Razor blade holder

Abstract

The present invention provides a razor cartridge, the razor cartridge comprising: a housing and a blade assembly mounted to the housing. The blade assembly may include at least one razor blade defined by a base including a first portion and a second portion. The first portion may include a first outer surface and a second outer surface. The second portion may include a first segment and a second segment separated by a dividing line. The first segment may include a first facet and a terminal facet. The second segment may include a terminal facet. The terminal facets of the first segment and the second segment may converge at a tip to define a cutting edge. A shoulder may be positioned between the first facet and the terminal facet of the first segment and define a skin contact surface.

Description

Technical Field

[0001] The present invention relates generally to razor cartridges and, more particularly, to razor cartridges having razor blades with skin contacting shoulders. Background Art

[0002] Razor blade cartridges typically include a cartridge housing including a cap structure and a guard structure and one or more razor blade assemblies located between the cap structure and the guard structure. A plane may extend between the upper surfaces of the cap structure and the guard structure to define a shaving plane. The razor blade assembly typically includes a razor blade having a symmetrical shape. As is well known, the shaving geometry of a razor blade cartridge is important in determining the shaving performance of the cartridge. The shaving geometry defines the position and orientation of the blade relative to other skin contacting components, particularly the cap structure and the guard structure of the razor blade cartridge. One parameter of the shaving geometry is the blade exposure, which is the vertical distance that the cutting edge of the blade protrudes above or below the shaving plane. Although current razor blades perform adequately, shaving geometries such as blade shape may be improved in order to better perform the next generation of products. Summary of the invention

[0003] According to a first aspect of the present disclosure, a razor cartridge is provided, comprising: a housing and a blade assembly mounted to the housing. The blade assembly may include at least one razor blade defined by a base including a first portion and a second portion. The first portion may include a first outer surface and a second outer surface. The second portion may include a first segment and a second segment separated by a dividing line. The first segment may include a first facet and a terminal facet. The second segment may include a terminal facet. The terminal facets of the first segment and the second segment may converge at a tip to define a cutting edge. A shoulder may be positioned between the first facet and the terminal facet of the first segment and define a skin contact surface.

[0004] The end facet of the second segment may include the second facet, and the end facet of the first segment may include the third facet.

[0005] The second segment may also include a second facet extending from the second outer surface of the first portion.The terminal facet of the second segment may include a fourth facet, and the terminal facet of the first segment may include a third facet.

[0006] The terminal facet of the second segment may be positioned closer to the separation line than the first facet and the terminal facet of the first segment.

[0007] The first and second outer surfaces of the first portion of the substrate may be substantially parallel to each other, and the segmentation line may pass through the tip and may be substantially parallel to the first and second outer surfaces of the first portion.

[0008] The first section and the second section of the second portion may define asymmetric first and second sections.

[0009] The first facet may extend directly from the first exterior surface of the first portion.

[0010] The housing may include a cap structure and a guard structure. A shaving plane may be defined between the cap structure and the guard structure. The blade assembly may also include a blade support member to which the razor blade base is coupled. The blade support member may be configured so that a shoulder positioned between the first facet and the end facet of the first segment is positioned in or near the shaving plane. The shoulder may be positioned near the shaving plane when the shoulder is located above or below the shaving plane at a distance of less than about 0.2 mm and less than about 0.5 mm from the shaving plane, respectively.

[0011] The cartridge may also include first and second clamps mounted to the housing and engaging opposite ends of a shoulder defining a base of the razor blade to secure the razor blade within the housing.

[0012] According to a second aspect of the present disclosure, a razor cartridge is provided, comprising: a housing; a first blade assembly mounted to the housing, the first blade assembly comprising a first razor blade; and a second blade assembly mounted to the housing, the second blade assembly comprising a second razor blade. At least one of the first razor blade or the second razor blade may be defined by a substrate comprising a first portion having a first outer surface and a second outer surface and a second portion having a first segment and a second segment separated by a dividing line. The first segment may comprise a first facet and an end facet. The second segment may comprise an end facet. The end facets of the first segment and the second segment may converge at a tip to define a cutting edge. A shoulder may be positioned between the first facet and the end facet of the first segment and define a skin contact surface.

[0013] The end facet of the second segment may include the second facet, and the end facet of the first segment may include the third facet.

[0014] The second segment may also include a second facet extending from the second outer surface of the first portion.The terminal facet of the second segment may include a fourth facet, and the terminal facet of the first segment may include a third facet.

[0015] The terminal facet of the second segment may be positioned closer to the separation line than the first facet and the terminal facet of the first segment.

[0016] The first and second outer surfaces of the first portion of the substrate may be substantially parallel to each other, and the segmentation line may pass through the tip and may be substantially parallel to the first and second outer surfaces of the first portion.

[0017] The first section and the second section of the second portion may define asymmetric first and second sections.

[0018] The first facet may extend directly from the first exterior surface of the first portion.

[0019] The housing may further include a cap structure and a guard structure. A shaving plane may be defined between the cap structure and the guard structure. The first blade assembly may further include a blade support member to which the first razor blade is coupled. The blade support member may be configured so that a shoulder of a base defining the first razor blade is positioned in or near the shaving plane. The shoulder may be positioned near the shaving plane when the shoulder is located above or below the shaving plane at a distance of less than about 0.2 mm and less than about 0.5 mm from the shaving plane, respectively.

[0020] The cartridge may also include first and second clamps mounted to the housing and engaging opposite ends of a shoulder defining a base of the first razor blade to secure the first razor blade in the housing.

