Corrugated Knife Assembly with Nested Tab Blades Without Bonding

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Solution Overview

Problem

Existing julienne-type knives require metallurgical bonding of tab blades to primary blades, which increases manufacturing costs and complexity.

Innovation Solution

A knife assembly comprising a primary blade with a corrugated wave pattern and a secondary blade that nests with the primary blade, featuring tab blades formed by modifying a blank identical to the primary blade, eliminating the need for metallurgical bonding.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If tab blades are metallurgically bonded to primary blades, then the knife assembly achieves structural integrity, but manufacturing costs and complexity increase

Engineering Contradiction:

Improvestructural integrityVSAvoidmanufacturing cost and complexity

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The knife assembly is divided into separate primary blade and secondary blade components, each manufactured independently from identical blanks. The secondary blade is then assembled onto the primary blade without metallurgical bonding, reducing manufacturing complexity while maintaining structural integrity through mechanical assembly

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The secondary blade featuring tab blades is nested onto the primary blade in a coordinated arrangement. The complementary geometry of the blades allows the secondary blade to be positioned precisely on the primary blade, creating a stable nested structure that eliminates the need for costly metallurgical bonding processes

Inventive Principle:

Principle #7Nested doll (Nesting)

2Strength

If tab blades are metallurgically bonded to primary blades, then the knife assembly achieves structural integrity, but device complexity increases

Engineering Contradiction:

Improvestructural integrityVSAvoidmanufacturing process complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The metallurgical bonding process is replaced with a mechanical assembly process. The secondary blade is attached to the primary blade through mechanical interlocking and positioning mechanisms, eliminating the need for complex welding or bonding operations while maintaining structural integrity

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Data Source

PatentUS12358172B2Knife assembly with tab blades and method of fabrication

Publication Date: 2025.07.15 URSCHEL LABORATORIES INC

AI summary

Knife assemblies having primary and secondary blades and at least one tab blade. The primary and secondary blades each have a corrugated shape as a result of defining a wave pattern that defines peaks and valleys. The primary and secondary blades each further having upper and lower surfaces, leading and trailing edges, and a depth defined by and between the leading and trailing edges. The upper surface of the primary blade and the lower surface of the secondary blade are complementary so that the secondary blade and the peaks and valleys thereof are able to nest on the primary blade and the peaks and valleys thereof. The secondary blade has at least one tab blade that projects from one of its peaks and is defined by a cut in the peak to form a tab that is bent so that the tab projects from the peak.