Stationary blade, blade set, and manufacturing method

Abstract

A stationary blade for a blade set of a hair cutting appliance includes a top wall, a bottom wall, and a guide slot formed between the top and bottom walls to accommodate a movable blade. The stationary blade further includes a plurality of stationary blade teeth each having a frontal end. The top and bottom walls are mutually joined at the frontal ends, where the top and bottom walls are, at least at the frontal ends, made from sheet metal material. Further, at the frontal ends, two or more sheet metal folded edges are present.

Claims

1. A stationary blade for a blade set of a hair cutting appliance, the stationary blade comprising: a top wall, a bottom wall, and a guide slot formed between the top wall and the bottom wall to accommodate a movable blade; and a plurality of stationary blade teeth extending from the top wall and the bottom wall, each tooth of the plurality of stationary blade teeth having a frontal end, wherein the top wall and the bottom wall are mutually joined at the frontal ends, wherein the top wall and the bottom wall are, at least at the frontal ends, made from sheet metal material, and wherein, at the frontal ends, two or more sheet metal folded edges are present including first sheet metal folded edges of the top wall forming a first gap below the top wall between the first sheet metal folded edges of the top wall, and second sheet metal folded edges of the bottom wall forming the guide slot above the bottom wall between the second sheet metal folded edges of the bottom wall.

2. The stationary blade as claimed in claim 1, wherein a rear portion of the frontal ends comprises four layers formed by sheet metal material, the rear portion being adjacent to the guide slot.

3. The stationary blade as claimed in claim 1, comprising an inner sheet and an outer sheet, wherein the outer sheet defines the top wall and the bottom wall, and wherein the inner sheet is arranged inside the outer sheet.

4. The stationary blade as claimed in claim 3, wherein the outer sheet is wrapped around the inner sheet.

5. The stationary blade as claimed in claim 3, wherein the inner sheet comprises an inner sheet folded edge at the frontal ends, wherein the outer sheet comprises an outer sheet folded edge at the frontal ends, and wherein the inner sheet folded edge is nestled in the outer sheet folded edge.

6. The stationary blade as claimed in claim 5, wherein the outer sheet comprises, adjacent to the outer sheet folded edge, a top layer and a bottom layer that are spaced away from one another by the inner sheet.

7. A stationary blade for a blade set of a hair cutting appliance, the stationary blade comprising: an outer sheet having a top wall, an inner sheet having a bottom wall, and a guide slot formed between the top wall and the bottom wall to accommodate a movable blade, wherein the inner sheet is arranged inside the outer sheet; and a plurality of stationary blade teeth extending from the top wall and the bottom wall, each tooth of the plurality of stationary blade teeth having a frontal end, wherein the top wall and the bottom wall are mutually joined at the frontal ends, wherein the top wall and the bottom wall are, at least at the frontal ends, made from sheet metal material, wherein the inner sheet comprises an inner sheet folded edge at the frontal ends, and wherein the inner sheet comprises, adjacent to the inner sheet folded edge, a top layer and a bottom layer that contact one another.

8. The stationary blade as claimed in claim 7, wherein the top layer of the inner sheet defines a frontal end of the guide slot.

9. A stationary blade for a blade set of a hair cutting appliance, the stationary blade comprising: an outer sheet having a top wall, an inner sheet having a bottom wall, and a guide slot formed between the top wall and the bottom wall to accommodate a movable blade, wherein the inner sheet is arranged inside the outer sheet; and a plurality of stationary blade teeth extending from the top wall and the bottom wall, each tooth of the plurality of stationary blade teeth having a frontal end, wherein the top wall and the bottom wall are mutually joined at the frontal ends, wherein the top wall and the bottom wall are, at least at the frontal ends, made from sheet metal material, wherein the inner sheet comprises an inner sheet folded edge at the frontal ends, wherein the plurality of stationary blade teeth comprises a first series of teeth at a first leading edge and a second series of teeth at a second leading edge, wherein the inner sheet connects the first leading edge and the second leading edge at the bottom wall, and wherein the outer sheet connects the first leading edge and the second leading edge at the top wall.

