . The linear movement of shuttle plate 80
68b , as described below . activates de - locking control hooks 66a and 66b (best seen in
As discussed above , known OTF knives are unable to lock FIGS . 62 and 63). When shuttle plate 80 is moved forward ,
up the open blade and adequately restrict all six degrees of in response to operator input , shuttle trip boss 72b contacts
freedom , resulting in undesirable play in the blade 2 . The 20 the de-locking shoulder 106 of de -locking control hook 66b,
present disclosure provides a system that more adequately which will set in motion the de -locking cycle , thereby
secures an open blade in all six degrees of freedom . FIGS. releasing blade 2 to be propelled to the open position . When
33 through 39 illustrate a system , which may be referred to shuttle plate 80 is made to move rearward , in response to
as the stop and wedge system , wherein the open blade of an operator input, shuttle trip boss 72a will come into contact
OTF automatic knife is held more ridged in all six degrees 25 with the de -locking shoulder 106 of de - locking control hook
of freedom . 66a (shown in FIG . 61a ), setting in motion the de -locking
FIG . 33 shows a bottom plan view of handle center cycle , releasing blade 2 to be propelled to the closed
section 4 with blade 2 and integral tang 34 , in the locked position . Also shown are the main spring pockets 74 , guide
open position . The locking mechanism of integral tang 34 pin channels 76 , and sliding button mounting holes 78 .
discussed above has been omitted for the sake of clarity. 30 Spring loaded control hooks 68a and 686 , and de -locking
Handle center section 4 includes a plurality of smooth bores control hooks 66a and 66b , are supported by and guided by ,
18 configured to accept threaded inserts . control hook cavity 82 as provided by the configuration of
FIG . 34 shows a top plan view of bottom handle cover 8 shuttle plate 80 . Main spring pockets 74 provide clearance
with stop plate 70 in place . FIG . 35 and FIG . 36 are cross for the location of main springs 94 ( not shown in FIGS.
sections of FIGS. 33 and 34 respectively . FIG . 35 shows the 35 40 - 44 ).Guide pin channels 76 control the linear motion and
relative position of blade tang 34 with respect to blade guide alignmentof a thrust block 84 and guide pin 88 combination
rails 22 . Stop pin 48 is shown protruding beyond the surface (not shown in FIGS. 40 -44 ). Sliding button mounting holes
of blade tang 34 , the free travel of which is accommodated 78 provide a means for fastening a sliding button 10 (not
for by the presence of stop pin clearance grove 32 of bottom shown in FIGS. 40 -44 ) to be manipulated by an operator.
handle cover 8 , shown in FIGS. 36 and 34 . When assembled , 40 FIGS. 45a through 48 illustrate the details of thrust blocks
the cross section ofhandle center section 4 shown in FIG . 35 84 and a method of attachment to main springs 94 by the use
follows the path of arrow (t) to join the cross section of of threaded spring anchors 92 . FIGS. 45a - c show a top , side
bottom handle cover 8 shown in FIG . 36 , resulting in the and end view of thrust block 84 . FIG . 46 is a disassembled
conjoined cross section of handle center section 4 and view showing thrust block 84 , with hidden lines indicating
bottom handle cover 8 shown in FIG . 37 , illustrating the 45 the location of spring anchor holes 86 , and hidden lines
relative position ofrelated components . FIG . 38 is a top plan showing location of guide pin hole 90 in thrust block 84 . As
view of stop plate 70 and its relationship to stop pin 48 . FIG . shown in FIGS. 46 , 47a and 47b , threaded spring anchors
39 is a cross section view of FIG . 38 in elevation , further 92 , which contain threads of a thread count-per - inch corre
indicating the relationship of stop pin 48 and stop plate 70 . sponding to the coils per inch of the main springs 94 , are
Stop plate 70 has a first angled surface 71 shown in FIG . 38 50 threaded into main springs 94 through spring anchor holes
and a second angled surface 73 shown in FIGS . 36 and 39 . 86 in the combined directions of arrows ( x ) to ( y ). Also
When blade 2 and stop pin 48 travel forward to the locked shown in FIG . 46 , guide pin 88 may be pressed into guide
open position ( shown in FIG . 30 ), in the direction of arrow pin hole 90 of thrust block 84 in direction of arrow (y ) in
( u ) shown in FIG . 38 , stop pin 48 simultaneously contacts order to form a combined unit as shown in FIGS. 47a , 47b ,
the first angled surface 71 of the stop plate 70 , as shown in 55 and 48 . The cross sectional view of FIG . 48 further illus
FIG . 38 , and contacts the second angled surface 73 shown in trates the relationship between the components of the thrust
FIG . 39 . The contact of stop pin 48 with the two angled block , main spring, sub -assembly.
