Razor Head Strip Bending for Reduced Scrap and Lubrication

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Solution Overview

Problem

The manufacturing of razor head components using traditional methods results in significant material wastage and environmental impact due to extensive lubrication and generation of scrap, particularly with the use of presses.

Innovation Solution

A method and apparatus that involves bending and fixing a razor blade onto a strip of material, minimizing cutting operations and utilizing an apparatus with stations for delivery, bending, and fixation, which maximizes the use of material and reduces waste.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If a press is used to form the support, then the support can be manufactured, but extensive lubrication is required and a lot of scrap is generated

Engineering Contradiction:

Improvesupport manufacturingVSAvoidmaterial wastage

Core Design Contradiction:

Ease of manufactureVSLoss of substance

Solution Approach 1:

The patent changes the manufacturing process parameters from press-forming to bending operations. The strip material is bent into the required L-shaped configuration using bending tools rather than being pressed from a flat blank, which eliminates the need for extensive lubrication and reduces material waste by allowing the entire strip to be utilized.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent extracts the harmful elements (lubrication and scrap generation) from the manufacturing process by replacing the press-forming method with a bending method. The bending process requires no lubrication and produces minimal scrap, as the strip is simply deformed rather than having material removed or wasted.

Inventive Principle:

Principle #2Taking out (Extraction)

2Ease of manufacture

If a press is used to form the support, then the support can be manufactured, but extensive lubrication is required

Engineering Contradiction:

Improvesupport manufacturingVSAvoidenvironmental impact

Core Design Contradiction:

Ease of manufactureVSObject-generated harmful factors

Solution Approach 1:

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent converts the potentially harmful press-forming process into a beneficial bending process. By using bending instead of pressing, the harmful effects (lubrication waste and environmental impact) are eliminated while the manufacturing capability is maintained or improved.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

3Manufacturing precision

If multiple cutting operations are required, then precise components can be manufactured, but high-speed operation becomes difficult

Engineering Contradiction:

Improvecomponent precisionVSAvoidoperation speed

Core Design Contradiction:

Manufacturing precisionVSProductivity

Solution Approach 1:

The patent changes the process from multiple cutting operations to a bending operation. The L-shaped support is formed by bending the strip material rather than cutting separate pieces and assembling them, which maintains precision while enabling high-speed continuous production.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent implements continuous bending of the strip material through the bending station, eliminating the need for multiple discrete cutting and assembly operations. This continuous process maintains manufacturing precision while significantly increasing operation speed and productivity.

Inventive Principle:

Principle #20Continuity of useful 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

This approach allows for high-speed operation with minimal scrap, utilizing almost the entire strip as useful material and reducing environmental impact by minimizing lubrication and waste generation.

Implementation Method 1

bending the intermediate portion of a part of the strip about a bending axis parallel to the first direction

Methodology Applied

Scientific EffectMechanical Force: Mechanical Force

Data Source

PatentUS9440282B2Method and apparatus for the manufacture of razor head component, and components thus manufactured

Publication Date: 2016.09.13 BIC VIOLEX SA

AI summary

A method of manufacturing a razor head component that includes the steps of: providing a strip of material elongated along a first direction, the strip having first and second edges parallel with the first direction; having a first portion that includes a first edge, a second portion having a second edge, and an intermediate portion intermediate the first and second portions; bending the intermediate portion of a part of the strip about a bending axis parallel to the first direction; and fixing a razor blade onto the second portion of the part.