10. A blade set for a hair cutting appliance, the blade set comprising: a stationary blade, and a movable blade comprising a plurality of movable blade teeth, wherein the stationary blade includes a top wall, a bottom wall, and a guide slot formed between the top wall and the bottom wall to accommodate a movable blade; and a plurality of stationary blade teeth extending from the top wall and the bottom wall, each tooth of the plurality of stationary blade teeth having a frontal end, wherein the top wall and the bottom wall are mutually joined at the frontal ends, wherein the top wall and the bottom wall are, at least at the frontal ends, made from sheet metal material, wherein, at the frontal ends, two or more sheet metal folded edges are present including first sheet metal folded edges of the top wall forming a first gap below the top wall between the first sheet metal folded edges of the top wall, and second sheet metal folded edges of the bottom wall forming the guide slot above the bottom wall between the second sheet metal folded edges of the bottom wall, wherein in the guide slot of the stationary blade, an intermediate guide element is arranged between the top wall and the bottom wall, wherein in the movable blade, a guide recess is formed, wherein the intermediate guide element extends in the guide slot in such a way that the movable blade is movably retained, and wherein the movable blade is arranged to be moved with respect to the stationary blade to cut hair.

11. The blade set of claim 10, wherein a rear portion of the frontal ends comprises four layers formed by sheet metal material, the rear portion being adjacent to the guide slot.

12. The blade set of claim 10, comprising an inner sheet and an outer sheet, wherein the outer sheet defines the top wall and the bottom wall, and wherein the inner sheet is arranged inside the outer sheet.

13. The blade set of claim 12, wherein the outer sheet is wrapped around the inner sheet.

14. The blade set of claim 12, wherein the inner sheet comprises an inner sheet folded edge at the frontal ends, wherein the outer sheet comprises an outer sheet folded edge at the frontal ends, and wherein the inner sheet folded edge is nestled in the outer sheet folded edge.

15. The blade set of claim 14, wherein the inner sheet comprises, adjacent to the inner sheet folded edge, a top layer and a bottom layer that contact one another.

16. A method of manufacturing a sheet metal based stationary blade of a blade set for a hair cutting appliance, the method comprising acts of: providing a sheet metal blank; forming a flat sheet metal component; forming at least one pattern of slots in the sheet metal component, thereby defining at least one toothed leading edge; and multiply folding the sheet metal component, thereby forming: a top wall, a bottom wall, and a guide slot formed between the top wall and the bottom wall to accommodate a movable blade, and a plurality of stationary blade teeth extending from the top wall and the bottom wall, each tooth of the plurality of stationary blade teeth having a frontal end, wherein the top wall and the bottom wall are mutually joined at the frontal ends, and wherein, at the frontal ends, two or more sheet metal folded edges are formed including first sheet metal folded edges of the top wall forming a first gap below the top wall between the first sheet metal folded edges of the top wall, and second sheet metal folded edges of the bottom wall forming the guide slot above the bottom wall between the second sheet metal folded edges of the bottom wall.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) These and other aspects of the disclosure will be apparent from and elucidated with reference to the embodiments described hereinafter. In the following drawings:

(2) FIG. 1 shows a perspective frontal view of an exemplary embodiment of a hair cutting appliance;

(3) FIG. 2 shows a perspective top view of an exemplary embodiment of a blade set for a hair cutting appliance;

(4) FIG. 3 shows a perspective bottom view of an exemplary embodiment of a blade set for a hair cutting appliance;

(5) FIG. 4 shows a bottom plan view of the arrangement of FIG. 3 in a exploded state;

(6) FIG. 5 is a partial top plan view of the arrangement of FIG. 3 including a hidden edge presentation;

(7) FIG. 6 is an enlarged lateral view of the arrangement of FIG. 5;

(8) FIG. 7 is an enlarged lateral cross-section along the line VII-VII in FIG. 5;

(9) FIG. 8 is an enlarged lateral exploded view of the arrangement of FIG. 5;

(10) FIG. 9 is a partial view of the arrangement of FIG. 3 in a partially detached state;

