Apparatus and improved method of manufacturing handles for butterfly defense knife

Claim 1

A method of manufacturing each of the two handle sections of a butterfly knife wherein each handle section is machined from a single piece of rectangular raw stock which contains an upper face and a lower face, a first end face and a second end face, and a first lateral face and a second lateral face, which comprises: a. cutting said piece of raw stock to a selected length; b. squaring said first end face to a selected dimension; c. squaring said second end face to a selected dimension; d. machining a central longitudinal slot in the longitudinal lower face of said piece of raw stock such that the central longitudinal slot extends along the entire length of the lower face and extends transversely through most of the depth of said piece of raw stock; e. cutting a first transverse slot in the central portion of said first end face such that the first transverse slot extends inwardly to a selected longitudinal distance along said upper face of said piece of raw stock and coincides with said central longitudinal slot along the lateral depth of said raw stock; f. cutting a second transverse slot in the central portion of said second end face such that the second transverse slot extends inwardly to a selected longitudinal distance along said upper face of said piece of raw stock and coincides with said central longitudinal slot along the lateral depth of said raw stock; g. machining a first lateral recess to a selected depth into said first lateral face of said piece of raw stock such that the first lateral recess extends transversely through the entire height of the first lateral face and extends longitudinally along the central portion of the first lateral face, beginning at a first recess edge and terminating in a second recess edge; h. machining a dovetail into said first recess edge and into said second recess edge of said first lateral recess; i. machining a second lateral recess to a selected depth into said second lateral face of said piece of raw stock such that the second lateral recess extends transversely through the entire height of the second lateral face and extends longitudinally along the central portion of the second lateral face, beginning at a first recess edge and terminating in a second recess edge; j. machining a dovetail into said first recess edge and into said second recess edge of said second lateral recess; k. tapering said lower face such that said piece of raw stock is tapered a selected amount from said second end face to said first end face; l. rounding the surfaces of said first and said second lateral faces adjacent said second end face such that the surfaces of said first and second lateral faces form part of the circumference of a circle which has its central point located at the center of said second end face; m. rounding the surfaces of said first and said second lateral faces adjacent said first end face such that the surfaces of said first and second lateral faces form part of the circumference of a circle which has its central point located at the center of said first end face; n. rounding said first end face; o. machining a depression into said upper face along each edge of said first transverse slot; p. drilling a central hole through said first and said second lateral face adjacent said second end face; g. drilling a central hole through said first and said second lateral face near said first end face; r. machining a multiplicity of partial holes into said first lateral recess such that said holes are aligned along the entire length of said first lateral recess and do not penetrate the lateral wall of said piece of raw stock so as not to come in contact with said central longitudinal slot; s. machining a multiplicity of partial holes into said second lateral recess such that said holes are aligned along the entire length of said second lateral recess and do not penetrate the lateral wall of said piece of raw stock so as not to come in contact with said central longitudinal slot; t. cutting a first piece of material to the exact interior dimensions of said first lateral recess; u. securing said first piece of material into said first lateral recess by applying adhesive material into each of said multiplicity of partial holes in the recess and along the interior surface of the first piece of material; v. cutting a second piece of material to the exact interior dimensions of said second lateral recess; and w. securing said second piece of material into said second lateral recess by applying adhesive material into each of said multiplicity of partial holes in the recess and along the interior surface of the second piece of material; x. whereby two such machined pieces of raw stock are used to form handle sections of a knife and are attached through said holes in their lateral faces near said first end face to the tang of a knife blade to form the handle of the knife such that the knife blade is completely concealed within said central longitudinal slot of each handle section when the knife is in a closed position and form the handle of the knife by having their upper faces adjacent each other when the knife is in an opened position.