[0021] For the first razor blade, the shaving plane can be defined by a plane extending from the uppermost surface portion of the skin contact element in front of and behind the cutting edge of the first razor blade. The first blade assembly can also include a blade support member to which the first razor blade is coupled. The blade support member can be configured so that the shoulder of the first razor blade is positioned in or near the shaving plane. BRIEF DESCRIPTION OF THE DRAWINGS

[0022] While the specification concludes with claims particularly pointing out and distinctly stating the subject matter regarded as forming the present invention, it is believed that the present invention will be better understood from the following description taken in conjunction with the accompanying drawings in which like reference numerals are used to designate substantially identical elements, and wherein:

[0023] Figure 1 is a front view of a razor system including a handle and a razor cartridge according to the present disclosure;

[0024] Figure 2A yes Figure 1 A cross-sectional view of a razor blade cartridge;

[0025] Figure 2B Schematically showing a top cover structure and a guard structure of a razor cartridge of the present disclosure and a first razor blade assembly, a second razor blade assembly, a third razor blade assembly, a fourth razor blade assembly, and a fifth razor blade assembly;

[0026] 3A is a cross-sectional side view of an asymmetric razor blade according to a first embodiment of the present disclosure;

[0027] FIG3B illustrates an enlarged view of the tip portion of the razor blade of FIG3A ;

[0028] Figure 3C shows a beveled shoulder on the razor blade of FIGS. 3A and 3B located in the shaving plane;

[0029] Figure 3D is a view taken along the line of sight 3D-3D in FIG. 3A ;

[0030] 4A is a cross-sectional side view of an asymmetric razor blade according to a second embodiment of the present disclosure; and

[0031] FIG. 4B shows an enlarged view of the tip portion of the razor blade of FIG. 4A . DETAILED DESCRIPTION

[0032] introduction

[0033] As used herein, the term "asymmetric blade" refers to a blade defined by a base having a first portion including a blade body and a second portion including a tip portion, wherein a dividing line passes through the tip of the tip portion, extends through the first portion and the second portion and divides the second portion into a substantially asymmetric first segment and a second segment. The outer surface of the first segment of the second portion is asymmetric relative to the outer surface of the second segment. The outer surface of the first segment of the second portion can be used as a skin contact surface, and the outer surface of the second segment of the second portion can be used as a hair cutting surface.

[0034] The term "bevel shoulder", "bevel shoulder structure" or "shoulder" used interchangeably herein refers to a structure on the outer surface of the first segment of the second portion of the base of a razor blade. The bevel shoulder structure is disposed at a position where the facets intersect in the first segment, and the bevel shoulder defines a significant portion of the skin contact surface of the blade. The bevel shoulder may be smooth, rounded or angled, and is generally a linear structure extending parallel to the cutting edge. The bevel shoulder structure of the present invention performs most of the skin contact function of the blade, and thus relieves pressure on the tip. In the case of providing minimum tip pressure to no tip pressure, the shoulder provides a highly defined skin protection benefit built into the first segment. In an asymmetric blade having a bevel shoulder on the outer surface of the first segment of the base of the blade of the present invention, the cutting force can be kept much lower than the case where the blade base is symmetrical. This is due to the fact that there is substantially no bevel shoulder or minimal shoulder on the hair cutting side (e.g., the second segment of the second portion). With a prominent bevel shoulder on the second segment, the segment controlling the hair cutting efficacy will unfavorably increase the hair cutting force. The beveled shoulder of the present invention will be described in more detail below.

[0035] As used herein, "partition line" refers to a line extending through the tip of the tip portion of the blade base, dividing the second portion into an asymmetrical first segment and a second segment, and is generally parallel to the generally parallel first and second outer surfaces of the first portion of the blade body defining the blade base.

[0036] As used herein, "shaving plane" refers to a plane extending between the upper surface of the cap structure of the razor cartridge housing and the upper surface of the guard structure of the razor cartridge housing. "Shaving plane" can be a plane tangent to each of the cap structure and the guard structure. In some embodiments, not all cap structures, guard structures, and uppermost surface portions of razor blades in the razor cartridge will be located in the same plane. For such embodiments, as used herein, "shaving plane" is intended to mean a plane extending between the uppermost surface portions of two skin contact elements, one immediately in front of the razor blade tip of the razor blade and the other immediately behind the razor blade tip of the razor blade. For the first blade in the blade sequence, the shaving plane is defined by a plane extending from the upper surface of the guard structure on the first side of the first razor blade tip (i.e., the uppermost surface portion) and the uppermost surface portion of the skin contact element directly adjacent to the second side of the first blade tip and located thereon. For the middle blade in the blade sequence, the shaving plane is defined by a plane extending from the uppermost surface portion of the adjacent skin contact element on either side of the middle razor blade tip. In the present invention, where the uppermost surface portion on the razor blade may be defined by a beveled shoulder, the uppermost surface portion of the skin contact element immediately behind the razor blade tip of the razor blade may include the beveled shoulder of the razor blade. The uppermost surface portions on the skin contact element on either side of the razor blade tip may be the uppermost surface on an adjacent razor blade, an element on the razor blade itself (such as a beveled shoulder), or a guard structure. Figure 2B 18A, the shaving plane is defined by a plane extending from the uppermost surface portion of razor blade 18B directly in front of blade 18A and the beveled shoulder (41, 81) of razor blade 18A. The uppermost surface portion of razor blade 18B as shown is also the beveled shoulder (e.g., 41, 81). For the first blade in the blade sequence, such as Figure 2B In the razor blade 18E, the shaving plane is defined by a plane extending from the uppermost surface portion of the aforementioned protective structure 28 and the uppermost surface portion immediately behind the razor blade tip of the razor blade, in which case the uppermost surface portion can be the blade bevel shoulder (e.g., 41, 81) of the razor blade 18E.