(11) FIG. 10 is a perspective top view of the arrangement of FIGS. 3 to 9 in a hidden edge representation, wherein an outer sheet is partially omitted for illustrative purposes;

(12) FIG. 11 is a perspective top view of a further exemplary embodiment of a blade set for a hair cutting appliance;

(13) FIG. 12 is an exploded view of the arrangement of FIG. 11;

(14) FIG. 13 is a unfolded view of a blank that forms a single sheet used in the arrangement of FIG. 11 and FIG. 12 to form a stationary blade thereof:

(15) FIG. 14 is an enlarged perspective bottom view of the arrangement of FIG. 11 in a partially detached state;

(16) FIG. 15 is an enlarged perspective bottom detail view of the stationary blade of the embodiment illustrated in FIGS. 11 to 14;

(17) FIG. 16 is a partial top plan view of the arrangement of FIG. 11 including a hidden edge presentation;

(18) FIG. 17 is an enlarged lateral cross-section along the line XVII-XVII in FIG. 16;

(19) FIG. 18 is an enlarged exploded lateral view of the arrangement of FIG. 16;

(20) FIG. 19 is an even further enlarged partial detail lateral view of the stationary blade illustrated in FIG. 17 and FIG. 18;

(21) FIG. 20 is a block diagram illustrating an exemplary embodiment of a method of manufacturing a stationary blade of a blade set;

(22) FIG. 21 is a block diagram illustrating an exemplary embodiment of a method of manufacturing a blade set for a hair cutting appliance; and

(23) FIG. 22 is a block diagram of yet another embodiment of a method of manufacturing a blade set for a hair cutting appliance.

DETAILED DESCRIPTION OF THE INVENTION

(24) FIG. 1 shows a perspective frontal view of a hair cutting appliance 10. The hair cutting appliance 10 is arranged as an appliance that is capable of both trimming and shaving.

(25) The appliance 10 comprises a housing 12 which is arranged in an elongated fashion. At the housing 12, a handle section 14 is defined. In the housing 12, a drive unit 16 is arranged. Further, a battery 18 may be arranged in the housing 12. In FIG. 1, the drive unit 16 and the battery 18 are represented by dashed blocks. At the housing 12, operator controls 20 such as on/off buttons and the like may be provided.

(26) At a top end thereof, the appliance 10 comprises a processing head 24 that is attached to the housing 12. The processing head 24 comprises a blade set 26. The blade set 26, particularly a movable blade thereof, may be actuated and driven by the drive unit 16 in a reciprocating fashion, refer also to the double arrow 28 in FIG. 1. As a result, respective teeth of the blades of the blade set 26 are moved with respect to one another, thereby effecting a cutting action. A top side or top surface of the blade set 26 is indicated by 30 in FIG. 1.

(27) The blades of the blade set 26 may be arranged at a first leading edge 32 and, in at least some embodiments, at a second leading edge 34 that is opposite to the first leading edge 32. The first leading edge 32 may be also referred to as frontal leading edge. A second leading edge 34 may be also referred to as rear leading edge.

(28) Further, a general advancing or moving direction of the appliance 10 is indicated in FIG. 1 by a double arrow 38. As the blade set 26 of the exemplary embodiment of FIG. 1 is equipped with two leading edges 32, 34, a push and a pull movement may be used to cut hair.

(29) In the following, exemplary embodiments of stationary blades and blade sets 26 will be elucidated and described in more detail. The blade sets 26 may be attached to the appliance 10, or to a similar appliance. It goes without saying the single features disclosed in the context of a respective embodiment may be combined with any of the other embodiments, also in isolated fashion, thereby forming further embodiments that still fall under the scope of the present disclosure.

(30) In some Figures shown herein, exemplary coordinate systems are shown for illustrative purposes. As used herein, an X-axis is assigned to a longitudinal direction. Further, a Y-axis is assigned to a lateral direction. Accordingly, a Z-axis is assigned to a vertical (height) direction. Respective associations of the axes/directions X, Y, Z with respective features and extensions of the blade set 26 can be derived from those Figures. It should be understood that the coordinate system X, Y, Z is primarily provided for illustrative purposes and not intended to limit the scope of the disclosure. This involves that the skilled person may readily convert and transform the coordinate system when being confronted with further embodiments, illustrations and deviating view orientations. Also a conversation of Cartesian coordinate systems into polar coordinate system may be envisaged, particularly in the context of a circular or curved blade set.