Claim 2

A method of manufacturing each of the two handle sections of a butterfly knife wherein each handle section is machined from a single piece of rectangular raw stock which contains an upper face and a lower face, a first end face and a second end face, and a first lateral face and a second lateral face, which comprises: a. cutting said piece of raw stock to a selected length; b. squaring said first end face to a selected dimension; c. squaring said second end face to a selected dimension; d. machining a central longitudinal slot in the longitudinal lower face of said piece of raw stock such that the central longitudinal slot extends along the entire length of the lower face and extends transversely through most of the depth of said piece of raw stock; e. cutting a first transverse slot in the central portion of said first end face such that the first transverse slot extends inwardly to a selected longitudinal distance along said upper face of said piece of raw stock and coincides with said central longitudinal slot along the lateral depth of said raw stock; f. cutting a second transverse slot in the central portion of said second end face such that the second transverse slot extends inwardly to a selected longitudinal distance along said upper face of said piece of raw stock and coincides with said central longitudinal slot along the lateral depth of said raw stock; g. machining a first lateral recess to a selected depth into said first lateral face of said piece of raw stock such that the first lateral recess extends transversely through the entire height of the first lateral face and extends longitudinally along the central portion of the first lateral face, beginning at a first recess edge and terminating in a second recess edge; h. machining a dovetail into said first recess edge and into said second recess edge of said first lateral recess; i. machining a second lateral recess to a selected depth into said second lateral face of said piece of raw stock such that the second lateral recess extends transversely through the entire height of the second lateral face and extends longitudinally along the central portion of the second lateral face, beginning at a first recess edge and terminating in a second recess edge; j. machining a dovetail into said first recess edge and into said second recess edge of said second lateral recess; k. tapering said lower face such that said piece of raw stock is tapered a selected amount from said second end face to said first end face; l. rounding the surfaces of said first and said second lateral faces adjacent said second end face such that the surfaces of said first and second lateral faces form part of the circumference of a circle which has its central point located at the center of said second end face; m. rounding the surfaces of said first and said second lateral faces adjacent said first end face such that the surfaces of said first and second lateral faces form part of the circumference of a circle which has its central point located at the center of said first end face; n. rounding said first end face; o. machining a depression into said upper face along each edge of said first transverse slot; p. drilling a central hole through said first and said second lateral face adjacent said second end face; g. drilling a central hole through said first and said second lateral face near said first end face; r. machining a multiplicity of partial holes into said first lateral recess such that said holes are aligned along the entire length of said first lateral recess and do not penetrate the lateral wall of said piece of raw stock so as not to come in contact with said central longitudinal slot; s. machining a multiplicity of partial holes into said second lateral recess such that said holes are aligned along the entire length of said second lateral recess and do not penetrate the lateral wall of said piece of raw stock so as not to come in contact with said central longitudinal slot; t. cutting a first piece of material to the exact interior dimensions of said first lateral recess; u. securing said first piece of material into said first lateral recess by applying adhesive material into each of said multiplicity of partial holes in the recess and along the interior surface of the first piece of material; v. cutting a second piece of material to the exact interior dimensions of said second lateral recess; and w. securing said second piece of material into said second lateral recess by applying adhesive material into each of said multiplicity of partial holes in the recess and along the interior surface of the second piece of material; x. whereby two such machined pieces of raw stock are used to form handle sections of a knife and are attached through said holes in their lateral faces near said first end face to the tang of a knife blade to form the handle of the knife such that the knife blade is completely concealed within said central longitudinal slot of each handle section when the knife is in a closed position and form the handle of the knife by having their upper faces adjacent each other when the knife is in an opened position.