[0037] refer to Figure 1 , the razor system 10 includes a handle 12 and a razor cartridge 14. In some examples, the razor cartridge 14 can be removably mounted to the handle 12 using a connector 20 as shown, and in other examples, the razor cartridge 14 can be permanently attached to the handle 12. The razor cartridge 14 can pivot relative to the handle 12. The razor cartridge 14 can include a cartridge housing 16 having one or more blades 18. Although in Figure 11, five blades are shown, but it should be understood that any number (more or less) of blades can be installed in the razor cartridge 14. As shown, the blade 18 can be installed in the cartridge housing 16 and fixed with clamps 24a and 24b. The cartridge housing 16 can also include a top cover structure 22 located near the rear of the cartridge housing 16 and one or more protective structures 28 located near the front of the cartridge housing 16. The top cover structure 22 can include one or more lubrication members (not labeled).

[0038] The substrate 30 may be coated. The coating on the substrate 30 may be in the range of 200 angstroms to 1500 angstroms, preferably between 300 angstroms and 1000 angstroms.

[0039] FIG. 3A is a cross-sectional side view of an asymmetric razor blade 18 according to a first embodiment of the present disclosure. The razor blade 18 is defined by a substrate 30 including a first portion 32 having a blade body 132A and a second portion 34 having a tip portion 134A. In the embodiment of FIG. 3A , a dashed line 33 extends between the first portion 32 and the second portion 34. The razor blade 18 may be formed of stainless steel, other metals and / or alloys, plastics, or any other material or combination thereof. The first portion 32 may include a first outer surface 32A and a second outer surface 32B that are substantially parallel, and may be defined by a portion of the substrate 30 where no facets are present. The second portion 34 may include ... 34 Separated substantially asymmetrical first and second segments 36, 38, wherein the first and second segments 36, 38 include asymmetrical third and fourth outer surfaces 36A, 38A. Separation line SL 34 The tip 46 of the tip portion 134A may extend through or radiate therefrom and may be generally parallel to the first and second outer surfaces 32A, 32B of the first portion 32 of the blade base 30, see FIG. 3A. The separation line SL 34 may extend through the first portion 32. In the exemplary embodiment of FIGS. 3A and 3B , the separation line SL 34 The first portion 32 and the second portion 34 are not divided into equal halves. In the illustrated embodiment, the asymmetrical first segment 36 and the second segment 38 of the second portion 34 may extend longitudinally away from the tip 46 at different distances.

[0040] The first segment 36 includes a first bevel or facet 40 and a third bevel or facet 44, and the second segment 38 includes a second bevel or facet 42. The first facet 40 can extend directly from the first outer surface 32A and can be positioned between the first outer surface 32A and the third facet 44. The third facet 44 can extend directly from the first facet 40. A bevel shoulder 41 can be defined where the first facet 40 and the third facet 44 intersect. The bevel shoulder 41 is a generally linear structure (e.g., extending into the page and extending in the X direction) extending parallel to the cutting edge 19 of the blade 18, such as, for example Figure 3D As shown. Bevel shoulder 41 can be smooth, rounded or angled. Second facet 42 can extend directly from second outer surface 32B. Second facet 42 and third facet 44 can define terminal facet, and this terminal facet converges at tip 46 to define cutting edge 19 of blade 18, and this cutting edge performs cutting hair. As will be discussed further below, during use of razor blade 18, bevel shoulder 41 between first facet 40 and third facet 44 can contact user's skin and move along it. Referring to Fig. 3A, the angle θ ' of bevel shoulder 41 extending from first facet 40 to third facet 44 can be 162 degrees to 176 degrees.

[0041] The length L of the first facet 40 40 may be greater than the length L of each of the second facet 42 and the third facet 44 42 and L 44 , see Figure 3A and Figure 3B. The length L of the third face 44 44 may be less than the length of the second facet 42. In the illustrated embodiment, the length L of the first facet 40 is 40 The length L of the second face 42 may be 100 μm to 500 μm. 42 can be 8 μm to 200 μm, and the length L of the third facet 44 is 44 It can be 8 microns to 150 microns, preferably 8 microns to 50 microns. The first facet 40 can extend inwardly from the first outer surface 32A toward the second outer surface 32B, and the second facet 42 can extend inwardly from the second outer surface 32B toward the first outer surface 32A, see Figure 3A. A plane P1 extending through the center of the first portion 32 parallel to the first outer surface 32A and the second outer surface 32B can extend through the first facet 40, see Figure 3A. As can be seen from Figure 3A, the plane P1 divides the first portion 32 into equal halves.

[0042] A first angle β between the first facet 40 and a first line extending from the first outer surface 32A of the first portion 32 1' The second angle α between the second facet 42 and a second line extending from the second outer surface 32B of the first portion 32 may be greater than 2', see Figures 3A and 3B. A third angle α between the third facet 44 and a third line extending from the first facet 40 1' The second angle α between the second facet 42 and a second line extending from the second outer surface 32B of the first portion 32 may be greater than 2' . Wedge Angle It may extend between the second facet 42 and the third facet 44, see FIG. 3B. Wedge Angle The value of can be equal to the first angle β 1' The value of the second angle α 2' The value of and the third angle α 1' The sum of the values ​​of and can fall within the range of 13.5 degrees to 30 degrees. Smaller wedge angle is advantageous because it can form a sharper cutting edge of the blade 18. The first angle β 1' Can fall within the range of 8 to 21 degrees; the second angle α 2' can fall within the range of 1 to 12 degrees, preferably within the range of 2 to 8 degrees; and the third angle α 1' The first angle β may fall within the range of 4 to 18 degrees, preferably within the range of 8 to 18 degrees. 1' and the third angle α 1' The sum of is greater than or equal to the blade tangent angle Ω discussed below.

[0043] As described above, the separation line SL separating the generally asymmetrical first segment 36 and second segment 38 of the second portion 34 of the razor blade 18 is 34 A substantial portion of the second facet 42 may be located closer to the separation line SL than a substantial portion of each of the first facet 40 and the third facet 44. 34 , see Figure 3A and Figure 3B.

