STATIONARY BLADE, BLADE SET, AND MANUFACTURING METHOD

Abstract

The present disclosure relates to a stationary blade (42) for a blade set (26) of a hair cutting appliance (10), said blade set (26) being arranged to be moved through hair in a moving direction to cut hair, said stationary blade (42) comprising a support insert (70), and a metal component (68) at least sectionally deformed to define a 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), wherein the first wall (100) and the second wall (102) are joined at the toothed leading edge (32, 34), wherein the support insert (70) connects the first wall (100) and the second wall (102), wherein the metal component (68) is held in place by the support insert (70), and wherein the metal component (68) and the support insert (70) jointly form a guide slot (60) for a movable blade (62). The disclosure further relates to a blade set (26) and to a method of manufacturing a blade set (26) for a hair cutting appliance (10).

Claims

1. A stationary blade for a blade set of a hair cutting appliance, said blade set being arranged to be moved through hair in a moving direction to cut hair, said stationary blade comprising: a support insert, and a metal component at least sectionally deformed to define a toothed leading edge having double-walled stationary blade teeth, wherein the metal component forms a first wall that is arranged to serve as a skin-facing wall when in operation, and a second wall that is facing away from the first wall, wherein the first wall and the second wall are joined at the toothed leading edge, wherein the support insert connects the first wall and the second wall, wherein the metal component is held in place by the support insert, and wherein the metal component and the support insert jointly form a guide slot for a movable blade.

2. The stationary blade as claimed in claim 1, wherein the stationary blade teeth are, when viewed in a cross-sectional plane perpendicular to a lateral direction, substantially U-shaped or V-shaped and comprise a first leg formed by the first wall and a second leg formed by the second wall, and wherein the first leg and the second leg merge into one another to form a tip of the stationary blade teeth.

3. The stationary blade as claimed in claim 1, wherein the first wall and the second wall are spaced away from one another by the support insert.

4. The stationary blade as claimed in claim 1, wherein the metal component and the support insert are force-fitted to one another in an assembled state of the stationary blade, and/or wherein the metal component and the support insert form an interference-fitted assembly.

5. The stationary blade as claimed in claim 1, wherein the first wall and the second wall of the metal component are, in an unassembled state, spaced away from one another in a contact region by a clearance that is smaller than a spacing offset that is present at the support insert in the contact region in the assembled state.

6. The stationary blade as claimed in claim 1, wherein the metal component is a sheet metal component, and wherein the support insert is a separately formed injection molded plastic part.

7. The stationary blade as claimed in claim 1, wherein the support insert defines a laterally extending guide contour for the movable blade, preferably wherein at the support insert a laterally extending guide projection is formed that forms a longitudinal boundary of the guide slot and that contacts the first wall of the metal component.

8. The stationary blade as claimed in claim 1, wherein the support insert forms a frontal longitudinal boundary and a rear longitudinal boundary for the guide slot, wherein the guide slot is bounded by the first wall at a top side thereof, and wherein the support insert preferably forms a bottom boundary of the guide slot.

9. The stationary blade as claimed in claim 1, comprising a first toothed leading edge and a second toothed leading edge opposite to the first toothed leading edge, wherein the first wall of the metal component extends from the first toothed leading edge to the second toothed leading edge.

10. The stationary blade as claimed in claim 1, wherein in the mounted state a longitudinal tip offset is provided between tips of the tooth portions of the support insert and tips of the tooth portions of the metal component that defines a clearance between the support insert and the metal component at least some of the a stationary blade teeth.

11. A blade set for a hair cutting appliance, the blade set comprising: a stationary blade as claimed in claim 1, and a movable blade comprising a plurality of movable blade teeth, wherein the movable blade is movably secured between the metal component and the support insert in the assembled state, particularly in an undetachable manner, and wherein the movable blade and the stationary blade are arranged to be moved with respect to one another to cut hair.

12. The blade set as claimed in claim 11, wherein in the movable blade, a guide recess is formed, and wherein a guide projection of the support insert extends into the guide recess to provide a positive-fit mounting for the movable blade at the stationary blade.

