CN1297395A - 一种剃刀的制造方法 - Google Patents

一种剃刀的制造方法 Download PDF

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CN1297395A
CN1297395A CN99805036A CN99805036A CN1297395A CN 1297395 A CN1297395 A CN 1297395A CN 99805036 A CN99805036 A CN 99805036A CN 99805036 A CN99805036 A CN 99805036A CN 1297395 A CN1297395 A CN 1297395A
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C·C·加兰德
A·J·库雷洛
B·C·约翰逊三世
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Abstract

公开了一种将刮面辅件(38、42)固定于剃刀(10)的方法,它具有将刮面辅料挤压成形为股条状(50)的步骤。股条(50)然后被连续地卷绕于一卷轴(48)上,以便于贮存。在组装期间,股条(50)被送至超声波焊接/切割器而将其切成预定长度的刮面辅件,之后被焊接于剃刀上。股条(50)为了增加韧性和改变形状,可在被切断和焊接前将其冷加工。

Description

一种剃刀的制造方法
本发明涉及一种剃刀制造方法，尤其是涉及一种制造具有刮面辅件的剃刀的方法。
在一次性使用的剃刀中结合一种刮面辅件是合乎需要的。美国专利US 4170821(“821专利”)公开了一种具有固体水溶性刮面辅件的剃刀架。刮面辅件可以是润滑剂、胡须软化剂、剃刀清洁剂、药物、芦荟类制剂(aloe Vera)、维生素E、羊毛脂、以及它们的其它混合物或组合物。一种刮面辅件的典型组份包括一亲水性聚合物和别的可溶性刮面辅件如上面列举的那些，它们被夹带在亲水性聚合物基体中。一般说来，聚乙烯氧化物用作亲水聚合物，聚苯乙烯用作憎水聚合物。其它组份也是可以的。
不管用作刮面辅件的实际化学组份如何，均可用注射模压成形或挤压成形工艺来大批量制作大量需要的刮面辅件。在注射模压成形时，刮面辅件如美国专利US 4778640所示那样，被共同直接模压成形在剃刀中。在挤压成形时，如在美国专利US 4624051所展示的那样，刮面辅件先被挤压成期望的形状，然后将它们切成需要的大小。而且，为了固定于剃刀而将此预制件安置在合适的方向和位置上而使制造工艺复杂化。
用来将预切制的刮面辅件紧固于剃刀的方法包括机械装置及粘接剂。在采用机械措施时，剃刀被制作得具有一内腔，该刮面辅件就如“051”专利所介绍的那样被插入该腔中。一种小调整片或类似物被用来将刮面辅件保持在腔中。此方法固有的不足之处包括需要以精确的公差精细地预先切制刮面辅件，以及附加的生产小调整片或类似物的制作成本及时间。
在使用如丙烯酸粘接剂那样的粘接剂时，在粘接剂施加之后必须使刮面辅件与剃刀正确定位，还要将两者紧夹在一起经历一时间期限以便形成粘接结构。虽然可以通过施加能量如用紫外线照射来缩减凝固时间，但这要附加别的制作步骤而使生产成本增加。此外，紫外线辐射可能被剃刀组件上的结构件吸收或折射，由此而使粘接剂凝固不均匀。在任何情况下，甚至一加快的凝固时间还使制造效率降低。粘接剂的其它不足是增加了粘接剂的费用及与处理粘接剂有关的困难。
应用超声波能来连接塑料构件已被使用于许多行业中。在超声波焊接中，一种固态动力源将电能转变为20KHz或40KHz的机械能。一转换器将此电能转变为超声波机械振动能，一喇叭形辐射体将超声波机械能直接传递到被组装的构件上。被连接构件之间配合表面上的分子内摩擦力、表面摩擦力及所施加的力相结合在一起，使温度升高，一直升到材料的熔点为止。在振动终止后在界面处保持作用力，因而产生分子粘接即焊接。在下列出版物中对超声波焊接进行了更完整的研讨：“用于高效组装的超声波及微信息处理机组合”载于1987.11.的(Assembly Engineering)装配技术上；及由Branson Uitrasonicscorporation出版的“超声波塑料组装”上。这些资料用作本发明的参考文献。
