Directly Deposited Razor Array on Flexible Substrate
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Solution Overview
Problem
Traditional shaving systems with individually fabricated blades are complex and inefficient, lacking flexibility and safety in conforming to body contours and effectively cutting hair without initial skin penetration.
Innovation Solution
A handheld shaving device with directly deposited, flexible razor structures on a thin substrate, featuring mesa structures to prevent skin penetration, and a novel manufacturing process allowing for easy modification of razor arrays, enabling effective and safe wet-shaving with minimal tooling costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional individually fabricated blades are used, then cutting effectiveness is achieved, but device complexity and manufacturing cost increase
Solution Approach 1:
Multiple razor structures are merged into a single substrate, forming an array of cutting elements that are manufactured together as one integrated component rather than assembling individual blades into a cartridge
Solution Approach 2:
The substrate serves multiple functions: it provides structural support, positions the razor structures, and enables flexibility for conforming to body contours, eliminating the need for separate cartridge components
2Ease of operation
If rigid blades are used for effective cutting, then cutting performance is improved, but flexibility and ability to conform to body contours deteriorates
Solution Approach 1:
The substrate is designed as a thin, flexible structure that allows the razor array to conform to curved body surfaces while maintaining the rigidity of individual razor structures for effective cutting
Solution Approach 2:
The cutting function is segmented into multiple small razor structures arranged in an array, where each razor is small enough to abrade hair tips without penetrating skin, providing both safety and flexibility
3Manufacturing precision
If traditional adhesive bonding is used to attach blades, then assembly is simplified, but manufacturing precision and durability deteriorate
Solution Approach 1:
The substrate acts as an intermediary that directly bonds to the razor structures through the deposition process itself, eliminating the need for separate adhesive layers while maintaining precise positioning and strong attachment
Solution Approach 2:
The razor structures are deposited directly onto the substrate in their final positions during the manufacturing process, ensuring precise placement without requiring subsequent assembly or adhesive bonding steps
4Object-affected harmful factors
If razor structures are made small for safety, then skin penetration is prevented, but cutting efficiency decreases
Solution Approach 1:
Instead of relying on a single deep-cutting razor, multiple small razors perform partial cutting actions that collectively achieve complete hair removal through abrasion of hair tips, preventing skin penetration while maintaining efficiency
Solution Approach 2:
The cutting function is divided into multiple small razor elements that work in parallel, with each razor being small enough to safely abrade hair tips without penetrating skin, and the array collectively providing efficient hair removal
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 device provides a flexible and safe shaving experience by cutting hair tips rather than the skin, with easy integration into traditional systems and potential applications in industrial, medical, and nano-technology fields due to its durable and adaptable design.
Implementation Method 1
The razor structures are deposited (formed) directly onto the substrate surface using a novel manufacturing process
Implementation Method 2
Mesa structures within the razor array are also formed during the manufacturing process. These mesa structures act so as to help to prevent the razors from penetrating the skin
Implementation Method 3
the trailing edge of the razor rows are designed to channel shaved material away
Implementation Method 4
a small curved tubular chute is affixed to the trailing edge of the device, which will clear shaved material off the skin during the shaving stroke
Data Source
AI summary
A shaving/cutting device with directly deposited (formed) razor structures without the use of intermediate adhesives. The device is in the form of a substantially flat substrate with miniature razors that have been directly deposited and formed onto the surface of the substrate. The substrate is of a rigid or flexible nature. The substrate is substantially thin and is therefore flexible and its shape is rectangular, circular or oval in nature. The razors are substantially deposited in plurality as an array formation onto the surface of the substrate. In most cases the razor array formation is in the form of parallel, curved and concentric nature. Flat mesa structures that are substantially the same height as the razor structures are incorporated in the razor array formations. The methods of manufacturing one or more directly deposited razor structures and mesa structures is disclosed.