13. A method of manufacturing a blade set for a hair cutting appliance, the method comprising: providing a metal component, comprising: forming at least one pattern of slots in the metal component, transforming the metal component, thereby forming a first wall and a second wall, wherein the at least one pattern of slots defines a series of stationary blade teeth arranged at a toothed leading edge that is jointly formed by the first wall and the second wall, providing a support insert having a mounting extension that is greater than a mounting clearance between the first wall and the second wall, in a contact region between the support insert and the metal component, providing a movable blade having movable blade teeth, arranging the movable blade at the support insert, joining the metal component and the support insert, involving laterally inserting the support insert in the metal component, wherein, in a mounted state, the metal component is held in place by the support insert in the contact region.

14. The method as claimed in claim 13, wherein the step of joining the metal component and the support insert involves a force-fitted joining of the metal component and the support insert.

15. The method as claimed in claim 13, wherein the step of providing the metal component involves defining a mounting clearance between the first wall and the second wall of the metal component that is smaller than the mounting extension of the support insert in the contact region.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0096] These and other aspects of the disclosure will be apparent from and elucidated with reference to the embodiments described hereinafter. In the following drawings:

[0097] FIG. 1 shows a perspective frontal view of an exemplary embodiment of a hair cutting appliance;

[0098] FIG. 2 shows a perspective top view of an exemplary embodiment of a blade set for a hair cutting appliance;

[0099] FIG. 3 shows a perspective top view of an exemplary embodiment of a blade set in accordance with the present disclosure;

[0100] FIG. 4 shows a perspective bottom view of the arrangement of FIG. 3;

[0101] FIG. 5 shows a top view of components of the blade set shown in FIG. 3 and FIG. 4 in an exploded state;

[0102] FIG. 6 shows a perspective exploded top view of the arrangement of FIG. 3;

[0103] FIG. 7 shows a perspective exploded bottom view of the arrangement of FIG. 6;

[0104] FIG. 8 shows a perspective top view of an embodiment of a blade set, wherein components thereof are shown in a detached state;

[0105] FIG. 9 shows a partial top view of an embodiment of a blade set in accordance with the present disclosure;

[0106] FIG. 10 shows a lateral cross-sectional view along the line X-X in FIG. 9;

[0107] FIG. 11 shows a lateral cross-sectional view along the line XI-XI in FIG. 9;

[0108] FIG. 12 shows a lateral cross-sectional view along the line XII-XII in FIG. 9;

[0109] FIG. 13 shows a lateral cross-sectional view of the stationary blade of the arrangement shown in FIG. 10, wherein components of the stationary blade are shown in a detached state;

[0110] FIG. 14 shows in a schematic simplified cross-sectional view a further embodiment of a blade set in accordance with the present disclosure;

[0111] FIG. 15 shows in a schematic simplified cross-sectional view a further embodiment of a blade set in accordance with the present disclosure;

[0112] FIG. 16 shows in a schematic simplified cross-sectional view a further embodiment of a blade set in accordance with the present disclosure; and

[0113] FIG. 17 shows a block diagram illustrating an exemplary embodiment of a method of manufacturing a blade set for a hair cutting appliance in accordance with the present disclosure.

DETAILED DESCRIPTION OF THE INVENTION

[0114] 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.

[0115] 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.

[0116] 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.

[0117] 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.

[0118] 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.

[0119] 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.

[0120] 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.

[0121] 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.

[0122] 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.

[0123] 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.

[0124] With reference to FIGS. 3 to 15, 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.

[0125] FIG. 3 and FIG. 4 show perspective views of an exemplary embodiment of a blade set 26 in accordance with the present disclosure. For illustrative purposes, a movable blade 62 of the blade set 26 that is fully covered in the views of FIG. 3 and FIG. 4 by the stationary blade 42 is shown in a dashed line presentation. The movable blade 62 is explicitly shown in the exploded views of FIG. 6 and FIG. 7.

