Integrated Razor Cartridge with Contractional Bridge Design
Solution Overview
Problem
The existing manufacturing process for razor cartridges is complex and prone to defects due to separate production of blades and blade housing, with aluminum clips being difficult to mass-produce and unable to securely fix multiple blades individually.
Innovation Solution
An integral razor cartridge design where the blade housing, side caps, and bridges are injection molded as a single unit, allowing the side caps to be pressed onto the blade housing to securely seat the blades, simplifying assembly and reducing defects through contractional deformation of the bridges.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If separate assembly process is used for blade housing and blades, then manufacturing flexibility is maintained, but manufacturing complexity increases and assembly defects occur
Solution Approach 1:
The patent merges the blade housing and blade securing components into a single integrally molded unit. The blade housing is formed as one piece with built-in securing features (such as recesses, clips, or interference-fit structures) that directly secure the blades, eliminating the need for separate assembly steps and reducing manufacturing complexity while maintaining flexibility.
2Reliability
If aluminum clips are used to wrap blades, then blade displacement is prevented, but mass production difficulty increases due to lightness and diminutive size
Solution Approach 1:
The securing components (originally separate aluminum clips) are merged into the blade housing structure itself through integral molding. This eliminates the need to separately manufacture and assemble tiny aluminum clips, enabling mass production of the entire cartridge as a single piece while maintaining reliable blade fixation through built-in securing features.
Solution Approach 2:
The material and structural parameters of the securing components are changed from separate aluminum clips to integrated plastic or composite structures molded into the housing. This parameter change enables the securing features to be produced simultaneously with the housing in high-volume injection molding processes, dramatically improving productivity while maintaining fixation reliability.
3Device complexity
If multiple blades are secured by a single clip surface, then structure is simplified, but individual blade control and adaptive fixation are lost
Solution Approach 1:
The single clip surface is segmented into multiple independent securing zones or features distributed across the blade housing. Each securing feature (such as individual recesses, clips, or engagement points) can independently adapt to and secure specific blades, providing individual blade control while maintaining overall structural simplicity through the integrated housing design.
4Ease of operation
If blades are bent into fixed positions, then blade positioning is achieved, but deviation from optimum bending conditions reduces fixation strength
Solution Approach 1:
The blade housing is designed with pre-formed securing features (recesses, clips, or interference-fit structures) that guide and position blades during assembly. These preliminary structural provisions ensure that blades are correctly positioned and secured without requiring precise manual bending operations, thereby maintaining fixation strength even when bending conditions vary.
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 simplifies the manufacturing process, enhances the assembly process by securely fixing blades, and strengthens the coupling between components, reducing defects and improving the overall stability of the razor cartridge.
Implementation Method 1
the pair of side caps and the bridges are moved closer to the blade housing
Data Source
Figure 1
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Figure 4
AI summary
A razor cartridge and a method for assembling a razor cartridge are disclosed. A razor cartridge includes: a blade housing including a seat configured to receive at least one blade; a pair of side caps respectively disposed at opposite ends of the blade housing, wherein each side cap is configured to be engaged with a corresponding end of the blade housing; and a plurality of bridges, wherein one or more bridges are disposed at each end of the blade housing and configured to provide a moveable connection between the side cap and the corresponding end of the blade housing, wherein the blade housing, the pair of side caps, and the one or more bridges are integrally formed, and wherein each side cap is configured to secure the at least one blade to the blade housing when the side cap is engaged with the corresponding end of the blade housing.