(31) In FIG. 2, a perspective view of a blade set 26 for a processing head or cutting head 24 of a hair cutting appliance 10 is shown. As with the embodiment shown in FIG. 1, a cutting direction and/or a direction of a relative movement of blades of the blade set 26 is indicated by an arrow 28. A top side of the blade set 26 that is facing the user when the appliance 10 is operated is indicated by 30. In the exemplary embodiment shown in FIG. 2, the blade set 26 is provided with a first leading edge 32 and a second leading edge 34. In FIG. 2 a stationary blade 42 of the blade set 26 is shown. A movable blade (cutter blade) is covered by the stationary blade 42 in FIG. 2. Stationary blade teeth are indicated by 44.

(32) The movable blade of the blade set 26 that is not visible in FIG. 2 is operated and actuated via a driving engagement element 48 that may also be referred to as driving bridge. At the element 48, a driving or engagement slot is formed that is engaged by a driving pin 50 of a driving shaft 52. The driving shaft 52 is rotated about a driving axis 54, refer to a curved arrow 56. The driving pin 50 is off-centered with respect to the driving axis 54. Consequently, as the driving pin 50 is revolving, a reciprocating movement of the movable blade with respect to the stationary blade 42 is effected.

(33) In FIG. 2, there is further indicated a pivot mechanism 58 which may be referred to as a contour following feature. The mechanism 58 enables a certain pivot movement of the blade set 26 about the Y-axis.

(34) With reference to FIGS. 3 to 19, exemplary embodiments of blade sets that are operable in an appliance 10 as shown in FIG. 1 and a processing head 24 as shown in FIG. 2 will be illustrated and described in more detail.

(35) FIG. 3 shows a perspective bottom view of a first embodiment of a blade set 64 in accordance with the present disclosure. As with the blade set 26 exemplarily illustrated in FIG. 2, also the blade set 64 comprises a stationary blade 66 which may also be referred to as guard, and a movable blade 68 which may also be referred to as cutter. In FIG. 3, the movable blade 68 is largely covered by the stationary blade 66.

(36) The blade set 64 comprises a first leading edge 70 and a second leading edge 72. At the stationary blade 66, stationary blade teeth 74 are provided both at the first leading edge 70 and the second leading edge 72.

(37) With reference to FIG. 3, and with additional reference to FIGS. 4 to 10, aspects and features of the blade set 64 will be illustrated and further detailed.

(38) The stationary blade 66 comprises a top wall 76, a bottom wall 78, and a guide slot 80 formed therebetween. The top wall 76 faces and contacts the user when an appliance implementing the blade set 64 is operated to cut hair. Hence, the bottom wall 78 is facing away from the user and facing the housing (reference numeral 12 in FIG. 1).

(39) FIG. 4 illustrates that in accordance with the embodiment described in FIG. 3 to FIG. 10, the stationary blade 66 comprises a so-called intermediate guide element 82 that matches a respective slot or window (guide recess 94) at the movable blade 68 to guide and retain the movable blade 68 in the guide slot 80. In an assembled state, the intermediate guide element 82 forms a portion of the stationary blade 66.

(40) Hence, the intermediate guide element 82 and the movable blade 68 have to be mounted to the guide slot 80 in a joined state.

(41) The outer sheet 86 may be regarded as an outer shell. The inner sheet 84 may be regarded as an inner shell. The outer sheet 86 is wrapped around the inner sheet 84. Together, the outer sheet 86 and the inner sheet 84 define the top wall and the bottom wall 78 and the guide slot 80 extending therebetween.

(42) In FIG. 4, movable blade teeth are indicated by reference numeral 68. Further, so-called alignment features 90 are provided at some of the components of the blade set 64. Alignment features 90 formed as recesses or holes are provided at the intermediate guide element 82, the inner sheet 84 and the outer sheet 86. In some embodiments, the alignment features ensure a proper and accurate alignment or the respective layers or sheets.