[0044] Referring to FIG. 3B , along the dividing line SL 34 At a first distance D of 4 micrometers from the tip 46 SL1 At, perpendicular to the dividing line SL 34 And from the dividing line SL 34 A first distance D extending to the third facet 44 SL1A and perpendicular to the dividing line SL 34 And from the dividing line SL 34 The sum of the second distances (not provided in FIG. 3B ) extending to the second facet 42 may be between 1.0 μm and 2.3 μm. 34 At a second distance D of 8 micrometers from the tip 46 SL2 At, perpendicular to the dividing line SL34 And from the dividing line SL 34 A first distance D extending to the first facet 40 or the third facet 44 SL2A and perpendicular to the dividing line SL 34 And from the dividing line SL 34 A second distance D extending to the second facet 42 or the second outer surface 32B of the first portion 32 SL2B The sum of can be between 1.9 micrometers and 4.6 micrometers. Along the dividing line SL 34 At a third distance D of 16 μm from the tip 46 SL3 At, perpendicular to the dividing line SL 34 And from the dividing line SL 34 A first distance D extending to the first facet 40 or the third facet 44 SL3A and perpendicular to the dividing line SL 34 And from the dividing line SL 34 A second distance D extending to the second facet 42 or the second outer surface 32B of the first portion 32 SL3B The sum of can be between 3.8 microns and 9.2 microns.

[0045] Figure 2AA cross-sectional view of a razor cartridge 14 is shown. The razor cartridge 14 also includes a first razor blade assembly, a second razor blade assembly, a third razor blade assembly, a fourth razor blade assembly, and a fifth razor blade assembly 180A-180E, which include a first razor blade, a second razor blade, a third razor blade, a fourth razor blade, and a fifth razor blade 18A-18E, wherein each of the razor blades 18A-18E is formed to correspond to the razor blade 18 shown in Figures 3A and 3B. The first blade assembly 180A may include a first blade 18A and a first blade support member or blade carrier 120A coupled to the first blade 18A. The second blade assembly 180B may include a second blade 18B and a second blade support member or blade carrier 120B coupled to the second blade 18B. The third blade assembly 180C may include a third blade 18C and a third blade support member or blade carrier 120C coupled to the third blade 18C. The fourth blade assembly 180D may include a fourth blade 18D and a fourth blade support member or blade carrier 120D coupled to the fourth blade 18D. The fifth blade assembly 180E may include a fifth blade 18E and a fifth blade support member or blade carrier 120E coupled to the fifth blade 18E. The blade support members 120A-120E may include, for example, stainless steel. The blade support members 120A-120E may be integral with their corresponding blades 18A-18E, or alternatively, the blades 18A-18E may be fixedly coupled to the respective blade support members 120A-120E, such as by welding, adhesive, or other suitable techniques. Each blade assembly 180A-180E may be mounted within the cartridge housing 16 of the razor cartridge 14. The blade support members 120A-120E may be positioned within a respective blade slot 162A-162E that extends in the cartridge housing 16 in the X direction of the housing 16 and may be fixed or floating, see Figure 1 For example, the blade support members 120A-120E may be resiliently mounted within the housing and may be biased to their raised resting positions (i.e., not loaded by shaving forces) via a polymeric leaf spring arm (not shown), an example of which is disclosed in U.S. Pat. No. 10,391,652, the entire disclosure of which is incorporated herein by reference. The blade assemblies 180A-180E may be secured to the housing by the clamp 24B (in the Figure 2A Only one of them is shown) or other known assembly methods.

[0046] Figure 2B Schematically shows Figure 2A The top cover structure 22, the guard structure 28 and the first razor blade assembly, the second razor blade assembly, the third razor blade assembly, the fourth razor blade assembly and the fifth razor blade assembly 180A-180E of the razor cartridge 14 are shown in FIG. Figure 2BThe plane extending between the top cover structure 22 of the cartridge housing 16 of the razor cartridge 14 and the upper surface of the guard structure 28 may define a shaving plane P S , i.e., a plane tangent to each of the cap structure 22 and the guard structure 28. For razor cartridge embodiments in which not all of the cap structures, guard structures, and uppermost surface portions of the razor blades lie in the same plane, the "shaving plane" for a given razor blade within such a razor cartridge can be defined as the plane extending between the skin contacting elements immediately in front of and behind the razor blade tip of the given razor blade. For example, in Figure 2B In the modified embodiment shown in dashed lines in FIG. 1 , the uppermost portion of blade 18E′ is located slightly below the upper surface of blade 18E and guard structure 28 shown in solid lines. Shaving plane P for modified blade 18E′ S' The uppermost portion of the skin contacting element extending from the upper surface of guard structure 28' to behind the tip of blade 18E includes the beveled shoulder of blade 18E'.

[0047] It is well known that the shaving geometry of a razor cartridge is important in determining the shaving performance of the cartridge. The shaving geometry defines the position and orientation of the blade relative to other skin contacting components, particularly the cap structure and guard structure of the razor cartridge. One parameter of the shaving geometry is the blade exposure, which is the vertical distance that the cutting edge of the blade protrudes above or below the shaving plane. Figure 2B In the illustrated embodiment, the first, second, third, fourth, and fifth blade support members 120A-120E can be configured to position their respective blades 18A-18E so that the beveled shoulder 41 defining the base 30 of each blade 18A-18E is positioned in the shaving plane P. S In or near, see also Figures 3A to Figure 3C More specifically, each of the blade support members 120A-120E may include a lower portion 121A and an upper portion 121B, the upper portion being angularly spaced from the upper portion 121B at an angle θ of 100 to 125 degrees. 121 Extending to the lower portion 121A, see Figure 2B The upper portion 121B of each blade support member 120A-120E can be coupled to the outer surface 32B of the first portion 32 of the base 30 defining the corresponding blade 18A-18E. Due to the asymmetric shape of the base 30 and the angle θ between the lower portion 121A and the upper portion 121B of each blade support member 121 The beveled shoulder 41 of the base 30 of each blade 18A-18E is positioned on the shaving plane P S In or near, see also Figures 3A to Figure 3C .