surfaces 71 and 73 of the stop plate 70 produces the duel FIGS. 49 through 52b show the assembly of shuttle plate
effect of wedging blade 2 and integral tang 34 into a fixed 80 with thrust blocks 84 and main springs 94 . FIG . 49 is a
position in two planes at once . As shown in FIG . 38 the first 60 bottom plan view showing thrust blocks 84 and main springs
angled surface 71 may be substantially at 24 degrees and the 94 retained by guide pins 88 within guide pin channels 76 of
second angled surface 73 may be substantially at 45 degrees, shuttle plate 80 and subject to the preload tension of main
as shown in FIG . 39 . As used herein , the term “ substantially ” springs 94 .Main springs 94 are connected to threaded spring
means at least almost entirely . In quantitative terms, " sub - anchors 92 of opposing thrust blocks 84 positioned at ends
stantially ” means at least 80 % of a stated reference . The stop 65 of the shuttle plate 80 . FIG . 50 shows a cross sectional view
pin 48 may include surfaces configured to mate with the first of shuttle plate 80 with main springs 94 positioned within
and second angled surfaces 71 and 73 . The configuration of main spring pockets 74 and guide pin 88 positioned within
 US 9, 764, 485 B1
13 14
guide pin channel 76 . FIG . 51 shows a long axis cross during the de - locking cycle . It should be noted that control
sectional view of the shuttle plate assembly . hooks 68b and 66b , are parts identical to 68a and 66a , but
FIG . 52a shows the shuttle plate 80 moved away from one positioned in reverse , and at the rear of the handle assembly ,
of the thrust blocks 84 in preparation for actuating the blade to perform similar functions at the opposite end of the cycle .
2 ( not shown in FIG . 52a ) from the open position to the 5 FIGS . 62 through 64 show how spring hooks 66a , 66b ,
closed position . The thrust block 84 is held in position away 68a , and 68b are relatively positioned , spring loaded , and
from shuttle plate 80 by its engagementwith the drive pin 60 manipulated by the forward and rearward movement of the
portion of the stop pin 48 (not shown in FIG . 52a ), while the shuttle plate 80 . Some components of the shuttle plate
shuttle plate 80 has been manually moved away from thrust assembly have been omitted for clarity . FIGS. 62 and 63 are
block 84 by means of sliding button 10 prior to firing. 10 bottom plan views of top handle cover 6 containing shuttle
Sliding button mounting holes 78 are configured to connect plate 80 with control hooks 66a , 666 , 68a , and 68b posi
sliding button 10 to shuttle plate 80 . FIG . 52b shows an end tioned in control hook pockets 24 . Control hook springs 96
view of the shuttle plate assembly and thrust block 84 . are positioned between control hook spring stops 26 and
FIGS. 53a through 55b illustrate the relationship between controlhooks 66a, 666 , 68a , and 686 . Control hook springs
blade 2 , shuttle plate 80 , and thrust block 84 . FIGS. 53a -b 15 96 bias control hooks 68a and 66b in a downward position .
are a top plan view and end view of blade 2 and integral tang Control hook springs 96 bias control hooks 68b and 66a in
34 . FIG . 54 is a partial top plan view of shuttle plate 80 and an upward position . FIG . 60 shows the shuttle plate assem
thrust block 84 . FIG . 55a is a combined cross sectional view bly in its rearmost position with control hook springs 96
of the blade 2 with integral tang 34 and shuttle plate 80 with corresponding to control hooks 68b and 66a in a compressed
connected thrust block 84 . The drive pin 60 portion of the 20 configuration. FIG . 61 shows the shuttle plate assembly in
stop pin 48 engages thrust block 84 . By way of example , its foremost position with control hook springs 96 corre
thrust block 84 may be positioned further from the center of sponding to control hooks 68a and 66b in a compressed
shuttle plate 80 than drive pin 60 such that a lower shoulder configuration . FIG . 62 shows a cross sectional view of the
of thrust block 84 contacts drive pin 60. FIG . 55b indicates shuttle plate assembly in its foremost positioned .