[0126] The movable blade 62 is accommodated in a guide slot 60 defined by the stationary blade 42. In the guide slot 60, the movable blade 62 is reciprocatingly movable, refer to the double-arrow 28 in FIG. 3. Hence, teeth 64 of the movable blade 62 may cooperate with teeth 44 of the stationary blade 42 to cut hair. Between the movable blade teeth 64, tooth slots 66 are formed, refer also to FIG. 8 and FIG. 9.

[0127] In accordance with major aspects of the present disclosure, the stationary blade 42 is an assembly that includes a metal component 68 and a support insert 70. In this context, reference is made to the exploded top view of FIG. 5. As shown therein, the stationary blade 42 is composed of at least two separate components that are mounted to one another. As shown in any of FIGS. 3 to 5, a first lateral end of the stationary blade 42 is formed by an end piece 74.

[0128] A second, opposite lateral end of the stationary blade 42 is formed in the exemplary embodiment by an end cap 76. As shown in FIG. 5, the end cap 76 of the exemplary embodiment is a separate part that is arranged to be attached to the support insert 70. By contrast, the end piece 74 is integrally formed with the support insert. In the assembled state as shown in FIG. 3 and FIG. 4, the metal component 68 and also the movable blade 62 are retained at the support insert 70 between the end piece 74 and the end cap 76. Hence, the end piece 74 and the end cap 76 form lateral ends of the blade set 26. In the mounted state, lateral ends 78 of the metal component 68 contact the end piece 74 and the end cap 76, respectively.

[0129] In at least some embodiments, the support insert 70 is a molded part. By way of example, the support insert 70 is an injection-molded plastic part. Hence, further features and elements may be integrally formed with the support insert 70. By way of example, at a bottom side of the support insert 70 that is visible in FIG. 4 and FIG. 7, mounting features 80 are formed thereon. The mounting features 80 may be arranged as mounting hooks that are arranged to engage corresponding locking features of the processing head 24, for instance locking features that are present at the contour following feature 58 indicated in FIG. 2.

[0130] A lateral end of the support insert 70 that is engaged by the end cap 76 in the mounted state is indicated by 82 in FIG. 5 and FIG. 6. The lateral end 82 contacts the end cap 76 in the mounted state. Further, the support insert 70 comprises a support wall 84 extending between the lateral end 82 and the end piece 74.

[0131] In the exemplary embodiments discussed in connection with FIGS. 3 to 12, the teeth 44 of the stationary blade 42 are jointly defined by tooth portions 88, 90 of the metal component 68 and the support insert 70. The tooth portions 88 are formed at the metal component 68. The tooth portions 90 are formed at the support insert 70. Between the tooth portions 88, tooth slots 92 are formed. Between the tooth portions 90, tooth slots 94 are formed, refer to FIG. 5.

[0132] The tooth portions 90 extend from the support wall 84 of the support insert 70 in a longitudinal direction. The tooth portions 88 of the metal component 68 are jointly defined by a first wall 100 and a second wall 102 thereof. In this context, reference is made to FIG. 6 and FIG. 7. As shown therein, the metal component 68 is obtained from sheet metal material through bending or folding. Hence, based on a single planar sheet metal blank, U-shaped or V-shaped tooth portions 88 may be obtained between which respective slots 92 are formed. By bending or folding the metal component 68, the first leading edge 32 and the second leading edge 34 of the stationary blade 42 are defined.

[0133] In the exemplary embodiments of FIGS. 3 to 12, the tooth portions 88 of the metal component 68 and the tooth portions 90 of the support insert 70 are aligned to one another, wherein the tooth portions 88 cover respective tooth portions 90.

[0134] At the leading edges 32, 34, a folding/bending edge 104 is provided at a transition between the first wall 100 and the second wall 102. In other words, the portion of the original planar sheet metal blank that forms the second wall 102 is bended by about 150 to 180 (degree) to define the U-shape or V-shape of the tooth portions 88 and the resulting teeth 44. At the folding/bending edge 104, a respective rounding may be provided.