(43) In the guide recess 94 formed in the movable blade 68, contact elements 96 are provided that are arranged as contact protrusions. The contact elements 96 are arranged to contact guide surfaces at the intermediate guide element 82 as the movable blade 68 is reciprocatingly driven in the guide slot 80 of the stationary blade 66.

(44) In FIG. 4, connector zones 92 that are arranged as mounting recesses are provided at the movable blade 68. The connector zones 92 are arranged to be contacted or engaged by a driving element (refer to driving element 48 in FIG. 2) to operate the movable blade 68.

(45) Particular reference is made to FIG. 5, FIG. 6, FIG. 7 and FIG. 8. FIG. 5 illustrates an assembled state of the blade set 64, wherein hidden components are shown in a hidden edge mode. The teeth 74 of the stationary blade 66 comprise frontal ends 100 that form respective tips. As can be best seen from FIGS. 6 to 8, the frontal ends 100 are mutually formed by a contact between the top wall 76 and the bottom wall 78.

(46) At the inner sheet 84, a folded edge 106 is provided at the frontal end 100 of the teeth 74. At the outer sheet 86, a folded edge 108 is provided at the frontal end 100 at the teeth 74. The folded edge 106 is nestled in the folded edge 108. This applies to both the first leading edge 70 and the second leading edge 72 at opposite sides of the blade set 64, refer to FIG. 3.

(47) In any of FIGS. 5, 6 and 7, a rear portion of the teeth 74 is indicated by 112. In the rear portion 112, the inner sheet 84 forms a top layer 114 and a bottom layer 116 that contact one another. Further, the outer sheet 86 forms, in the rear portion 112, a top layer 120 and a bottom layer 122 that are spaced away from one another by the top layer 114 and the bottom layer 116 of the inner sheet 84. The top layer 114 of the inner sheet 84 defines a frontal end of the guide slot 80 that is provided for the movable blade 86.

(48) The terms “top” and “bottom” as recited in the claims are defined as directions relative to the orientation of the stationary blade as shown in FIG. 7, whereas the “frontal” direction as recited in the claims is defined as referring to either of the left and right ends of the stationary blade when oriented as shown in FIG. 7.

(49) Overall, the inner sheet 84 and the outer sheet 86 define a layered arrangement having four layers 114, 116, 120, 122 that are arranged, in the rear portion 112 of the teeth 74 on top of one another. The top layer 114 and the top layer 120 jointly define the top wall 76. The bottom layer 116 and the bottom layer 122 jointly define the bottom wall 78.

(50) Hence, as can be best seen in FIG. 6 and FIG. 7, the bottom wall 78 is thicker than the top wall 76 of the stationary blade 66. The guide slot 80 is formed between the top layer 120 of the outer sheet 86 and the bottom layer 116 of the inner sheet 84.

(51) FIG. 9 illustrates the layered arrangement of the components of the blade set 64. Similarly, FIG. 10 illustrates the blade set 64 in a mounted state, wherein for illustrative purposes, the outer sheet 86 is partially omitted.

(52) By providing two folded sheets 84, 86, the freedom of design may be greatly enlarged, resulting in differently sized walls at the top and the bottom of the stationary blade 66.

(53) With reference to FIG. 11 to FIG. 19, a further exemplary embodiment of a sheet metal based blade set 164 is illustrated and further detailed. FIG. 11 is a perspective bottom view of the blade set 164. FIG. 12 is a corresponding exploded view. The blade set 164 comprises a stationary blade 166 and a movable blade 168. The blade set 164 forms a first leading edge 170 and a second leading edge 172. At each of the first leading edge 170 and the second leading edge 172, teeth 174 of the stationary blade 166 are provided. The stationary blade 166 comprises a top wall 176 and a bottom wall 178 that define therebetween a guide slot 180 to accommodate the movable blade 168. To form the stationary blade 166, a single sheet 184 is used. Further, in accordance with the exemplary embodiment of FIGS. 11 to 19, no separate, distinct intermediate guide element (refer to reference numeral 82 in FIGS. 3 to 10) is present. Teeth of the movable blade 168 are indicated by 188 in FIG. 12. Further, as with the stationary blade 68 illustrated herein before, also the movable blade 168 comprises a guide window or guide recess 194, wherein contact elements 196 are provided that cooperate with a corresponding guide contour of the single sheet stationary blade 166. The contact elements 196 may be referred to as contact protrusions that contact corresponding guide walls or guide faces in the guide slot 180 of the stationary blade 166.