[0048] Refer to Figure 3B and Figure 3C When a portion of the bevel shoulder 41 is located on the shaving plane P S When the beveled shoulder 41 is located in the shaving plane P S In or near the shoulder 41, the shoulder 41 extends in the X direction, see Figure 1 and FIG. 3A , i.e., shaving plane P S Tangent to the portion of the bevel shoulder 41, or a portion of the bevel shoulder 41 is spaced from the shaving plane P S The distance D1 less than about 0.2 mm is located at the shaving plane P S Slightly above, or at a distance from the shaving plane P S The distance D2 less than about 0.5 mm is located at the shaving plane P S Slightly below, see Figure 3C When the bevel shoulder 41 is positioned on the shaving plane P S When the blade 18 is in or near the center, due to the asymmetric shape of the blade 18 and the angle θ between the lower portion 121A and the upper portion 121B of the corresponding blade support member 121 , the cutting edge 19 of the blade 18 can be vertically spaced from D 46 In the shaving plane P S The vertical distance D 46 It may fall within the range of 0 microns to 46.4 microns, and preferably includes 20 microns, see FIG. 3B. Because the cutting edge 19 of the blade 18 is preferably located at the shaving plane P S The cutting edge 19 is spaced from the skin during shaving to improve shaving comfort and reduce skin irritation. In addition, because the angle θ' of the beveled shoulder 41 is large, the beveled shoulder 41 defines a generally smooth surface for engaging the user's skin, thereby reducing friction as the blade moves over the skin during shaving, see also Figure 2B .

[0049] As described above, the blades 18A-18E may be mounted within the cartridge housing 16 and secured with the clamps 24A and 24B. Because the beveled shoulder 41 defining the base 30 of each blade 18A-18E is positioned in the shaving plane P S In or near, see also Figures 3A to Figure 3C , so that the clamps 24A and 24B engage the beveled shoulder 41 of each blade 18A-18E, see Figure 2A. Prior art razor blades are aligned with features during welding operations to secure the blades to corresponding blade support members. The alignment features will typically damage or squeeze the end of the blade tip. In prior art razor cartridges where the blade tip is positioned in or near the shaving plane, the clamp will engage the end of the blade tip. However, because the end of the blade tip was squeezed during the previous welding operation, the engagement of the squeezed blade tip by the clamp results in inconsistent positioning of the blade cutting edge relative to the shaving plane. In the present invention, because the clamps 24A and 24B engage the beveled shoulder 41 of each blade 18A-18E, which shoulder 41 is typically not damaged during the previous welding operation, the position of the blade cutting edge 19 along its entire range is more consistently and predictably positioned relative to the shaving plane.

[0050] Another important factor in shaving geometry is the blade tangent angle Ω, see FIG. 3A , which is the angle between the cut line SL and the asymmetric blade 18. 34 With shaving plane S P Angle of intersection. In the embodiment of Figures 3A and 3B, the blade tangent angle Ω may fall within the range of 10 to 36 degrees, and is preferably 17 degrees.

[0051] FIG. 4A is a cross-sectional side view of an asymmetric razor blade 50 according to a second embodiment of the present disclosure. The razor blade 50 is defined by a substrate 70 including a first portion 72 having a blade body and a second portion 74 having a tip portion. In the embodiment of FIG. 4A , a dashed line 73 extends between the first portion 72 and the second portion 74. The razor blade 50 may be formed of stainless steel, other metals and / or alloys, plastics, or any other material or combination thereof. The first portion 72 may include first and second outer surfaces 72A, 72B that are substantially parallel, respectively. The second portion 74 may include a first outer surface 72A, 72B that is substantially parallel, respectively. The second portion 74 may include a first outer surface 72A, 72B that is substantially parallel, respectively. The second portion 74 may include a second outer surface 72B that is substantially parallel, respectively, and a second outer surface 72B that is substantially parallel, respectively. 74 Separated substantially asymmetrical first and second segments 76, 78, wherein the first and second segments 76, 78 include asymmetrical third and fourth outer surfaces 76A, 78A. Separation line SL 74 The segmentation line SL may pass through the tip 88 of the tip portion 74 and may be substantially parallel to the first outer surface 72A and the second outer surface 72B of the first portion 72 of the blade base 70, see FIG. 3A. 74 may extend through the first portion 72. In the exemplary embodiment of FIGS. 4A and 4B , the separation line SL 74 The first portion 72 and the second portion 74 are not divided into equal halves.

[0052] The first segment 76 includes a first facet 80 and a third facet 84, and the second segment 78 includes a second facet 82 and a fourth facet 86. The first facet 80 can extend directly from the first outer surface 72A and can be positioned between the first outer surface 72A and the third facet 84. The third facet 84 can extend directly from the first facet 80. A beveled shoulder 81 can be defined where the first facet 80 and the third facet 84 intersect. The beveled shoulder 81 can be smooth, rounded, or angled. The beveled shoulder 81 is a generally linear (e.g., extending into the page or extending in the X direction) structure extending parallel to the cutting edge 50A, such as, for example Figure 3D 4A , the angle θ of the bevel shoulder 81 extending from the first facet 80 to the third facet 84 can be 162 to 176 degrees.

[0053] The length L of the first facet 80 and the second facet 82 80 and L 82 may be greater than the length L of each of the third facet 84 and the fourth facet 86 84 and L 86 , see FIG. 4A. As shown in FIG. 4A, the length of the second facet 82 may be greater than the length of the first facet 80. The length L of the third facet 84 84 It can be greater or less than the length L of the fourth facet 86 86 In the illustrated embodiment, the length L of the first facet 80 is 80 The length L of the second face 82 may be 100 μm to 500 μm. 82 can be 100 μm to 1000 μm, and the length L of the third facet 84 is 84 It can be 8 micrometers to 150 micrometers, preferably 8 micrometers to 50 micrometers, and the length L of the fourth facet 86 is 86It can be 8 microns to 200 microns. The first facet 80 can extend inwardly from the parallel first outer surface 72A at a first angle β1, the second facet 82 can extend inwardly from the parallel second outer surface 72B at a second angle β2, the third facet 84 can extend inwardly from the first facet 80 at a third angle α1, and the fourth facet 86 can extend inwardly from the second facet 82 at a fourth angle α2, see FIG. 4A. A plane P2 extending through the center of the first portion 72 parallel to the first outer surface 72A and the second outer surface 72B extends through the first facet 80, see FIG. 4A.

