Blade Support Aluminum Coating Corrosion

Solution Overview

Problem

Shaving razors with aluminum clips face corrosion issues, which can lead to safety hazards and aesthetic problems, and existing designs may still experience blade corrosion due to insufficient contact between blades and clips.

Innovation Solution

Applying a thin aluminum coating to the blade support surfaces, eliminating the need for aluminum clips and enhancing corrosion inhibition, especially in cases of insufficient contact, using methods like PVD, CVD, or plating to deposit a layer less than 5 μm thick.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If aluminum clips are used to secure blades, then corrosion of the blade support is prevented through galvanic coupling, but the clips themselves corrode and become aesthetically unattractive

Engineering Contradiction:

Improvecorrosion protection of blade supportVSAvoidaesthetic degradation and structural failure of clips

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent extracts the sacrificial anode function from the mechanical fastening function by applying aluminum coating only to the blade support rather than using separate aluminum clips. This eliminates the clips while maintaining corrosion protection through the coated support structure itself.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent merges the mechanical support function and the sacrificial anode function into a single integrated blade support component with aluminum coating, eliminating the need for separate aluminum clips and creating a unified corrosion-resistant structure.

Inventive Principle:

Principle #5Merging (Combining)

2Reliability

If aluminum clips are used to secure blades, then corrosion protection is provided, but insufficient contact between blades and clips can still allow blade corrosion

Engineering Contradiction:

Improvecorrosion protectionVSAvoidcontact consistency between blade and clips

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The patent merges the mechanical support function and the sacrificial anode function into a single integrated blade support component with aluminum coating, eliminating the need for separate aluminum clips and creating a unified corrosion-resistant structure.

Inventive Principle:

Principle #5Merging (Combining)

3Device complexity

If aluminum clips are eliminated to simplify the design, then device complexity is reduced, but corrosion protection capability is compromised

Engineering Contradiction:

Improvenumber of componentsVSAvoidcorrosion protection

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The patent extracts the sacrificial anode function from the mechanical fastening function by applying aluminum coating only to the blade support rather than using separate aluminum clips. This eliminates the clips while maintaining corrosion protection through the coated support structure itself.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent uses a composite structure combining steel blade support with aluminum coating, creating a material system that provides both mechanical strength and corrosion resistance through galvanic protection without requiring separate sacrificial anode components.

Inventive Principle:

Principle #40Composite materials

4Reliability

If the aluminum coating is made thicker to enhance corrosion protection, then corrosion resistance is improved, but manufacturing cost and processing complexity increase

Engineering Contradiction:

Improvecorrosion resistanceVSAvoidcoating application complexity

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The patent optimizes the aluminum coating thickness parameter to less than 5 μm, which provides sufficient galvanic protection while minimizing material consumption and coating process complexity, achieving a balance between corrosion resistance and manufacturability.

Inventive Principle:

Principle #35Parameter changes

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

Prevents corrosion effectively without clips, maintaining the blade's integrity and safety, and can withstand corrosion tests like ASTM G44-99 for extended use, such as 12 hours or more.

Implementation Method 1

The aluminum clips tend to function as the anode (preferentially corroded part) in the galvanic couple formed by the clips and blades/supports, thereby inhibiting corrosion of the steel blades and blade support

Methodology Applied

Scientific EffectGalvanic corrosion:

Implementation Method 2

The aluminum clips tend to function as the anode (preferentially corroded part) in the galvanic couple formed by the clips and blades/supports, thereby inhibiting corrosion of the steel blades and blade support. This sacrificial function of the clips is advantageous

Methodology Applied

Scientific EffectSacrificial anode:

Implementation Method 3

using methods like PVD, CVD, or plating to deposit a layer less than 5 μm thick

Methodology Applied

Scientific EffectPhysical vapor deposition: Physical Vapour Deposition

Implementation Method 4

using methods like PVD, CVD, or plating to deposit a layer less than 5 μm thick

Methodology Applied

Scientific EffectChemical vapor deposition: Chemical Vapour Deposition

Implementation Method 5

using methods like PVD, CVD, or plating to deposit a layer less than 5 μm thick

Methodology Applied

Scientific EffectPlating: Electroplating

Data Source

PatentUS8443519B2Blade supports for use in shaving systems

Publication Date: 2013.05.21 THE GILLETTE CO

AI summary

Supported blades for use in shaving systems are disclosed. The supported blades include a blade support having a surface that is coated with aluminum. The aluminum coating is on a portion of an outer surface of the blade support or on the lower surface of the blade support or covering the entire lower surface of the blade support. The aluminum coating is less than 5 μm thick and is made of substantially pure aluminum. By providing aluminum coating, corrosion is prevented without the need for aluminum clips. The supported blades may be mounted in a blade unit housing without clips within a cartridge which can be mounted on a detachable or permanent handle of a shaving razor.