超声波焊接也已被用在剃刀制作业中。例如，美国专利No.US5070613介绍了一种剃刀刀片与刀架组件，其刀架通过超声波焊接一固定条被固定于剃刀组件的下部来进行固定。此外，利用超声波将一次性使用的即用后即弃的(disposable)剃刀头部焊接在一手柄部分上也是公知技术。但是，在本领域中并没有建议或公开过用超声波焊接刮面辅件。
因此，需要一种行之有效的方法来将刮面辅件用超声波焊接在剃刀上。
本发明的一个目的是提供一种制造剃刀的方法，其中，至少一个刮面辅件被以超声波焊接到所述剃刀上。
本发明的另一个目的是优化其上固定有一刮面辅件的剃刀之制造方法。
本发明的又一目的是将一刮面辅件挤压成形为一连续股条状，以方便将其贮存及最后固定于剃刀。
本发明的还有一个目的是将股条状刮面辅件在被固定于剃刀前用冷加工制成所期望的形状。
本发明这些以及其它目的通过将刮面辅件固定于剃刀的方法来实现，此方法具有步骤：将刮面辅件挤压成一连续股条，将此股条卷绕在一卷轴上，将该股条从卷轴送至一切割器，将该条切割成为一预定长度的刮面辅件，然后将至少一个刮面辅件固定在剃刀上。此方法也可以包括将刮面辅件挤压成一具有圆截面形状的连续股条，以及在切断该股条之步骤前的冷加工该股条的步骤。因此，所述方法也可以包括用超声波焊接将刮面辅件焊在剃刀上的步骤，它通过将超声波能量导引至剃刀上适于接纳至少一个刮面辅件的槽侧壁处来焊接。
图1是分解立体图，它展示一具有根据本发明制造的刮面辅件的剃刀；
图2是使用本发明制造剃刀方法的制造设备简图；
图3是制造设备之冷加工部分的放大简图；
图4是一超声波焊机/切割器的喇叭形辐射体立体图；
图5是一带刮面辅件的剃刀盖之剖视图；
图6是图4所示的不带刮面辅件的剃刀盖剖视图。
如图1所示，一剃刀包括一带安装部分12及一连接部分14的刀片座10。连接部份与手柄18的臂杆16相配接，在图1中只展示了手柄18的一部分。连接部分14和臂杆16采用合适的方法，如采用粘接剂或超声波焊接被永久地连接在一起。图1所示的剃刀是一种可用后抛弃的剃刀，在这种剃刀之刀片变钝后，此整个组件就被扔掉。本发明也可以用来制造一适合于连接到一可重复使用之柄上或从其上拆卸的可用后抛弃的刀架。因此，本发明不只被局限在任何具体类型的剃刀结构上。
安装部分12在其每端上含有一矩形孔20，在孔20之间置有多个圆孔22。安装部分12被构制和尺寸设置得容纳至少一个刀片24。刀片24具有端槽口26，端槽之间置有多个圆孔28。当刀片24被准确地安装在安装部分12上时，该槽口26与孔20对准，孔22则与孔28对准。虽然所展示的剃刀只有一刀片24，但本发明的制造方法也可以被使用于具有多个刀片的一次性剃刀或刀架上。一盖件32覆盖除了切割刃30以外的刀片24其余部分。在盖32的背面延伸出(在图5中示出的)铆钉33及柱件34。刀片24由通过刀片24上的孔28插入安装部分12之孔22中的铆钉33及通过(刀片)端槽口26插入矩形孔20中的柱件34所握持。铆钉33的端部35被冲压以使盖件32和刀片24永久地连接在刀片座10上。
盖32有一用于接纳一第一刮面辅件38的上槽36及一用于接纳第二刮面辅件42的下槽40。第一、二刮面辅件38、42可以是润滑剂、胡须软化剂、剃刀清洁器、药剂、芦荟类制剂(aloe Vera)、维生素E、羊毛脂或这类物品的组合。推荐每个刮面辅件承载不同的刮面辅料。指出本发明可用于任何数量的刮面辅件的情况也很重要。在剃刀被组装好后，在其被使用前和使用期间，用防护盖44将切割刃30覆盖住以防护它被损。
在一推荐实施例中，一刮面辅件被以公知的方式挤压成一种连续股条，在其被卷绕于一卷轴贮存起来之前经空气冷却。用于挤压成形该辅件的方法已公开在“821”专利中，此专利在本文中引证过，用作本申请的参考文献。美国专利No US 4182582也公开了同时挤压包括亲水和疏水材料的不同聚合物的方法，此专利作为本申请的参考资料。“051”专利还公开了疏水聚合物基体能够占据刮面辅件体积的50％或更多。该疏水聚合物可以占据刮面辅件之体积的20％-80％。所述基体占据刮面辅件之体积的推荐百分比值约25％-35％。该基体材料是聚苯乙烯。其余体积的刮面辅件是各种水溶性刮面辅料。推荐的用于刮面辅件条的形状是圆形横截面，因为其是用于贮存在卷轴上的最佳形状。最好是将挤压期间如温度、湿度那种的环境因素加以控制，以便减少由含在刮面辅件中的亲水聚合物吸收的水量。