the new relative position of the same components when 25 FIGS. 65 through 68 shows how top handle cover 6 and
shuttle plate 80 is moved in the direction of arrow ( aa ) its assembly interface with center section 4 , and how control
preparatory to actuating the blade 2 . As shown in FIG . 55b , hooks 68a and 66a are positioned to manipulate control pins
thrust block 84 is positioned further from the center of 56 and 57. FIG . 65 is a partial bottom plan view , of top
shuttle plate 80 and thrust block guide pin 88 is partially handle cover 6 with shuttle plate 80, control hooks 68a and
extended from the end of shuttle plate 80 . Further, the 30 66a , and control hook springs 96 installed . Some parts have
configuration of thrust block 84 and shuttle plate 80 corre - been omitted for clarity . FIG . 66a is a cross section of top
sponds to the configuration shown in FIG . 52a , in prepara - handle cover 6 and its assembly , as indicated in FIG . 65 .
tion for actuating the blade 2 from an open position to a FIG . 67 is a partial top plan view of handle center section 4
closed position . with blade 2 in the open locked position . FIG . 68 is a cross
FIGS. 56 through 59 show a complete subassembly of top 35 section of handle center section 4 as indicated in FIG . 67 .
handle cover 6 with shuttle plate 80 and its related compo - FIG . 66b shows the relative position of top handle cover 6
nents installed and secured by the installation of sliding and its assembly after having traveled along the path of arc
button 10 . Sliding button 10 may capture the shuttle plate a r, and prior to final fastening to center section 4 . For the
assembly and simultaneous allow it to move forward and benefit of clarity , only the control hooks 66a and 68a are
rearward by manipulating sliding button 10 , by virtue of the 40 shown in the final assembly as indicated by dotted lines in
access provided by sliding button slot 12 and according to FIG . 67. When shuttle plate 80 is moved in the direction of
the linear limitations established by shuttle plate 80 within arrow (s) shown in FIG . 65 , by operator input, shuttle plate
shuttle plate pocket 28 . trip boss 72a contacts de -locking shoulder 106 of control
FIGS. 60a through 61c show spring loaded control hook hook 66a , causing control hook 66a to move in the same
68a, and de -locking control hook 66a , in bottom plan view 45 direction against the force of control spring 96 . Referencing
and related side and end views, indicating the various now to FIG . 67, when control hook 66a travels in the
surface features established for guidance , clearance and direction of arrow ( s ), control hook pin pocket 108 of control
engagement. Control hook engagement level 98 is on a plane hook 66a contacts control pin 57 of rocker bar 52, causing
of engagement corresponding to that of control pin 56 of rocker bar 52 to rotate in a counter clockwise direction as
lock bar 50 ( shown in FIG . 30 ) and control pin 57 of rocker 50 indicated by arrow ( r ) , which in turn will move lock bar 50
bar 52 ( also shown in FIG . 30 ). Control hook clearance level upward , thereby releasing blade 2 to be propelled toward the
102 is on a plane corresponding to the surface of shuttle closed position .
plate 80 to maintain clearance for the travel of control pins
56 and 57 . Control hook spring level 100 is on a plane In Operation
corresponding to the control hook pocket 24 to guide control 55
hooks and engage controlhook springs 96 with controlhook A user of the double action , out- the - front automatic knife
spring stops 104 . The spring travel stop 110 of the spring 1 may initiate opening of the blade 2 by applying forward
loaded control hook 68a engages control hook spring stop pressure on sliding button 10 . As sliding button 10 is moved
26 of handle frame top cover 6 to limit travel of spring forward , the shuttle plate 80 and its sub - assembly of main
loaded control hook 68a . FIG . 60a shows spring loaded 60 springs 94 and forward thrust block 84 move in unison via
control hook 68a in plan view . FIG . 60b shows a right side , the fixed connection between sliding button 10 and shuttle
side view of FIG . 60a , FIG . 60c shows an end view of FIG . plate 80 . By way of example , such fixed connection may be
60a . FIG . 61a shows a plan view of de-locking hook 66a . provided by standard fasteners utilizing sliding button
FIG . 61b shows a left side , side view of FIG . 61a , and FIG . mounting holes 78 . Shuttle plate 80 is constrained to linear
61c shows an end view of FIG . 6la . As shown in FIG . 61a , 65 motion by virtue of its contact within the limits of shuttle
a de-locking shoulder 106 of de-locking hook 66a is con - plate pocket 28 of top handle frame cover 6 . During the first
figured to engage shuttle trip boss 72a of shuttle plate 80 approximately 90 % of totaltravel of sliding button 10 , blade
 US 9 ,764 ,485 B1
15 16
2 will remain fixed in the locked closed position ( shown in may provide for separate lock mechanisms. One for
FIG . 32 ), by virtue of a positive engagement between lock locked open and another one for locked closed . The
ball 36 and dowel pin 205 . Because of the positive engage resultant saving of space significantly contributes to a
ment between rear thrust block 84 and the drive pin portion more favorable handle to blade ratio in terms of relative
60 of stop pin 48 , main springs 94 will be extended under 5 size .
