Blade Carrier Assembly With Flexing Tab for Razor Attachment Durability
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Solution Overview
Problem
There is a need for a simpler, more robust, and intuitive connection mechanism between shaving razor handles and cartridges, especially with heavier metal handles that are prone to mechanical failure when dropped.
Innovation Solution
A blade carrier assembly with a tab that flexes between two positions to securely and detachably attach the cartridge to the handle, featuring a crest positioned between angled surfaces for engagement with the handle, providing a robust yet easy-to-use attachment system.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the handle weight is increased to provide improved control and pleasing feel, then the user experience is improved, but the likelihood of attachment mechanism breaking during drops increases
Solution Approach 1:
The attachment mechanism transitions from a static rigid connection to a dynamic system where the blade carrier can pivot and the attachment forces can redirect. The blade carrier pivots relative to the handle to follow skin contours, and during drops, the attachment forces redirect through the pivot point rather than concentrating stress at the attachment interface, allowing the mechanism to absorb impact without breaking
Solution Approach 2:
The attachment mechanism utilizes friction between the blade carrier and handle surfaces, where the normal force and friction coefficient are adjusted to provide appropriate retention. The system maintains sufficient friction for normal use but allows controlled slippage during extreme impacts, changing the interaction parameters from purely rigid to friction-based with controlled compliance
2Reliability
If the attachment forces are increased to maintain integrity during high-force shaving, then the retention is improved, but the ease of cartridge replacement deteriorates
Solution Approach 1:
The blade carrier pivots relative to the handle during attachment and removal operations. This pivot motion transforms the static attachment problem into a dynamic one, where the user can easily lift the cartridge off by pivoting it away from the handle, reducing the effective retention force during removal while maintaining strong friction-based retention during normal shaving
3Device complexity
If a simple attachment mechanism is used to reduce complexity, then the device simplicity is improved, but the robustness against mechanical failure from drops deteriorates
Solution Approach 1:
The pivot-capable blade carrier creates a dynamic attachment system that remains mechanically simple without requiring complex shock-absorbing components. The simplicity is maintained through friction-based retention and pivot motion, while robustness against drop failure is achieved through the same pivot mechanism that redirects impact forces away from the attachment interface
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution enhances the reliability and durability of the handle-to-cartridge connection, allowing for easy cartridge replacement and improved user feedback during shaving, while also protecting against mechanical failure from drops.
Implementation Method 1
The tab flexes between a first position and a second position to secure and detach the shaving razor cartridge from the handle
Data Source
AI summary
A method of manufacturing a blade carrier assembly. A sheet of metal having a thickness of 0.1 mm to 1 mm is provided. The sheet of metal is cut to form a blade carrier blank having a blade platform and a tab extending from the blade platform. The tab is coined to form a crest. At least one window is cut into the sheet of metal. The blade carrier blank is bent along the at least one window to form an upper portion and a lower portion. A blade is mounted to the lower portion. The blade is clamped by bending the upper portion toward the lower portion until the blade is in contact with both the upper portion and the lower portion.