Double-Walled Hair Clipper Blade Assembly With Force-Fit Structure

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Solution Overview

Problem

Existing manufacturing methods for double-walled stationary blades in hair cutting appliances are costly and complex, requiring expensive tooling and hybrid techniques like insert molding and overmolding, which increase production costs and complexity.

Innovation Solution

A blade set design featuring a stationary blade with a support insert and a metal component that are force-fitted together, where the metal component is deformed to form a double-walled structure with a guide slot for a movable blade, allowing for simpler manufacturing using sheet metal processing and injection molding, eliminating the need for complex bonding techniques.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If insert molding and overmolding techniques are used to manufacture double-walled stationary blades, then the structural integrity and precision of the blade is improved, but the manufacturing cost and process complexity increases significantly

Engineering Contradiction:

Improveblade structure precisionVSAvoidmanufacturing process complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The stationary blade is divided into two separate components: a metal component (providing structural integrity and cutting edges) and a plastic component (providing structural support and guiding the movable blade). These components are manufactured separately using simple processes and then assembled together, avoiding the need for complex insert molding or overmolding techniques while maintaining the benefits of a double-walled structure.

Inventive Principle:

Principle #1Segmentation

2Reliability

If hybrid manufacturing techniques combining sheet metal and injection molding are used, then the functional performance of the blade is improved, but the production cost increases

Engineering Contradiction:

Improveblade functional performanceVSAvoidmanufacturing cost

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The metal component and plastic component are designed to work together as an integrated assembly. The metal component provides the cutting functionality while the plastic component provides structural support and guidance. By combining these two simple components through a straightforward assembly process (such as injection molding the plastic component around the metal component), the patent achieves high functional performance without the need for expensive hybrid manufacturing techniques.

Inventive Principle:

Principle #5Merging (Combining)

3Strength

If complex bonding techniques are used to assemble blade components, then the structural strength of the blade set is improved, but the manufacturing simplicity is reduced

Engineering Contradiction:

Improveblade structural strengthVSAvoidassembly simplicity

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The plastic component serves as an intermediary that mechanically connects and secures the metal component. Through features such as ribs, protrusions, or interference fits in the plastic component, the metal component is firmly held in place without requiring additional bonding techniques. This mechanical interlocking provides strong structural strength while keeping the assembly process simple.

Inventive Principle:

Principle #24Intermediary (Mediator)

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

This approach enables cost-efficient production of double-walled blade sets with improved accuracy and performance, reducing manufacturing costs and complexity while maintaining the benefits of the double-walled design.

Implementation Method 1

the metal component is at least sectionally deformed to define at least one toothed leading edge having double-walled stationary blades teeth

Methodology Applied

Scientific EffectPlastic deformation: Plasticity

Implementation Method 2

the moving blade can move back and forth relative to the fixed blade to cut hair

Methodology Applied

Scientific EffectMechanical motion:

Data Source

PatentUS11780104B2Blade set for a hair cutting appliance arranged to be moved through hair in a moving direction to cut hair

Publication Date: 2023.10.10 KONINKLIJKE PHILIPS NV

AI summary

A blade set for a hair cutting appliance is described. The blade set (26) is arranged to be moved through hair in a moving direction to cut hair, and includes a stationary blade including a support insert and a metal component. The metal component and the support insert are force-fitted to one another. The metal component is at least sectionally deformed to define at least one toothed leading edge having double-walled stationary blade teeth. The metal component forms a first wall that is arranged to serve as a skin-facing wall when in operation, and a second wall that is facing away from the first wall. A guide slot for a movable blade is defined between inwardly facing inner surfaces of the metal component and the support insert and a movable blade having a plurality of movable blade teeth.