Double-Walled Hair Clipper Blade Assembly With Force-Fit Guide Slot
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Solution Overview
Problem
Existing manufacturing methods for double-walled stationary blades in hair cutting appliances are costly due to the need for complex and expensive tooling, as well as hybrid manufacturing approaches like insert molding and overmolding, which require specialized facilities and processes.
Innovation Solution
A method involving simple sheet metal processing and injection molding to form a blade set with a metal component and support insert, where the metal component is deformed to create a guide slot that expands upon insertion of the movable blade, allowing for a force-fitted assembly without complex bonding techniques, using a plastic support insert and sheet metal machining.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If hybrid manufacturing approaches like insert molding and overmolding are used to manufacture double-walled stationary blades, then the structural integrity and precision of the blade can be improved, but the manufacturing cost and complexity increase significantly
Solution Approach 1:
The stationary blade is divided into two separate components: a metal component providing structural integrity and a plastic support insert providing precision and stability. These components are manufactured separately using simple processes and then assembled together, avoiding the need for complex hybrid manufacturing while achieving the benefits of both materials.
Solution Approach 2:
The metal component and plastic support insert are combined through a force-fit assembly where the plastic insert is inserted into the metal component. This merging of components achieves the structural and precision benefits of hybrid manufacturing through simple assembly rather than complex integrated manufacturing processes.
2Reliability
If complex tooling and hybrid manufacturing methods are used, then the blade set performance can be improved, but the manufacturing cost increases
Solution Approach 1:
By segmenting the blade into separately manufacturable metal and plastic components, each can be produced using simple, cost-effective processes. The metal component is formed by sheet metal processing and the plastic insert by injection molding, both of which are mature and economical technologies that avoid the need for expensive complex tooling.
Solution Approach 2:
The plastic support insert is designed with features that enable preliminary positioning and force-fit assembly into the metal component. This preliminary action during assembly ensures proper alignment and secure attachment without requiring complex bonding techniques or specialized manufacturing facilities, thereby reducing costs while maintaining performance.
3Stability of the object's composition
If bonding techniques are used to assemble the metal component and support insert, then the structural stability can be improved, but the manufacturing complexity and cost increase
Solution Approach 1:
The plastic support insert is designed with geometric features that enable self-aligning and self-securing through force-fit assembly into the metal component. The interference fit between the insert and metal component creates inherent stability without requiring external bonding agents or complex assembly equipment, achieving structural stability through the design of the components themselves.
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 reduces manufacturing costs and complexity by eliminating the need for expensive tooling and hybrid methods, while ensuring a precise and accurate blade set with improved cutting performance through preloading and accurate fitment of components.
Implementation Method 1
the metal component is deformed, in particular bent, to form a guide slot which is expandable in a height direction upon insertion of the movable blade into the guide slot
Data Source
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AI summary
The present disclosure relates to a blade set (26) for a hair cutting appliance (10), said blade set (26) being arranged to be moved through hair in a moving direction (38) to cut hair, said blade set (26) comprising a stationary blade (42) comprising a support insert (70) and a metal component (68), wherein the metal component (68) and the support insert (70) are force-fitted to one another, wherein the metal component (68) is at least sectionally deformed to define at least one toothed leading edge (32, 34) having double-walled stationary blade teeth (44), wherein the metal component (68) forms a first wall (100) that is arranged to serve as a skin-facing wall when in operation, and a second wall (102) that is facing away from the first wall (100), and wherein a guide slot (60) for a movable blade (62) is defined between inwardly facing inner surfaces of the metal component (68) and the support insert (70), and a movable blade (62) comprising a plurality of movable blade teeth (64), wherein the movable blade (62) is movably arranged between the metal component (68) and the support insert (70) in the guide slot (60), and wherein the movable blade (62) is, in the mounted state, preloaded and movably arranged in the guide slot (60) between the metal component (68) and the support insert (70). The disclosure further relates to a corresponding manufacturing method.