[0054] A first angle β1 between first facet 80 and a first line extending from first outer surface 72A of first portion 72 may be greater than a second angle β2 between second facet 82 and a second line extending from second outer surface 72B of first portion 72. A third angle α1 between third facet 84 and a third line extending from first facet 80 may be greater than a fourth angle α2 between fourth facet 86 and a fourth line extending from second facet 82. Wedge Angle It may extend between the third facet 84 and the fourth facet 86. Wedge Angle The value of may be equal to the sum of the values ​​of the first angle β1, the second angle β2, the third angle α1, and the fourth angle α2. The first angle β1 may fall within the range of 8 to 18 degrees; the second angle β2 may fall within the range of 0.5 to 6.0 degrees; the third angle α1 may fall within the range of 4 to 18 degrees, and preferably within the range of 8 to 18 degrees; and the fourth angle α2 may fall within the range of 1 to 12 degrees, and preferably within the range of 2 to 8 degrees. The sum of the first angle β1 and the second angle β2 may fall within the range of 8.5 to 24 degrees. The sum of the first angle β1 and the third angle α1 may fall within the range of 12 to 28.5 degrees. The sum of the second angle β2 and the fourth angle α2 may fall within the range of 1.5 to 18 degrees. The difference between the first angle β1 and the second angle β2 results in an asymmetric first segment 36 and second segment 38, and may fall within the range of 4 to 17.5 degrees. Preferably, the second angle β2 is small so that the overall thickness T of the blade 50 is 50 Can be minimized. Limit wedge angle The sum of the first angle β1, the second angle β2, the third angle α1 and the fourth angle α2 may fall within the range of 13.5 degrees to 30 degrees. This is advantageous because it can form a sharper cutting edge 50A of the blade 50.

[0055] As described above, the separation line SL separating the generally asymmetrical first segment 76 and second segment 78 of the second portion 74 of the razor blade 50 is 74A substantial portion of the second facet 82 and the fourth facet 86 may be located closer to the separation line SL than a substantial portion of each of the first facet 80 and the third facet 84. 74 , see Figure 4A and Figure 4B.

[0056] Referring to FIG. 4B , along the dividing line SL 74 At a first distance D of 4 μm from the tip 88 SL10 At, perpendicular to the dividing line SL 74 And from the dividing line SL 74 A first distance D extending to the third facet 84 SL10A and perpendicular to the dividing line SL 74 And from the dividing line SL 74 The sum of the second distances (not provided in FIG. 4B ) extending to the fourth facet 86 may be between 1.0 μm and 2.3 μm. 74 At a second distance D of 8 micrometers from the tip 88 SL11 At, perpendicular to the dividing line SL 74 And from the dividing line SL 74 A first distance D extending to the first facet 80 or the third facet 84 SL11A and perpendicular to the dividing line SL 74 And from the dividing line SL 74 A second distance D extending to the second facet 82 or the fourth facet 86 SL11B The sum of is between 1.9 μm and 4.6 μm. Along the dividing line SL 74 At a third distance D of 16 μm from the tip 46 SL12 At, perpendicular to the dividing line SL 34 And from the dividing line SL 74 A first distance D extending to the first facet 80 or the third facet 84 SL12A and perpendicular to the dividing line SL 74 And from the dividing line SL 74 A second distance D extending to the second facet 82 or the fourth facet 86 SL12B The sum of the two ranges from 3.8 μm to 9.2 μm.

[0057] The razor blade 50 of FIG. 4A and FIG. 4B may be substituted for Figure 1 and Figure 2AOne or more razor blades 18, 18A-18E used in the razor cartridge 14 of the present invention are used. Just as the razor blades 18A-18E are connected to the first blade support member, the second blade support member, the third blade support member, the fourth blade support member and the fifth blade support member 120A-120E, each razor blade 50 for the razor cartridge 14 will also be connected to the corresponding blade support member. The blade support member will then be positioned in the corresponding blade slot, which extends in the cartridge housing and can be fixed or floating. Each blade assembly including the blade 50 can be fixed by a clamp or other known assembly methods.

[0058] As mentioned above about Figure 2B As discussed, each of the blade support members may include a lower portion 121A and an upper portion 121B, the upper portion being oriented at an angle θ of 100 to 125 degrees. 121 The upper portion 121B of each blade support member may be coupled to the second facet 82 of the second portion 74 of the base 70 defining the corresponding blade 50. Due to the asymmetric shape of the base 70 and the angle θ between the lower portion 121A and the upper portion 121B of each blade support member, 121 , defining the beveled shoulder 81 of the base 30 of each blade 50 positioned on the shaving plane P S In or near, see also Figures 4A to 4B.

[0059] As described above, the second facet 82 may extend inwardly from the parallel second outer surface 72B at a second angle β2. Because each blade support member upper portion 121B is coupled to the second facet 82 of its corresponding blade 50, rather than to the second facet 82 of FIGS. Figure 3C The outer surface of the first portion of the blade 18 is the same, so the cutting edge 50A of the blade 50 is positioned larger than that of FIG. 3A to FIG. Figure 3C The cutting edge 19 of the blade 18 of the embodiment of is further away from the shaving plane Ps. Because the cutting edge 50A is positioned further away from the shaving plane Ps, an advantageous benefit of improved comfort during shaving is provided.