tension as shuttle plate 80 is moved forward , in preparation d ) Other than the lock mechanisms contained within the
for the final release to occur at the end point of sliding button blade tang, all other internal moving parts may travel
10 travel within sliding button slot 12 . During the last only in a linear path . A feature which serves two
remaining 10 % of total travel of sliding button 10 within important advantages. First, the fact that the parts are
sliding button slot 12, shuttle trip boss 72b of shuttle plate 10
80 engages de -locking control hook 66b , which in turn subjected only to the forces of tension , but not, bend
makes contactwith control pin 56 of lock bar 50 , causing the ing, means they can be made thinner than otherwise .
forward motion of lock bar 50 within lock bar pocket 46 . As Second , the linear path eliminates the necessity to
lock bar 50 moves forward lock ball 36 will be free to recede provide a rocking or rotating part, with the necessary
into lock ball relief cavity 55 of lock bar 50 , thereby 15 space to accommodate the same part, in two different
releasing blade 2 with respect to dowel pin 20b of handle positions. All of which further contributes to a more
frame center section 4 , allowing blade 2 to “ fly ” forward desirable handle to blade ratio .
toward the open and locked position (shown in FIG . 2 ), Accordingly, it may be seen that the double action ,
propelled by the stored energy in main springs 94 , atwhich out-the-front, automatic knife , of the present disclosure
point thrust block 84 will re -contact shuttle plate 80 , to 20 provides a remarkably secure and robust locking system that
re - assume a pre - load condition . The momentum of blade 2 requires less internal handle space as well as less cost to
and integral tang 34 will propel the blade forward along rails produce . Also , the compound angle , wedge lock system
22 and extend beyond the end of center section 4 . The ensures that the open and locked blade is held more ridged
locking mechanism is carried with the tang 34 . The control than known systems.
pin 56 of lock bar 50 contacts control hook 68a . The force 25 Other embodiments include a single action , out- the -front,
of control hook spring 96 resists the travel of control pin 56 automatic knife that includes some, or all, of the advantages
against control hook 68, thereby sliding lock bar 50 rearward and /or features described above . Automatic opening of a
within lock bar pocket 46 . The rearward movement of lock single action , out-the - front, automatic knife may operate is
bar 50 rotates rocker bar 52 about rocker bar pivot point 58 a similar manner to the embodiments of the double action ,
and causes control pin 57 to move within control pin slot 40 . 30 out- the - front, automatic knife described above, as would be
When the lock bar 50 is moved to its full rearward position , appreciated by a person having ordinary skill in the art
lock bar ramp 54 forces lock ball 36 to protrude at least having the benefit of this disclosure . Automatic opening is
partially from integral tang 34 , resulting in a locked engage achieved by activating a trigger mechanism , which releases
mentwith a dowel pin 20a . The user , then desiring to close the stored energy of a compressed spring and propels the
the blade 2 , will apply pressure to the sliding button 10 in a 35 blade along a linear path , out the front of the handle , to an
rearward direction which will reverse the above described open and locked position . A secondary operation may be
order of events causing the blade 2 to automatically close used to close and reload the blade against spring pressure , in
and lock . preparation of the next firing. In some embodiments , the
From the description provided above a number of advan - secondary operation may simply close the blade and addi
tages of the current disclosure becomes evident. 40 tional actions may be used to reload the blade in preparation
a ) The tapered stop pin 48 , in conjunction with a tapered for firing.