[0135] Further, as shown in FIG. 6 and FIG. 7, at the movable blade 62, a guide recess 106 that forms a guide window is formed. The guide recess 106 cooperates with a guide protrusion 108 at the support insert 70. As a consequence, a positive fit guiding feature for the movable blade 62 in the guide slot 60 is formed. Hence, a longitudinal position of the movable blade 62 in the guide slot 60 is accurately defined. In operation, the movable blade 62 is moved in the lateral direction, involving a sliding movement between the guide recess 106 and the guide protrusion 108.

[0136] The guide recess 106 of the movable blade 62 is formed between a first support wall 110 and a second support wall 112. From the support walls 110, 112, the movable blade teeth 64 extend in the longitudinal direction. Further, the support walls 110, 112 are connected at the lateral ends of the movable blade 62, thereby defining the guide recess 106.

[0137] In an exemplary embodiment, the end cap 76 is arranged to be fitted in/onto the support insert 70. To this end, mounting recesses 114 are formed at the lateral end 82 of the support insert 70, refer to FIG. 6. At the end cap 76, mounting pins 116 are formed, refer to FIG. 5 and FIG. 7. The mounting pins 116 are arranged to engage the mounting recesses 114, thereby attaching the end cap 76 at the support insert 70.

[0138] Needless to say, there are further alternatives to attach the end cap 76 at the support insert 70. Further, in alternative embodiments, no separate end cap 76 is necessary. The mounting of the end cap 76 may involve a snap-on locking, a bonding procedure, and/or similar connection techniques.

[0139] In FIG. 6, a guide surface or guide contour for the movable blade 62 in the guide slot 60 at the stationary blade 42 is indicated by 118. The guide contour involves at least a bottom guide surface for the movable blade 62. Hence, in the attached state, the movable blade 62 is retained between the first wall 100 of the metal component 68 and the guide contour 118 formed at the support insert 70.

[0140] In FIG. 6 and FIG. 7, also the driving engagement element 48 is illustrated. Element 48 is arranged to be attached to a driving connector 120. The driving connector 120 may also be referred to as driving bridge. The driving connector 120 connects the driving engagement element 48 and the movable blade 62. Hence, via the driving connector 120, a driving movement may be transferred to the movable blade 62. At the support insert 70, a driving slot 122 for the driving connector 120 is formed. Hence, a defined laterally movable mounting for the driving connector 120 at the stationary blade 42 is provided.

[0141] In FIG. 6, there is further shown a guide stub 124 formed at the lateral end 82 of the support insert 70. In the mounted state, the guide stub 124 cooperates with a mating recess 126 at the end cap 76. Hence, the guide stub 124 defines the mounting position for the end cap 76.

[0142] As shown in FIG. 8, lateral limit stops 128, 130 for the movement of the movable blade 62 in the guide slot 60 at the stationary blade 42 are provided. The limit stop 128 is formed at the end piece 74. The limit stop 130 is formed at the end cap 76.

[0143] Further reference is made to the partial top view of FIG. 9, and to the corresponding cross-sectional lateral views of FIG. 10, FIG. 11 and FIG. 12. Additional reference is made to the enlarged lateral cross-sectional view of FIG. 13. FIG. 10 is a cross-sectional view along the line X-X in FIG. 9. FIG. 11 is a cross-sectional view along the line XI-XI in FIG. 9. FIG. 12 is a cross-sectional view along the line XII-XII in FIG. 9. FIG. 13 shows an exploded view of an exemplary embodiment of a stationary blade 42 in accordance with the arrangement of the cross-sectional view of FIG. 10.

[0144] In the cross-sectional view of FIG. 10, a cross-section of stationary blade teeth 44 and movable blade teeth 62 is shown. In FIG. 11, a cross-sectional view through a tooth slot 66 of the movable blade 62 and through tooth slots 92, 94 of the stationary blade 42 is shown. In FIG. 12, a cross-sectional view of the movable blade teeth 64 and the tooth slots 92, 94 of the stationary blade 42 is shown.