[0060] 4B, when a portion of the bevel shoulder 81 is located on the shaving plane P S When the beveled shoulder 81 is located in the shaving plane P S In or near the shoulder 81, the shoulder 81 extends in the X direction, see Figure 1 and FIG. 4B , i.e., shaving plane P S The portion of the bevel shoulder 81 is tangent to the bevel shoulder 81, or the portion of the bevel shoulder 81 is at a distance from the shaving plane P. S Less than about 0.2 mm (see Figure 3C The distance D1) is located on the shaving plane PS Slightly above, or at a distance from the shaving plane P S A distance of less than about 0.5 mm (see Figure 3C The distance D2) is located on the shaving plane P S When the bevel shoulder 81 is positioned on the shaving plane P S When the blade 50 is in the middle or near the blade support member, due to the asymmetric shape and the angle θ between the lower portion 121A and the upper portion 121B of the blade support member, 121 The cutting edge 50A of the blade 50 can be vertically spaced from D 76 In the shaving plane P S When the upper portion 121B of the blade support member is coupled to the second facet 82 of the blade 50, the distance D can be changed by changing the second angle β2 between the second facet 82 and the parallel second outer surface 72B of the blade 50. 76 . Vertical distance D 76 It can fall within the range of 0 microns to 46.4 microns, see FIG. 4B . Because the cutting edge 50A of the blade 50 can be located at the shaving plane P S Below, so cutting edge 50A is spaced apart from the skin during shaving, so as to improve shaving comfort and reduce skin irritation. In addition, because the angle θ of bevel shoulder 81 is large, bevel shoulder 81 defines a generally smooth surface for engaging the user's skin, thereby reducing the friction generated as blade 50 moves on the skin during shaving.

[0061] When the razor blade 50 is used in a razor cartridge, the blade tangent angle Ω may fall within the range of 10 degrees to 36 degrees, and is preferably 17 degrees.

[0062] The representative embodiments of the present disclosure described above can be described as follows:

[0063] A. A razor blade cartridge, comprising:

[0064] shell;

[0065] a blade assembly mounted to the housing, the blade assembly including at least one razor blade defined by a base, the base comprising:

[0066] a first portion comprising a first outer surface and a second outer surface; and

[0067] A second part, the second part includes a first segment and a second segment separated by a dividing line, wherein the first segment includes a first facet and a terminal facet, and the second segment includes a terminal facet, the terminal facets of the first segment and the second segment converge at a tip to define a cutting edge, wherein a shoulder is positioned between the first facet and the terminal facet of the first segment and defines a skin contact surface.

[0068] B. The razor cartridge of paragraph A, wherein the terminal facet of the second segment comprises a second facet and the terminal facet of the first segment comprises a third facet.

[0069] C. The razor cartridge of paragraph A, wherein the second segment further comprises a second facet extending from the second exterior surface of the first portion, the terminal facet of the second segment comprises a fourth facet, and the terminal facet of the first segment comprises a third facet.

[0070] D. The razor cartridge of any of paragraphs A to C, wherein the terminal facet of the second segment is positioned closer to the split line than the first facet and the terminal facet of the first segment.

[0071] E. The razor cartridge of any of paragraphs A to D, wherein the first and second outer surfaces of the first portion of the base are substantially parallel to each other, and the parting line passes through the tip and is substantially parallel to the first and second outer surfaces of the first portion.

[0072] F. The razor cartridge of any of paragraphs A to E, wherein the first and second segments of the second portion define asymmetric first and second segments.

[0073] G. The razor cartridge of any of paragraphs A to F, wherein the first facet extends directly from the first outer surface of the first portion.

[0074] H. A razor cartridge according to any one of paragraphs A to G, wherein the housing includes a top cover structure and a guard structure, a shaving plane is defined between the top cover structure and the guard structure, the blade assembly also includes a blade support member, the razor blade base is connected to the blade support member, and the blade support member is configured so that the shoulder positioned between the first facet and the end facet of the first segment is positioned in or near the shaving plane.

[0075] I. The cartridge of paragraph H, wherein the shoulder is positioned proximate the shaving plane when the shoulder is located above or below the shaving plane at a distance of less than about 0.2 mm and less than about 0.5 mm, respectively.

[0076] J. A cartridge according to any one of paragraphs A to I, further comprising a first clamp and a second clamp mounted to the housing and engaging opposite ends of the shoulder defining the base of the razor blade to secure the razor blade within the housing.

[0077] K. A razor blade cartridge, comprising:

[0078] shell;

[0079] a first blade assembly mounted to the housing, the first blade assembly comprising a first razor blade;

[0080] a second blade assembly mounted to the housing, the second blade assembly including a second razor blade;

[0081] At least one of the first razor blade or the second razor blade is defined by a substrate comprising:

[0082] a first portion comprising a first outer surface and a second outer surface; and

[0083] A second part, the second part includes a first segment and a second segment separated by a dividing line, wherein the first segment includes a first facet and a terminal facet, and the second segment includes a terminal facet, the terminal facets of the first segment and the second segment converge at a tip to define a cutting edge, wherein a shoulder is positioned between the first facet and the terminal facet of the first segment and defines a skin contact surface.

[0084] L. The razor cartridge of paragraph K, wherein the terminal facet of the second segment comprises a second facet and the terminal facet of the first segment comprises a third facet.

[0085] M. The razor cartridge of paragraph K, wherein the second segment further comprises a second facet extending from the second exterior surface of the first portion, the terminal facet of the second segment comprises a fourth facet, and the terminal facet of the first segment comprises a third facet.

[0086] N. The razor cartridge of any of paragraphs K to M, wherein the terminal facet of the second segment is positioned closer to the split line than the first facet and the terminal facet of the first segment.

[0087] O. The razor cartridge of any of paragraphs K to N, wherein the first outer surface and the second outer surface of the first portion of the base are substantially parallel to each other, and the dividing line passes through the tip and is substantially parallel to the first outer surface and the second outer surface of the first portion.