(54) Further, alignment features 190 are indicated in FIG. 12, refer also to FIG. 13 in this context. The alignment features 190 contribute to a final accurately folded shape of the single sheet 184 that forms the stationary blade 166.

(55) Further, as with the embodiment illustrated in FIGS. 3 to 10, also the movable blade 168 shown in FIG. 12 is provided with a connector zone 192 or connector geometry for a respective driving element.

(56) FIG. 13 illustrates a flat blank 198 from which the single sheet 184 may be obtained by punching or stamping. In the unfolded state, respective portions are arranged in a series that define in the finally folded state the teeth 174, the top wall 176, and the bottom wall 178. Further, tips or frontal ends 200 are illustrated in FIG. 13, wherein at each teeth 174, in the unfolded state, two frontal ends 200 are provided, and wherein an inward portion 202 is formed therebetween. The series of teeth 174 is provided in a respective pattern for both the first leading edge 170 and the second leading edge 172 in the blank 198 illustrated in FIG. 13. The series of teeth 174 may be defined by forming respective slots 204 between neighboring teeth. Further reference is made to FIG. 14 and FIG. 15, illustrating the stationary blade 166 in a folded state. In FIG. 14, the movable blade 168 is arranged in the guide slot 180 of the stationary blade 166. A guide for the movable blade 168 is provided by folded edges 214, 216 in a central or back portion 218 of the stationary blade 166. In this connection, further reference is made to FIG. 17, FIG. 18 and FIG. 19.

(57) FIG. 14 and FIG. 15 show that frontal ends 200 of the teeth 174 of the stationary blade 166 are formed by multiply folding the single sheet 184. In this way, folded edges 206, 208, 210 are formed at the frontal ends 200. The folded edge 206 may be referred to as top folded edge. The folded edge 208 may be referred to as bottom folded edge. The folded edge 210 may be referred to as intermediate folded edge. Overall, the frontal end 200 of the teeth 174 are M-shaped or lower case omega-shaped.

(58) In FIG. 16, FIG. 17 and FIG. 18, rear portions of the teeth 174 are indicated by dashed boxes. In the rear portion 212, the folded edges 206, 208, 210 define a frontal end of the guide slot 180.

(59) Further, as shown in FIG. 19 in more detail, at the back portion 218 of the stationary blade 166, folded edges 214, 216 are present that provide for a contact or connection between the top wall 176 and the bottom wall 178. The folded edge 214 is a rearwardly facing folded edge. The folded edge 216 is a frontal folded edge. The movable blade 168 is guided between the folded edges 210, 216.

(60) The single sheet 184 forms a top layer 230, a bottom layer 232, a first inner layer 234, and a second inner layer 236. In this way, using only a single sheet 184, a double walled stationary blade 166 and a precisely shaped and delimited guide slot 180 for the movable blade 168 may be formed. Further, the height of the guide slot 180 is accurately defined by the respective height (thickness) of the inner layers 234, 236 that is basically constant all over the sheet 180.

(61) Reference is made to FIG. 20, illustrating an exemplary embodiment of a method of forming a stationary blade for a blade set of a hair cutting appliance. In a first step S10, a sheet metal blank is provided. In a subsequent step S12, a sheet metal component is obtained therefrom. The step S12 may involve a punching or cutting operation. Further, in a step S14, a series of slots is formed in the sheet metal component that defines a series of teeth in the final state of the stationary blade. The steps S12 and S14 may be performed simultaneously.

