BACKGROUND OF THE INVENTION 10002] Many conventional tools for manipulating materials include various types of leveraging systems for imparting a force against the material. When a relatively strong material is being punched or embossed, it is highly desirable to provide the user with additional leverage such that an extraordinary amount of force is not required to perform the required action. For example, products such as hole punches, border embossers, rivet setters and staplers often include mechanisms for improving the user's leverage when cutting, embossing, riveting or otherwise manipulating a material such as paper, cloth, cardboard, vellum, foil, or other materials.

10003] Although reasonably effective in imparting the required force, conventional mechanisms of this sort suffer from a number of significant drawbacks. Several conventional tools, such as die punching devices, use levers to increase the mechanical advantage of the punch. The primary disadvantage of lever-based systems, however, is that they can only be used on a flat surface and in only one orientation. Many users in the craft industry like to use punches in the"upside down position"so that they can see the die opening and align the material that will be punched in a more precise manner."One orientation"punches therefore pose a special problem. Conventional systems also often include several moving parts, adding to the complexity and cost of the product. Furthermore, much of the force that is used to punch paper is used to overcom the spring that returns the punch to the open position after the punching operation is complete. This results in the user having to apply significantly more force than is actually required to punch or otherwise manipulate the material in question.

[0004] Furthermore, for products such as punches, if the operator does not press down on the exact middle of the actuating button, the punch and the die can become misaligned and become locked. Additionally, conventional systems require a high tolerance which further adds to the cost of manufacturing the product.

[0005] For all these reasons it would be desirable to develop an improved mechanism for use in a tool which overcomes the aforementioned deficiencies.

SUMMARY OF THE INVENTION [0006] It is therefore an object of the invention to provide a tool with an improved leveraging mechanism that provides an increased mechanical advantage for the user during operation.

[0007] It is another object of the invention to provide a tool with an improved leveraging mechanism that does not require a significant amount of force to overcome the counteracting forces imparted by the internal structure of the device.

[0008] It is still another object of the invention to provide a tool with an improved leveraging mechanism that can be used in multiple positions and/or orientations.

[ooos] It is yet another object of the invention to provide a tool with an improved leveraging mechanism that is less likely to become misaligned during use than conventional mechanisms.

[0010] It is another object of the invention to provide a tool with an improved leveraging mechanism that is relatively simple to manufacture.

[0011] It is yet another object of the invention to provide a tool with an improved leveraging mechanism that is relatively inexpensive to manufacture.

[0012] It is another object of the invention to provide an improved leveraging mechanism that may be used in a variety of tools.

[0013] These and other objects, advantages, and features of the invention, together with the organization and manner of operation thereof, will become apparent from the following detailed description when taken in conjunction with the accompanying drawings, wherein like elements have like numerals throughout the several drawings described below.

BRIEF DESCRIPTION OF THE DRAWINGS [ooi4] FIGURE 1 is a perspective view of a material punching device constructed according to the present invention; [0015] FIGURE 2 is an exploded perspective view of the material punch device of FIG. 1; [0016] FIGURE 3 is a segmented perspective view of the material punch device of FIG. 1; and [0017] FIGURE 4 is a front end view of one of the pinions shown in FIGS. 2 and 3.

DETAILED DESCRIPTION OF THE INVENTION [0018] A gear punch system constructed according to the present invention is shown generally at 10 in FIG. 1-3. The gear punch system 10 comprises a plunger 12 coupled to an inner tube 22. The inner tube 22 is biased by a biasing member 26 towards the plunger 12.

The inner tube 22 fits within an outer tube 24, and the outer tube 24 fits within a brace 28.

The brace 28 abuts against a punch 30 (which is connected to the outer tube 24), which acts against a die 32. The brace 28 is operatively connected to the die 32 by a plurality of fasteners 36. The die 32 is snap fit to a base 18, although other fastening arrangements may also be possible. A cover 20 is located on an outside surface of the base 18. A right housing 14 and a left housing 16 cover the sides of the gear punch system 10.

[0019] The present invention involves the use of a dual rack-and-pinion system for imparting force against the die 32. As can be seen clearly in FIGS. 2 and 3, the inner tube 22 includes a plurality of inner tube gear teeth 23 on the outside thereof. Similarly, the outer tube 24 includes a plurality of outer tube gear teeth 25 on the outside thereof. The outer tube 24 also includes an outer tube slot 27 on each side of the outer tube 24.