[0145] As can be best seen in FIG. 13, the support insert 70 defines a frontal longitudinal boundary 138, a rear longitudinal boundary 140, and a bottom boundary 142 for the guide slot 60. A top boundary of the guide slot 60 is defined by the first wall 100. The bottom boundary 142 is formed by the support wall 84. As the support insert 70 is in at least some embodiments molded, it is easy to define the guide slot 60 in such a way that the movable blade 62 is accurately accommodated therein. It is important to receive the movable blade 62 in such a way in the guide slot 60 that a defined contact between the movable blade teeth 62 and the stationary blade teeth 44 is provided. Hence, a defined vertical clearance is necessary to provide a certain ease of motion for the movable blade 62. On the other hand, the vertical clearance in the guide slot 60 may not be too large since otherwise no tight contact between the movable blade teeth 64 and the stationary blade teeth is ensured. Basically the same applies to the longitudinal position of the movable blade 62 in the guide slot 60 that is defined by the frontal longitudinal boundary 138 and/or the rear longitudinal boundary 140.

[0146] In FIG. 9 and FIG. 10, tips of the stationary blade teeth 44 are indicated by 144. The tips 144 are primarily defined by the first wall 100 and the second wall 102 that merge into one another at the tips 144.

[0147] Between the first wall 100 and the second wall 102, adjacent to the guide slot 60, a connector arm 148 is formed at the support insert 70. The connector arm 148 extends between the first wall 100 and the second wall 102. The connector arm 148 forms the frontal longitudinal boundary 138, the rear longitudinal boundary 140, and the bottom boundary 142. Further, the connector arm 148 defines an offset that ensures a tight and close contact between the support insert 70 and the first wall 100 and the second wall 102 of the metal component 68 in the mounted state.

[0148] In some embodiments, as indicated in FIG. 10, a tip offset 152 between the tooth portion 88 of the metal component 68 and the tooth portion 90 of the support insert 70 is present. The tip offset 152 enables a certain flexibility of the second wall 102 with respect to the first wall 100 that contributes to the pretensioned well-defined mounting of the metal component 68 and the support insert 70.

[0149] Further, the tip offset 152 facilitates mounting the metal component 68 and the support insert 70. The mounting procedure typically involves a relative lateral sliding movement between the metal component 68 and the support insert 70. When the tooth portions 90 of the support insert 70 would completely fill the gap defined by the metal component tooth portions 88 in the longitudinal direction, there might be a certain likelihood of damaging or even breaking the tooth portions 90. So it is beneficial to form the tooth portions 90 of the support insert 70 in the longitudinal direction in such a way that the interior space provided by the convexly shaped tooth portions 88 of the metal component 68 is not completely filled.

[0150] In FIGS. 10 to 13, a contact region 156 between the metal component 68 and the support insert 70 is indicated by 156. As used herein, the contact region 156 is a region wherein a contact between the metal component 68 and the support insert 70 is possible, and wherein at least a part of the guide slot 80 is formed. In the contact region 156, a tight, at least slightly preloaded contact between the metal component 68 and the support insert 70 is provided. The support insert 70, particularly the connector arm 148 thereof, is arranged between the first wall 100 and the second wall 102.

[0151] As discussed above, the metal component 68 is arranged such that in an unassembled state a distance or gap between the first wall 100 and the second wall 102 in the contact region 156 is smaller than a corresponding mating contour of the connector arm 148 of the support insert 70. Hence, in the mounted state, a certain preloading and the metal component 68 is induced, as the first wall 100 and the second wall 102 are at least slightly urged away from one another in the contact region 156.

[0152] As indicated herein before, the tooth portions 88 of the metal component 68 that form a considerable portion of the stationary blade teeth 44 are U-shaped or V-shaped. That is, the tooth portions 88 comprise a first leg 160 and a second leg 162 that contact one another to form the tips 144. The first leg 160 is formed by the first wall 100. The second leg 162 is formed by the second wall 102.

[0153] In FIG. 13, respective mating dimensions of the support insert 70 and the metal component 68 are indicated. At the metal component 68, at least one of a vertical clearance l.sub.cl and/or a clearance angle .sub.cl (alpha.sub.cl) is present between the first wall 100 (or the first leg 160) and the second wall 102 (or the second leg 162).