(62) Having prepared a semi-finished product in this way, a folding step S16 may be started. As illustrated in FIG. 20, the following step S16 may involve sub steps S18, S20, each involving the formation of one folded edge. In this way, the sheet metal component may be folded two or more times to form a double-walled stationary blade that defines a guide slot, wherein at least one leading edge having a plurality of teeth is provided, wherein the teeth are, at a frontal end thereof, defined by two or more folded edges of the sheet metal material.

(63) Further reference is made to FIG. 21, illustrating an associated method of manufacturing a blade set for a hair cutting appliance.

(64) The method involves a step S50, relating to the provision of an inner sheet blank. In a subsequent step S52, a sheet metal component is formed, for instance by cutting. In a subsequent step S54, slots are processed in the sheet metal component that define a series of teeth. Further, a folding step S56 may follow wherein at least one folded edge in the sheet metal component is formed. Similarly, in a parallel sequence comprising steps S60, S62, S64, S66, an outer sheet is formed. In a step S60, an outer sheet blank is provided. In a subsequent step S62, a sheet metal component for the outer sheet is formed by cutting or stamping. In a further step S64, a series of slots is processed therein to define a series of teeth. Further in a step S66, the sheet metal component is folded.

(65) The steps S52/S54 and S62/S64, respectively, may be performed simultaneously.

(66) Both the inner sheet and the outer sheet are joined in a joining step S70. Eventually, the outer sheet is wrapped around the inner sheet.

(67) Further, provision steps S72 and S74 are provided. In the step S72, a movable blade is provided. In the step S74, an intermediate guide element is provided. The movable blade and the intermediate guide element are arranged such that they have to be jointly inserted in a guide slot defined by the inner sheet and the outer sheet. Consequently, an assembly step S76 follows, wherein the inner sheet, the outer sheet, the movable blade and the intermediate guide element are joined and assembled.

(68) Further, in a subsequent step S78, the inner sheet, the outer sheet and the intermediate guide element are fixedly attached to one another, for instance by bonding.

(69) Reference is made to FIG. 22, illustrating an alternative embodiment of a method of manufacturing a blade set for a hair cutting appliance. The method involves a step S100 relating to the provision of a sheet metal blank. In a subsequent step S102, a sheet metal component is obtained from the blank, for instance by cutting or stamping. In a further step S104, a series of slots is processed in the sheet metal component to define a plurality of stationary blade teeth. The steps S100 and S102 may be performed simultaneously.

(70) In a following folding step 106, three or more folding (sub-) steps S108, S110, S112 are performed. Hence, in accordance with the embodiment shown in FIG. 22, three folded edges are processed that are adjacent to one another to define a frontal end of the teeth of the stationary blade.

(71) In some embodiments, the folding step S106 further involves the formation of folded edges in a central region of the stationary blade as therein an intermediate guide element or guide structure for a movable blade of the blade set may be formed.

(72) In a step S114, a respective movable blade is provided. Hence, in an assembly step S116, the movable blade and the stationary blade may be joined and assembled. This may involve that the intermediate guide portion of the stationary blade engages a guiding recess at the movable blade to retain the movable blade in a guide slot of the stationary blade in an undetachable manner.

(73) A further step S118 may follow wherein a top wall and a bottom wall of the stationary blade that are formed as a result of the folding step S106 are attached to one another, for instance by bonding. Bonding may involve soldering, welding, laser welding, clinching, etc.

(74) While the invention has been illustrated and described in detail in the drawings and foregoing description, such illustration and description are to be considered illustrative or exemplary and not restrictive; the invention is not limited to the disclosed embodiments. Other variations to the disclosed embodiments can be understood and effected by those skilled in the art in practicing the claimed invention, from a study of the drawings, the disclosure, and the appended claims.

(75) In the claims, the word “comprising” does not exclude other elements or steps, and the indefinite article “a” or “an” does not exclude a plurality. A single element or other unit may fulfill the functions of several items recited in the claims. The mere fact that certain measures are recited in mutually different dependent claims does not indicate that a combination of these measures cannot be used to advantage.

(76) Any reference signs in the claims should not be construed as limiting the scope.