[0020] As shown in FIGS. 2 and 3, the gear punch system 10 also includes a plurality of. pinions 38, with one pinion 38 located on each side of the brace 28. In a preferred embodiment of the invention, each of the pinions 38 is coupled to the brace 28 by a shaft 42.

Each of the pinions 38 comprises an inner pinion 39 integrally connected to an outer pinion 41 on each side thereof, as shown in detail in FIG. 4. As can be seen in FIG. 4, the inner pinion 39 includes a plurality of inner pinion gear teeth 43, while the outer pinions 41 include a plurality of outer pinion gear teeth 45. The pinions 38 are arranged relative to the brace 28 such that the inner pinion 39 of each of the pinions 38 passes through a brace slot 47 and the outer tube slot 27 in order to contact the inner tube gear teeth 23 of the inner tube 22 (see FIG. 3). The outer pinions 41 of each of the pinions 38 are arranged such that the outer pinion gear teeth 45 contact the outer tube gear teeth 25. This creates a dual rack-and-pinion arrangement between the inner pinions 39 and the inner tube 22 and the outer pinions 41 and the outer tube 24.

[0021] The operation of the gear punch system 10 is generally as follows. The material to be punched or otherwise manipulated is located within a slot 31 of the die 32 (see FIG. 2).

When the material has been correctly positioned, the user presses against the plunger 12, shown in FIG. 1. The movement of the plunger 12 pushes the inner tube 22 downward against the biasing device 26. The interaction of the inner tube gear teeth 23 and the inner pinion gear teeth 43 causes the inner pinions 39 to rotate. The rotation of the inner pinions 39 causes a similar rotation of the outer pinions 41 in the same direction as the respective inner pinions 29. The interaction of the outer pinion gear teeth 45 and the outer tube gear teeth 25 causes the outer tube 24 to move, also moving the punch 30. The movement of the outer tube 24 with the punch 30 causes the punch 30 to press against the die 32, manipulating the material located within the slot 31.

[0022] When the punch operation is complete, the user releases the plunger 12. When the user no longer imparts any force on the gear punch system 10, the biasing member 26 biases the inner tube 22 and the plunger 12. The movement of the inner tube 22 causes a rotation in the inner pinions 39. This simultaneously causes a rotation in the same direction by the outer pinions 41, which results in the upward movement of the outer tube 24 and the punch 30 from the die 32, pennitting a user to remove the material being manipulated.

[0023] The present invention can be used in a variety of fields, although the present invention may be incorporated into tools primarily used by crafters to punch or otherwise manipulate materials such as bond paper, card stock, vellum, foil and similar materials. Importantly, the gear punch system 10, as described in FIGS. 1-4, allows the user to operate the product when it is in both the"upside down"or in other positions, which is a significant improvement over conventional punch systems. Furthermore, the dual rack-and-pinion system of the present invention provides the user with the mechanical advantage of up to forty percent over conventional punch systems. This translates into nearly a thirty pound force reduction when punching cardstock. Furthermore, the dual rack-and-pinion system provides a mechanical advantage when the punch 30 is being moved away from the die 32. This allows for the use of a spring with a relatively low resilient force to be used in the gear punch system relative to conventional punch systems, further reducing manufacturing costs.

[0024] The present invention also minimizes the possibility of misalignment between the punch and the die. The present invention permits the operator to press anywhere on the plunger while having the punch and the die maintain perfect alignment throughout the punching cycle. This results in a reduction of operating forces while also permitting looser manufacturing tolerances which results in a cost savings for the manufacturer.

[0025] The present invention has been described herein in terms of a particular embodiment in the form of a punch and die system. The main features of the present invention, however, could be incorporated in a number of other devices including three hole punches, two hole "European"style office punches, border punches, border embossers, combination punch and embossing systems, grommet/eyelet setters, rivet setters, staplers, guillotine cutters, die cutters, combination stampers/embossers and other products.

[0026] It should be understood that the above description of the invention and the specific examples and embodiments, while indicating the preferred embodiments of the present invention, are given by demonstration and not limitation. For example, the particular arrangement, number and sizes of the racks and pinions and their respective gear teeth can vary depending upon the particular requirements of the product at issue. Many changes and modifications within the scope of the present invention may therefore be made without departing from the spirit of the invention, and the invention includes all such inventions and modifications.