Claim 3

A method of manufacturing each of the two light weight handle sections of a butterfly knife wherein each handle section is machined from a single piece of rectangular raw stock which contains an upper face and a lower face, a first end face and a second end face, and a first lateral face and a second lateral face, which comprises: a. cutting said piece of raw stock to a selected length; b. squaring said first end face to a selected dimension; c. squaring said second end face to a selected dimension; d. machining a central longitudinal slot in the longitudinal lower face of said piece of raw stock such that the central longitudinal slot extends along the entire length of the lower face and extends transversely through most of the depth of said piece of raw stock; e. cutting a first transverse slot in the central portion of said first end face such that the first transverse slot extends inwardly to a selected longitudinal distance along said upper face of said piece of raw stock and coincides with said central longitudinal slot along the lateral depth of said raw stock; f. cutting a second transverse slot in the central portion of said second end face such that the second transverse slot extends inwardly to a selected longitudinal distance along said upper face of said piece of raw stock and coincides with said central longitudinal slot along the lateral depth of said raw stock; g. tapering said lower face such that said piece of raw stock is tapered a selected amount from said second end face to said first end face; h. rounding said first end face; i. machining a depression into said upper face along each edge of said first transverse slot; j. drilling a central hole through said first and said second lateral face adjacent said second end face; k. drilling a central hole through said first and said second lateral face near said first end face; l. drilling a multiplicity of variable sized large holes into said first lateral face such that the large holes are aligned along the longitudinal axis of said first lateral face and extend through the entire thickness of said first lateral face and into said central longitudinal slot; m. drilling a multiplicity of small holes into said first lateral face such that the small holes are interspersed between said variable sized large holes and also extend through the entire thickness of said first lateral face and into said central longitudinal slot; n. drilling a multiplicity of variable sized large holes into said second lateral face such that the large holes are aligned along the longitudinal axis of said second lateral face and extend through the entire thickness of said second lateral face and into said central longitudinal slot; and o. drilling a multiplicity of small holes into said second lateral face such that the small holes are interspersed between said variable sized large holes and also extend through the entire thickness of said second lateral face and into said central longitudinal slot; p. whereby two such machined pieces of raw stock are used to form light weight handle sections of a knife and are attached through said holes in their lateral faces near said first end face to the tang of a knife blade to form the light weight handle of the knife such that the knife blade is completely concealed within said central longitudinal slot of each handle section when the knife is in a closed position and form the handle of the knife by having their upper faces adjacent each other when the knife is in an opened position.

Claim 4

A method of manufacturing each of the two light weight handle sections of a butterfly knife wherein each handle section is machined from a single piece of rectangular raw stock which contains an upper face and a lower face, a first end face and a second end face, and a first lateral face and a second lateral face, which comprises: a. cutting said piece of raw stock to a selected length; b. squaring said first end face to a selected dimension; c. squaring said second end face to a selected dimension; d. machining a central longitudinal slot in the longitudinal lower face of said piece of raw stock such that the central longitudinal slot extends along the entire length of the lower face and extends transversely through most of the depth of said piece of raw stock; e. cutting a first transverse slot in the central portion of said first end face such that the first transverse slot extends inwardly to a selected longitudinal distance along said upper face of said piece of raw stock and coincides with said central longitudinal slot along the lateral depth of said raw stock; f. cutting a second transverse slot in the central portion of said second end face such that the second transverse slot extends inwardly to a selected longitudinal distance along said upper face of said piece of raw stock and coincides with said central longitudinal slot along the lateral depth of said raw stock; g. tapering said lower face such that said piece of raw stock is tapered a selected amount from said second end face to said first end face; h. rounding said first end face; i. machining a depression into said upper face along each edge of said first transverse slot; j. drilling a central hole through said first and said second lateral face adjacent said second end face; k. drilling a central hole through said first and said second lateral face near said first end face; l. drilling a multiplicity of variable sized large holes into said first lateral face such that the large holes are aligned along the longitudinal axis of said first lateral face and extend through the entire thickness of said first lateral face and into said central longitudinal slot; m. drilling a multiplicity of small holes into said first lateral face such that the small holes are interspersed between said variable sized large holes and also extend through the entire thickness of said first lateral face and into said central longitudinal slot; n. drilling a multiplicity of variable sized large holes into said second lateral face such that the large holes are aligned along the longitudinal axis of said second lateral face and extend through the entire thickness of said second lateral face and into said central longitudinal slot; and o. drilling a multiplicity of small holes into said second lateral face such that the small holes are interspersed between said variable sized large holes and also extend through the entire thickness of said second lateral face and into said central longitudinal slot; p. whereby two such machined pieces of raw stock are used to form light weight handle sections of a knife and are attached through said holes in their lateral faces near said first end face to the tang of a knife blade to form the light weight handle of the knife such that the knife blade is completely concealed within said central longitudinal slot of each handle section when the knife is in a closed position and form the handle of the knife by having their upper faces adjacent each other when the knife is in an opened position.