Pivotable Blade Holder for Distressed Wood Edges

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Solution Overview

Problem

Existing cutting apparatus fail to produce desired features of a distressed material surface, particularly in creating irregularities and imperfections along edges, such as those found in wood, which are essential for a rustic or antiqued appearance.

Innovation Solution

An edge cutter head apparatus with a pivotable blade holder and support system that allows for controlled cutting contact with the material edge, enabling the formation of random irregularities and imperfections, including variations in depth, width, and length, and abrupt changes in mechanical properties like knots and grain direction, to create a distressed edge with discontinuities.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Shape

If a conventional cutting apparatus is used to cut material edges, then a straight and uniform edge is produced, but the desired distressed appearance with random irregularities cannot be achieved

Engineering Contradiction:

Improveedge irregularityVSAvoidedge uniformity

Core Design Contradiction:

ShapeVSManufacturing precision

Solution Approach 1:

The blade holder is made pivotable about an axis, allowing the blade to dynamically adjust its position and angle during the cutting operation. This dynamic capability enables the blade to create random irregularities and distressed appearance on the edge while maintaining control over the overall cutting process, resolving the contradiction between achieving irregular shape and maintaining manufacturing precision.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The cutting apparatus is segmented into a support structure and a separately movable blade holder. This segmentation allows the blade holder to be independently positioned and angled relative to the material edge, enabling creation of distressed edges with random irregularities while the support structure maintains stable operation and control.

Inventive Principle:

Principle #1Segmentation

2Shape

If the blade holder is made pivotable to create random irregularities, then distressed appearance is achieved, but control over cutting depth and angle becomes more difficult

Engineering Contradiction:

Improvedistressed edge appearanceVSAvoidcutting control

Core Design Contradiction:

ShapeVSEase of operation

Solution Approach 1:

The pivotable blade holder provides dynamic adjustment capability that allows the operator to control the degree of distressing by adjusting the pivot angle. This maintains ease of operation while achieving the desired distressed appearance, as the operator can easily adjust the blade angle during operation.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The apparatus provides visual feedback through the distressed edge appearance, allowing the operator to adjust the blade holder position and pivot angle in real-time to achieve the desired level of distressing while maintaining control over cutting depth and angle.

Inventive Principle:

Principle #23Feedback

3Shape

If multiple distressing operations are performed manually on furniture surfaces, then desired distressed appearance can be achieved, but the process is time-consuming and labor-intensive

Engineering Contradiction:

Improvedistressed surface appearanceVSAvoiddistressing process speed

Core Design Contradiction:

ShapeVSProductivity

Solution Approach 1:

The apparatus combines multiple distressing functions into a single device that can create various edge irregularities, chattering effects, and distressed appearances through the pivotable blade holder. This multi-functionality allows the apparatus to perform what previously required multiple separate manual operations, significantly improving productivity while maintaining the desired distressed appearance.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The apparatus performs preliminary distressing action on the material edge during the cutting process itself, rather than requiring separate subsequent distressing operations. The pivotable blade holder creates random irregularities and chattering effects as the blade cuts through the material, eliminating the need for multiple manual distressing steps and improving overall process speed.

Inventive Principle:

Principle #10Preliminary action

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 apparatus effectively produces distressed edges with random irregularities and imperfections, achieving a unique and rustic appearance by allowing for adjustable bevel angles and depth control, ensuring consistency and continuity with adjacent surfaces.

Implementation Method 1

an edge cutter head including a pivotable blade holder

Methodology Applied

Scientific EffectPivoting motion:

Implementation Method 2

In response to the edge cutter head and the at least one edge of the material being brought into cutting contact and moved relative to each other, a resulting portion of the at least one edge of the material is distressed

Methodology Applied

Scientific EffectMechanical cutting:

Data Source

PatentUS9434087B2Apparatus and method for distressing an edge of a material

Publication Date: 2016.09.06 AHF LLC D B A AHF PROD

AI summary

An apparatus including a support for supporting a material having at least one edge, an edge cutter head, and an edge cutter head support for supporting the edge cutter head. In response to the edge cutter head and the at least one edge of the material being brought into cutting contact and moved relative to each other, a resulting portion of the at least one edge of the material is distressed.