stop plate 70 , consisting of duel angles of engagement, The single action , out-the - front automatic knife includes
will guarantee that the blade 2 will be wedged tightly a blade 2 with an integral tang 34 , handle frame 4 , and a
against any possible movement in the two principle locking mechanism positioned at least partially within the
planes , responsible for rigidity . Movement side to side 45 tang 34 of the blade 2, as described above with respect to
along the flat plane of the blade is controlled by the first FIGS. 19 -28 . The single action , out- the- front automatic
angled surface 71 and movement up and down , per - knife may include de - locking control hooks 66a and 66b and
pendicular to the flat plane of the blade is controlled by locking control hooks 68 and 68b , as described above with
the second angled surface 73 corresponding to the taper respect to FIGS. 29 - 32 and 60a -61c . The single action ,
of the stop pin . 50 out-the- front automatic knife may include a shuttle plate 80,
b ) Because the blade locking mechanism depends upon as described above with respect to FIGS . 40 -44 . The single
the interface between a traveling ball and stationary action , out-the - front automatic knife may include a top
dowel pins, lock failure can only occur in the highly handle cover 6 and bottom handle cover 8 as described
unlikely event that either the ball or the dowel pin above with respect to FIGS. 1 - 18 .
would collapse under excess loading , due to the forces 55 The blade 2 is propelled from a locked closed position as
of compression . A further advantage is available in the shown in FIG . 32 to a locked open configuration as shown
fact that both the hardened polished ball and the in FIG . 30 . In the locked open position , the blade 2 may be
hardened polished dowel pin are easily available as a secured by a compound angle , wedge lock system as
mass produced part, of standard dimensions and very described above with respect to FIGS. 33 - 39 . To close the
high quality , from a wide array of suppliers . In contrast, 60 blade 2 , a secondary operation releases the locking mecha
known designs may rely on difficult to machine con - nism and manually retracts the blade away from the front of
figurations thatmust be made to close tolerances, then the handle . A protrusion may extend from a side of the
hardened and ground at the interface . handle and the secondary operation may include moving the
c ) Because the lock mechanism , into itself, is completely protrusion away from the front of the handle , thereby sliding
contained within the tang of the traveling blade , the 65 the blade 2 into the handle and to the locked closed position
lock mechanism is therefore occupying space that as shown in FIG . 32 . With reference to FIG . 30 , the
would otherwise remain underutilized . Known designs secondary operation may also slide control hook 66a in the
 US 9 ,764,485 B1
17 18
direction of arrow (j) to engage control pin 57 , which will blade and tang are positioned within the handle and an
then rotate rocker bar 52 in a clockwise direction and unlock open position wherein the blade extends from the first
blade 2 , as described above . end of the handle ;
In some embodiments, the secondary operation may be a locking mechanism positioned within the tang ; and
used to close and reload the blade against spring pressure, in 5 a thrust mechanism ;
preparation of the next firing . For example , movementof the wherein when the blade is in the closed position and
blade 2 away from the front of the handle may cause the selectively locked , actuation of the button selectively
drive pin extension 60 of blade 2 to engage the rear thrust releases the locking mechanism and the thrust mecha
block 84 . Forward thrust block 84 may be secured from nism moves the blade to the open position , the blade
movement. Because of the positive engagement between 10 then being selectively locked in the open position by
rear thrust block 84 and the drive pin portion 60 of stop pin the locking mechanism ;
48 , main springs 94 will be extended under tension . Further the locking mechanism further comprising :
movement of the blade 2 away from the front of the handle
may occur until the blade 2 is secured in the locked closed a lock bar, the lock bar having a control pin and a cavity,
position shown in FIG . 32 , with the main springs 94 held in 15 the lock bar being configured to axially move within a
tension . A button may then be actuated to disengage the cavity in the tang;
lockingmechanism and release the blade 2, allowing blade a rocker bar having a control pin , a portion of the rocker
2 to " fly ” forward toward the open and locked position bar connected to the lock bar, the rocker bar configured
( shown in FIG . 2 ), propelled by the stored energy in main to pivot about an axis within a cavity in the tang,
springs 94 . The button may be a sliding button 10 and causes 20 wherein rotationalmovement of the rocker bar axially
shuttle plate 80 to engage de -locking control hook 66b , as moves the lock bar ; and
described above. a ball, wherein when the locking mechanism is unlocked
In some embodiments, the secondary operation may sim the ball is positioned within the cavity of the lock bar
ply close the blade without introducing additional tension and when the locking mechanism is locked the ball is
into themain springs 94 and additional actions may be used 25 positioned between the lock bar and a dowel pin
to reload the blade 2 in preparation for firing . For example , connected to the handle .