将刮面辅件固接于剃刀的方式展示于图2。一制造设备46使用一其上含有上述讨论过的连续股条50形式之刮面辅件的卷轴48。股条50从卷轴48经张紧件52送进，张紧件52将股条50拉紧送入左滚子54A和右滚子54B中，以便将股条切成预定长度后被固定在剃刀上。
这样，根据本发明，那些如’051专利所描述的：将刮面附件切成规定的分段以便存放然后在其被固定于剃刀之前确定方位及配置步骤已被取消了。
滚子54A，54B用来将股条50从卷轴48拉曳出来后送入剃刀装配单元。滚轮54A及54B也可以对股条50进行冷加工，从而将刮面辅件制成任何想要的形状，该形状可是对称截面形状如圆形、方形、矩形、三角形和椭圆形，也可以是不对称形状。如从图3最清楚地看到的那样，左、右滚轮54A，54B分别有各自的接触面56A，56B。刮面辅件被冷加工的程度及其最后的轮廓取决于接触面56A，56B的形状和尺寸。接触面56A，56B无需一样。例如，接触面56A可以是矩形，但接触面56B则可以是圆形。已被观察到，冷加工也可以使股条50的延展性增大。股条50之加大的延展性可在其制作过程中提供更大的柔性。作为一种替换，也加以给滚轮54A、54B加热来使该加工方便。
参考图2及3，股条50在冷加工步骤后被送入轮子58。轮子58上具有多个安装器60。每个安装器被构造和尺寸设置得可接纳一盖件32，并可应用任何一种将盖件32装入安装器60上的方法。例如，盖件32可以用由如美国印第安那州印第安那玻利斯市Moorseed公司供应的那类振动槽送入安装器60。当股条50的部分已被送入和对准安装器60时，一预定长度的股条50就被切下，然后使刮面辅件被固定于盖件32的上槽或下槽36、40中。
超声波焊接/切割器62将股条50切成为一预定长度的刮面辅件并将其用超声波焊接在剃刀上。超声波焊接/切割器62有一致动器，它含有一转换器、增压机(booster)、喇叭辐射体，及气动或伺服控制。在焊接和切割期间致动器体喇叭辐射体64与安装器60接触并施加一合适的力，在焊接工作之后将喇叭辐射体缩回。在刮面辅件被用超声波焊接在盖件32上后，盖件32就被传送至一质量控制机构66处进行检验。
为了简便起见，图2和3只展示了一个刮面辅件与盖32的连接配置。为了连接一第二个刮面辅件，一卷轴、张紧构件和滚子的第二组合方案可以将第二个股条50送入轮子58。第二个超声波焊接/切割器被用来切割第二刮面辅件并将之焊接在盖件32上。
在本发明的另一推荐实施例中，从喇叭辐射体64辐射出的超声波能量被导引着离开槽36、40的底部而朝向它们的侧壁。如图4所示，喇叭辐射体64有一锥楔形本体68，本体68终止于一能量转换器70。该喇叭辐射体64的几何形状最好能控制超声波能量的方向朝向槽36、40的侧壁72A，72B(参看图5，6)。更具体地说，能量转换器70包括一圆形部分71，其形状及大小被设置得可配置于刮面辅件38、42上面。圆形部分71终止于角部74A，74B。从转换器70辐射出的能量最好能如图6所示那样局部地熔化侧壁72A，72B的一部分，从而在这些侧壁和刮面辅件间形成一焊接缝。如图5所示，刮面辅件与侧壁72A，72B形成搭叠关系。在施加超声波能量之后，搭叠区域被熔合在一起，在各槽36，40和每个刮面辅件之间分别形成两条连续焊缝(线)，从而将刮面辅件永久性地连接在剃刀盖件上。
众所周知，强固的超声波焊接结构能在相同或相似材料构成的连接件之间形成。因此，如果聚苯乙烯被用作刮面辅件38，42的疏水剂，就推荐使盖件32也用聚苯乙烯来制作。但是，本发明的方法可在不同材料之间产生有足够强度的连接。因此，即使刮面辅件38，42与盖件32由不同材料制作，在它们之间也能形成有足够强的连接。
虽然在此公开的说明性实施例已实现了上述发明目的，但可体会到：本领域的那些熟练人员可以作出无数改进及别的实施方案。因此应该明白，后附的权利要求将覆盖在本发明基本精神范围内的所有改进和
实施方案。