[0154] At the support insert 70, particularly at the connector arm 148, at least one of a vertical offset l.sub.o or a vertical mounting angle .sub.o (alpha.sub.o) is present at opposite surfaces that are arranged to contact the first wall 100 and the second wall 102 in the mounted state, respectively.

[0155] In the detached state as shown in FIG. 13, the first leg 160 and the second leg 162 are closer to one another than in the assembled state (as indicated in FIGS. 10 to 12) as in the assembled state. The relative position between the first wall 100 and the second wall 102 is defined by the connector arm 148. In other words, the vertical clearance l.sub.cl is smaller than the vertical offset l.sub.o and/or the clearance angle .sub.cl is smaller than the offset angle .sub.o, at least slightly.

[0156] As a consequence, a force-fitted or interference-fitted mounting of the metal component 68 and the support insert 70 is enabled. Preferably, a close contact between any of the first leg 160 and the second leg 162 and the corresponding surfaces of the connector arm 148 is possible. Hence, any resulting gaps after the mounting procedure are preferably avoided.

[0157] In connection with the above-described FIGS. 1 to 13, several aspects and embodiments of the present disclosure have been discussed with reference to relatively detailed embodiments. Based thereon, reference is made to FIG. 13, FIG. 14 and to FIG. 15 each schematically illustrating alternative embodiments that may however utilize at least some of the above-discussed features, components and sub-assemblies. Therefore, in the following primarily deviations are emphasized and explicitly discussed. Apart from that, the arrangements of any of FIGS. 14, 15 and 16 may be arranged in accordance with the above-discussed embodiments.

[0158] FIG. 14 schematically illustrates a lateral cross-sectional view of a blade set 226. In FIG. 14, a view of a metal component 268 in isolation is provided. Further, a corresponding view of a stationary blade 242 that implements the metal component 268 and a corresponding support insert 270 is shown. In addition, an assembled state of the blade set 226 is shown, wherein a movable blade 262 is mounted to the stationary blade 242.

[0159] As already discussed herein before, the metal component 268 comprises a first wall 300 and a second wall 302. In the mounted state of the stationary blade 242, the support insert 270 is arranged between the first wall 300 and the second wall 302 to form the blade set 226, and to define a guide slot 260 therein. In the mounted state, the movable blade 262 is accommodated in the guide slot 260, refer to reference numerals 310, 312 indicating respective support walls of the movable blade 262. Further, a contact region between the metal component 268 and the support insert 270 is indicated by a dashed box 356.

[0160] FIG. 15 schematically illustrates a lateral cross-sectional view of a further exemplary arrangement of a blade set 426. In FIG. 15, a view of a metal component 468 in isolation is provided. Further, a corresponding view of a stationary blade 442 that implements the metal component 468 and a corresponding support insert 470 is shown. In addition, an assembled state of the blade set 426 is shown, wherein a movable blade 462 is mounted to the stationary blade 442.

[0161] The metal component 268 comprises a first wall 500 and a second wall 502. In the mounted state of the stationary blade 442, the support insert 570 is arranged between the first wall 500 and the second wall 502 to form the blade set 426, and to define a guide slot 460 therein. In the mounted state, the movable blade 462 is accommodated in the guide slot 460, refer to reference numerals 510, 512 indicating respective support walls of the movable blade 562. Further, a contact region between the metal component 568 and the support insert 570 is indicated by a dashed box 556.

[0162] FIG. 16 schematically illustrates a lateral cross-sectional view of a further exemplary arrangement of a blade set 626. In FIG. 16, a view of a metal component 668 in isolation is provided. Further, a corresponding view of a stationary blade 642 that implements the metal component 668 and a corresponding support insert 670 is shown. In addition, an assembled state of the blade set 626 is shown, wherein a movable blade 662 is mounted to the stationary blade 642.

