Blade set, hair cutting appliance, and related manufacturing method

1. A method of manufacturing an integrally formed metal-plastic composite stationary blade of a blade set for a hair cutting appliance, the method comprising:

providing a substantially flat metal component;

forming at least one pattern of slots in the metal component, thereby defining at least one toothed leading edge;

forming a metal shell comprising a first wall portion and a second wall portion, wherein the step of forming the metal shell includes bending the substantially flat metal component, wherein the second wall portion is formed from a frontal portion and a rear portion that are arranged at opposite ends of the substantially flat metal component, wherein the first wall portion and the second wall portion jointly form at least one toothed leading edge, the first wall portion being arranged to serve as a skin facing wall when in operation, the second wall portion being at least partially offset from the first wall portion, such that the first wall portion and the second wall portion define therebetween a guide slot for a movable cutter blade, wherein the at least one toothed leading edge comprises a plurality of teeth;

providing a substitute component that is configured to keep clear a to-be-formed guide slot of the stationary blade when molding;

providing a mold that defines a shape of a plastic component;

arranging the bent metal component and the substitute component in the mold;

forming the plastic component by arranging a plastic material in at least a portion of a remainder of the mold not occupied by the metal component and the substitute component, wherein the plastic component comprises at least one mounting element; and

removing the substitute component from the metal-plastic composite stationary blade.

2. The method of claim 1 , wherein the substantially flat metal component comprises a sheet metal component.

3. The method of claim 1 , wherein the mold is an injection mold.

4. The method of claim 1 , wherein the forming the component further comprises injection molding the component.

5. The method as claimed in claim 1 , wherein the forming the metal shell further comprises:

providing a substantially laterally extending bending core, wherein the bending core remains in the guide slot after bending;

forming at least one toothed leading edge at a bending zone of the metal component; and

mutually connecting opposing narrow sides of the frontal portion and the rear portion.

6. The method of claim 5 , wherein the bending zone is U-shaped.

7. The method of claim 5 , wherein the connecting the opposing narrow sides further comprises bonding the opposing narrow sides.

8. The method as claimed in claim 1 , wherein the forming at least one pattern of slots in the metal component further comprises machining the metal component, wherein machining the metal component comprises machining substantially longitudinally extending slots, forming cutting edges at a first wall portion of the slots and forming tapered portions at a second wall portion of the slots, and wherein the step of machining the metal component includes at least one process selected from the group consisting of:

cutting, particularly laser cutting;

etching, particularly electrochemical etching;

stamping;

coining;

eroding; and combinations thereof.

9. A method of manufacturing a blade set for a hair cutting appliance, the method comprising:

manufacturing a stationary blade in accordance with the method as claimed in claim 1 ;

providing a movable cutter blade comprising at least one toothed leading edge arranged to cooperate with at least one respective toothed leading edge of the stationary blade; and

inserting the movable cutter blade into the guide slot of the stationary blade.