Claims (20)

1.一种用于将刮面辅件连接于一剃刀上的方法，它包括步骤：
将刮面辅料挤压成为一连续股条；
将该股条卷绕于一卷轴上；
将该股条从卷轴送至一切割器；
将该股条切成预定长度的刮面辅件；以及
将至少一个刮面辅件连接于一剃刀上。
2.如权利要求1所述的方法，其特征在于，挤压刮面辅件的步骤包括将刮面辅件挤压成一具有圆形截面的连续股条的步骤。
3.如权利要求1所述的方法，其特征在于，它还包括在切割该股条步骤之前对该股条进行冷加工的步骤。
4.如权利要求1所述的方法，其特征在于，将至少一个刮面辅件连接于剃刀的步骤还包括用超声波将该刮面辅件焊接在该剃刀上的步骤。
5.如权利要求4所述的方法，其特征在于，超声波焊接步骤还包括将超声波能量引导至剃刀上适于接纳一刮面辅件的槽之侧壁上的步骤。
6.一种用于制造具有至少一刮面辅件的一次性使用剃刀的方法，它包括步骤：
将至少一个刮面辅件用超声波焊接在该剃刀上；
将至少一个剃刀刀片安置在刀片座中；以及
将该至少一剃刀刀片固定在刀片座与一盖件之间。
7.如权利要求6所述的方法，其特征在于，它还包括将超声波能量引导至该盖中其尺寸至少容纳一刮面辅件的槽之侧壁上的步骤，从而使所述至少一个刮面辅件与盖件被在所述侧壁与至少一个刮面辅件之间形成的焊缝相连接。
8.如权利要求6所述的方法，其特征在于，它还包括将刮面辅件挤压成形为一连续股条的步骤。
9.如权利要求8所述的方法，其特征在于，它还包括将连续股条在使用前一直贮存于一卷轴上的步骤。
10.如权利要求8所述的方法，其特征在于，它还包括将连续股条冷加工成一具有与盖上的至少一个槽型廓匹配之轮廓的步骤。
11.如权利要求10所述的方法，其特征在于，该冷加工步骤是通过使该连接股条经过两个滚轮之间来实现的。
12.如权利要求8所述的方法，其特征在于，它还包括将连续股条切成一预定长度之刮面辅件的步骤。
13.如权利要求6所述的方法，其特征在于，盖件是由聚苯乙烯制作的，所述至少一个刮面辅件也含有聚苯乙烯。
14.如权利要求13所述的方法，其特征在于，该至少一个刮面辅件含有25％-35％的聚苯乙烯。
15.如权利要求8所述的方法，其特征在于，它还包括控制环境温度和湿度的步骤；以便使股条吸收的水分减少。
16.一种一次性使用的剃刀或刀架，它包括一刀片座，至少一片剃刀刀片，一盖件及至少一个刮面辅件，其中，
所述至少一个刮面辅件被用超声波方法焊接在该剃刀或刀架上。
17.如权利要求16所述的剃刀或刀架，其特征在于，该焊接缝置于盖件与至少一个刮面辅件之间。
18.如权利要求17所述的剃刀或刀架，其特征在于，盖件具有至少一个用于接纳至少一个刮面辅件的槽部。
19.如权利要求18所述的剃刀或刀架，其特征在于，焊接缝置于该至少一个槽部的侧壁上。
20.如权利要求16所述的剃刀或刀架，其特征在于，该盖件是用聚苯乙烯制作的，至少一个刮面辅件含有聚苯乙烯。
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