[0163] The metal component 668 comprises a first wall 700 and a second wall 702. In the mounted state of the stationary blade 642, the support insert 670 is arranged between the first wall 700 and the second wall 702 to form the blade set 626, and to define a guide slot 660 therein. In the mounted state, the movable blade 662 is accommodated in the guide slot 760, refer to reference numerals 710, 712 indicating respective support walls of the movable blade 762. Further, a contact region between the metal component 668 and the support insert 670 is indicated by a dashed box 756.

[0164] In any of FIG. 14, FIG. 15 and FIG. 16, the first wall 300, 500, 700 and the second wall 302, 502, 702 of the metal component 268, 468, 668 are closer to one another in a separated, isolated state than in the mounted state of the stationary blade 242, 442, 642.

[0165] Hence, in FIG. 14, a clearance angle between the first wall 300 and the second wall 302 is smaller than an offset angle .sub.o of the support insert 270 in the contact region 356. In FIG. 15, a vertical clearance l.sub.cl between the first wall 500 and the second wall 502 of the metal component 468 is smaller than a mounting offset l.sub.o provided by the support insert 470 in the contact region 556.

[0166] Similarly, in FIG. 16, a clearance angle .sub.cl between the first wall 700 and the second wall 702 of the metal component section 668 is smaller than an offset angle .sub.o provided by the support insert 670 in the contact region 756. Further, in FIG. 16, a longitudinal extension of the support insert 670 towards the respective tips of the teeth is smaller than in any of the support inserts 370, 570 of FIG. 14 and FIG. 15. However, also in the embodiment schematically illustrated in FIG. 16, an interference-fitted or force-fitted mounting of the metal component 668 and the support insert 670 to define the guide slot 670 therebetween is possible.

[0167] Further reference is made to FIG. 17, schematically illustrating an exemplary embodiment of a method of manufacturing a blade set for a hair cutting appliance. The method involves the provision of a metal component, and a support insert that jointly form a stationary blade in which a movable blade is accommodated.

[0168] In a first step S10, a sheet metal blank is provided based on which the metal component is formed. In a following step S12, a series of tooth slots is processed in the sheet metal blank, preferably in an unfolded state. Hence, relatively simple manufacturing methods may be used. In a further step S14, the originally planar sheet metal blank is transformed. This may involve bending or folding the sheet metal material around a folding edge that is parallel to and crosses the series of tooth slots. Hence, a first wall and a second wall are formed that are connected to define a series of stationary blade teeth.

[0169] In a further step S20, a support insert is provided that is arranged to be inserted in the metal component processed in steps S10 to S14. The support insert may be obtained through molding, particular through injection-molding. Hence, the support insert may be made from plastic material, for instance. At the support insert, further features may be integrally formed, for instance a guide protrusion, mounting features, lateral end pieces, etc.

[0170] Further, in a step S30, a movable blade for the blade set is provided. Generally, the movable blade is adapted to be accommodated in a guide slot that is jointly defined by the metal component and the support insert.

[0171] To assemble the blade set, in a first assembly step S40, the movable blade is arranged in a mounting position at the support insert. In the joined state obtained through step S40, the sub-assembly of the support insert and the movable blade may be inserted in the metal component in a further assembly step S50. The first wall and the second wall of the metal component embrace or cover the support insert and also the movable blade, at least partially. Both the metal component and the support insert form the stationary blade.

[0172] Preferably, the metal component and the support insert are force-fitted or interference-fitted. Hence, a certain preloading or pretensioning is induced in the metal component that generates a retaining force. In the resulting assembled blade set, the movable blade is movably accommodated in a guide slot formed between the metal component and the support insert.

[0173] As indicated by dashed blocks, further optional steps S60 and S70 may follow. The optional step S60 involves the provision of an end cap for the stationary blade. The end cap may be an injection-molded plastic part.

[0174] In the step S70, the end cap is mounted to the support insert, to secure the assembly of the metal component and the support insert, and to retain the movable blade between respective lateral ends of the stationary blade.

[0175] In alternative embodiments, the mounted state of the metal component and the support insert and the defined movable arrangement of the movable blade in the guide slot is otherwise secured.

[0176] While the disclosure 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.

[0177] 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.

[0178] Any reference signs in the claims should not be construed as limiting the scope.