it may be undesirable for the main springs 94 to remain 2 . The knife of claim 1, wherein the knife is configured to
under tension when the blade 2 is in the locked closed attach to the muzzle end of a firearm .
position . A user may initiate opening of the blade by 3 . The knife of claim 1, further comprising:
applying forward pressure on sliding button 10 . As sliding 30 an upper unlocking control hook ;
button 10 is moved forward , the shuttle plate 80 and its a lower unlocking control hook ;
sub -assembly of main springs 94 and forward thrust block wherein actuation of the button controls movement of the
84 move in unison via the fixed connection between sliding upper and lower unlocking control hooks;
button 10 and shuttle plate 80 . During the first approxi wherein when the blade is in the locked open position
mately 90 % of total travel of sliding button 10 , blade 2 will 35 movement of the upper unlocking control hook towards
remain fixed in the locked closed position (shown in FIG . the second end of the handle engages the control pin on
32 ), by virtue of a positive engagement between lock ball 36 the rocker bar to pivot the rocker bar to move the lock
and dowel pin 20b . Because of the positive engagement bar towards the first end of the handle to permit the ball
between rear thrust block 84 and the drive pin portion 60 of to move into the cavity on the lock bar to selectively
stop pin 48 , main springs 94 will be extended under tension 40 release the blade from the locked open position ;
as shuttle plate 80 is moved forward , in preparation for the wherein when the blade is in the locked closed position
final release to occur at the end point of sliding button 10 movement of the lower unlocking control hook towards
travel within sliding button slot 12 . During the last remain the first end of the handle engages the control pin on the
ing 10 % of total travel of sliding button 10 within sliding locking bar moving the locking bar towards the first
button slot 12 , shuttle trip boss 72b of shuttle plate 80 45 end of the handle to permit the ball to move into the
engages de-locking control hook 66b , thereby allowing cavity on the lock bar to selectively release the blade
blade 2 to “ fly ” forward toward the open and locked position from the locked closed position .
(shown in FIG . 2 ), propelled by the stored energy in main 4 . The knife of claim 3, wherein the button is configured
springs 94 , as described above . to axially slide along a surface of the handle and the thrust
A single action , out-the- front, automatic knife or a double 50 mechanism comprises a shuttle plate connected to the but
action , out -the -front, automatic knife may be a bayonet ton , the shuttle plate having :
configured to attach to the muzzle end of a firearm , such as a first end ;
a rifle . a second end;
Although this disclosure has been described in terms of a lower profile configured to engage the lower unlocking
certain preferred embodiments , other embodiments that are 55 control hook , wherein when the blade is in the locked
apparent to those of ordinary skill in the art, including closed position movement of the shuttle plate engages
embodiments that do not provide all of the features and and moves the lower unlocking control hook ; and
advantages set forth herein , are also within the scope of this an upper profile configured to engage the upper unlocking
disclosure. Accordingly, the scope of the present disclosure control hook , wherein when the blade is in the locked
is defined only by reference to the appended claims and 60 open position movement of the shuttle plate engages
equivalents thereof. and moves the upper unlocking control hook .
What is claimed is : 5 . The knife of claim 4 , the thrust mechanism further
1. A knife comprising : comprising:
a handle having a first end and a second end ; an upper thrust block positioned at the first end of the
a button ; 65 shuttle plate;
a blade with an integral tang , the blade and tang config a lower thrust block positioned at the second end of the
ured to move between a closed position wherein the shuttle plate ; and
 US 9 , 764,485 B1
19 20
a plurality of springs positioned between the upper thrust a stop plate positioned within the handle , the stop plate
block and the lower thrust block , wherein movement of having a plurality of angled surfaces; wherein the stop
the shuttle plate when the blade is in the locked closed pin engages the plurality of angled surfaces when the
position increases the distance between the upper thrust blade is in the open position ;
block and the lower thrust block . wherein the engagement of the stop pin with the plurality
6 . The knife of claim 1 , wherein the knife is double action . of angled surfaces restricts movement of the blade in at
7 . The knife of claim 3 , further comprising : least two planes .
a stop pin connected to the tang ; and 11 . The knife of claim 10 , wherein the knife is configured
a stop plate positioned within the handle , the stop plate? 10 o 12attach
1ste to to the muzzle end of a firearm .
having a first angled surface and a second angled 10 comprisingknife
. The of claim 10 , the locking mechanism further
a ball positioned in a ball pocket of the tang of
surface ;
wherein the stop pin is configured to mate with both the the blade , the ball extending beyond a surface of the tang and
contacting a portion of the handle to restrict movement of
first angled surface and the second angled surface ; the blade with respect to the handle when the locking
wherein when the stop pin mates with both the first and 15 mechanism is in the lock position .
second angled surfaces the blade is constrained from 15 13 . The knife of claim 12 , the locking mechanism further
movement in two planes. comprising a lock bar configured to axially move along the
8 . A knife comprising : tang , the lock bar having a recess configured to receive the
a handle ;
a button ; ball when the locking mechanism is in the unlock position
a thrust mechanism ; 20 and having a ramp adjacent the recess , the ramp shaped to
guide the ball from the recess to the ball pocket with axial
a blade having an integral tang connected to the thrust movement
gul
mechanism and the button , wherein when the button is of the tang .
actuated the thrust mechanism moves the blade from 14 . The knife of claim 13 , the locking mechanism further
comprising a rocker bar pivotally connected to the tang of
being positioned entirely within the handle to a position 25 the
extending from an end of the handle ; blade, the rocker bar configured to engage the lock bar
a stop pin connected to the tang; and and convert rotational motion of the rocker bar into axial
a stop plate positioned within the handle , the stop plate motion of the lock bar.
having a first angled surface and a second angled 15 . The knife of claim 14 , further comprising :
surface ; an upper locking control hook , positioned to engage a
wherein the stop pin is configured to mate with both the 30 portion of the lock bar when the blade slides from the
first angled surface and the second angled surface when closed position to the open position ;
the blade is in the position extending from the end of an upper unlocking control hook , wherein when the blade
the handle ; is in the open position movement of the upper unlock
wherein when the stop pin mates with both the first and ing control hook engages a portion of the rocker bar ;
second angled surfaces the blade is constrained from 35 a lower locking control hook , positioned to engage a
movement in two planes . portion of the rocker bar when the blade slides from the
9 . The knife of claim 8 , wherein the first angled surface open position to the closed position ; and
is substantially at 24 degrees with respect to a direction of a lower unlocking control hook , wherein when the blade
travel of the stop pin and a horizontal axis of the blade and is in the closed position movement of the lower unlock
the second angled surface is substantially at 45 degrees with 40 theingswitch
control hook engages a portion of the lock bar;
controlling movement of the upper unlocking
respect to an axis of the stop pin and the horizontal axis of
the blade. control hook and the lower unlocking control hook .
10 . A knife comprising: 16 . The knife of claim 15 , the thrust mechanism com
a handle ; prising a shuttle plate connected to the switch , the shuttle
a blade having a tang and figured to avially slide 45 plate having :
configured to axially slide 45 plat
within the handle between an open position with at a first end ;
least a portion of the blade extending from the handle a second end ;
and a closed position with the blade within the handle ; a lower profile configured to engage the lower unlocking
a thrust mechanism configured to actuate the blade from 50 an control hook; and
upper profile configured to engage the upper unlocking
the closed position to the open position ; control hook .
a locking mechanism within the tang of the blade having
17. The knife of claim 16 , the thrust mechanism further
a lock position and an unlock position , the lock position comprising
restricting movement of the blade with respect to the :
handle and the unlock position permitting movement of an upper thrust block positioned at the first end of the
same 5555
the blade with respect to the handle , wherein the same shuttle plate ;
locking mechanism is configured to selectively lock the a lower thrust block positioned at the second end of the
blade in the open position and closed position ; and shuttle plate ; and
a switch having a first position and a second position , at least one spring positioned between the upper thrust
wherein movement of the switch from the first position block and the lower thrust block , wherein movement of
to the second position selectively actuates the locking 60 the shuttle plate when the blade is in the closed position
mechanism from the lock position to the unlock posi increases the distance between the upper thrust block
tion and the thrust mechanism moves the blade from and the lower thrust block .
the closed position to the open position , and further 18 . The knife of claim 10 , wherein the knife is double
comprising: action .
a stop pin connected to the tang ; and * * * * *