[0088] P. The razor cartridge of any of paragraphs K-O, wherein the first and second segments of the second portion define asymmetrical first and second segments.

[0089] Q. The razor cartridge of any of paragraphs K-P, wherein the first facet extends directly from the first outer surface of the first portion.

[0090] R. A razor cartridge according to any one of paragraphs K to Q, wherein the first razor blade is defined by the base, the base includes the first part and the second part, and includes the shoulder positioned between the first facet and the end facet of the first segment, the housing also includes a top cover structure and a guard structure, and a shaving plane is defined between the top cover structure and the guard structure, and the first blade assembly also includes a blade support member, the first razor blade is connected to the blade support member, and the blade support member is configured so that the shoulder of the base defining the first razor blade is positioned in or near the shaving plane.

[0091] S. The cartridge of paragraph R, wherein the shoulder is positioned proximate the shaving plane when the shoulder is located less than about 0.2 mm and less than about 0.5 mm above or below the shaving plane, respectively.

[0092] T. A blade cartridge according to any of paragraphs K to S, further comprising a first clamp and a second clamp mounted to the housing and engaging opposite ends of the shoulder defining the base of the first razor blade to secure the first razor blade in the housing.

[0093] U. A razor cartridge according to any one of paragraphs K to Q or T, wherein the first razor blade is defined by the base, the base includes the first part and the second part, and includes the shoulder positioned between the first facet and the end facet of the first segment, for the first razor blade, a shaving plane is defined by a plane extending from the uppermost surface portions of the skin contact element in front of and behind the cutting edge of the first razor blade, and the first blade assembly also includes a blade support member, the first razor blade is connected to the blade support member, and the blade support member is configured so that the shoulder of the first razor blade is positioned in or near the shaving plane.

[0094] The illustrations presented herein are not intended to be actual views of any particular substrate, apparatus (eg, device, system, etc.), or method, but are merely idealized and / or schematic representations used to describe and illustrate various embodiments of the present disclosure.

[0095] The dimensions and values ​​disclosed herein are not to be understood as being strictly limited to the exact numerical values ​​cited. Instead, unless otherwise indicated, each such dimension is intended to represent the stated value and a functionally equivalent range around that value. For example, a dimension disclosed as "40 mm" is intended to mean "about 40 mm".

[0096] Unless expressly excluded or otherwise limited, each document cited herein, including any cross-referenced or related patent or patent application and any patent application or patent to which this application claims priority or the benefit of, is hereby incorporated by reference in its entirety. The citation of any document is not an admission that it is prior art to any of the present invention disclosed or claimed herein, or an admission that it, by itself or in combination with any one or more of the references, proposes, suggests, or discloses any such invention. In addition, to the extent that any meaning or definition of a term in this invention conflicts with any meaning or definition of the same term in a document incorporated by reference, the meaning or definition assigned to that term in this invention shall govern.

[0097] Although specific embodiments of the present invention have been illustrated and described, it will be apparent to those skilled in the art that various other changes and modifications may be made without departing from the spirit and scope of the present invention. Therefore, it is intended that all such changes and modifications within the scope of the present invention be covered in the appended claims.

Claims

1. A razor blade cartridge, comprising: shell; a blade assembly mounted to the housing, the blade assembly including at least one razor blade defined by a base, the base comprising: a first portion, the first portion comprising a first outer surface and a second outer surface; and A second part, the second part includes a first segment and a second segment separated by a dividing line, wherein the first segment includes a first facet and a terminal facet, the second segment includes a terminal facet, the terminal facets of the first segment and the second segment converge at a tip to define a cutting edge, wherein the terminal facet of the second segment includes a second facet, and the terminal facet of the first segment includes a third facet, wherein a shoulder is positioned between the first facet and the third facet and defines a skin contact surface, wherein the angle of the shoulder extending from the first facet to the third facet is 162 degrees to 176 degrees, wherein the shoulder is positioned near a shaving plane, the shaving plane is tangent to a portion of the shoulder or the portion of the shoulder is located slightly above the shaving plane at a distance of less than about 0.2 mm from the shaving plane, and wherein a plane extending through the center of the first part parallel to the first outer surface and the second outer surface extends through the first facet.

2. The razor cartridge of claim 1 wherein the second facet extends from the second outer surface of the first portion, the terminal facet of the second segment comprising a fourth facet.

3. The razor cartridge of claim 1 wherein the terminal facet of the second segment is positioned closer to the split line than the first facet and the terminal facet of the first segment.

4. The razor cartridge of claim 1 wherein the first and second outer surfaces of the first portion of the base are substantially parallel to each other and the parting line passes through the tip and is substantially parallel to the first and second outer surfaces of the first portion.

5. The razor cartridge of claim 1 wherein the first and second segments of the second portion define asymmetrical first and second segments.

6. The razor cartridge of claim 1 wherein said first facet extends directly from said first exterior surface of said first portion.

7. The razor cartridge of claim 1 , wherein the housing comprises a cap structure and a guard structure, the shaving plane being defined between the cap structure and the guard structure, the blade assembly further comprising a blade support member, the razor blade base being coupled to the blade support member, the blade support member being configured such that the shoulder positioned between the first facet and the end facet of the first segment is positioned in or near the shaving plane.

8. The cartridge of claim 7, wherein the shoulder is positioned proximate the shaving plane when the shoulder is located less than about 0.2 mm and less than about 0.5 mm above or below the shaving plane, respectively.

9. The cartridge of claim 1 further comprising a first clamp and a second clamp mounted to the housing and engaging opposite ends of the shoulder of the base defining the at least one razor blade to secure the razor blade within the housing.

10. The razor cartridge of claim 1 , wherein for said at least one razor blade, said shaving plane is defined by a plane extending from uppermost surface portions of skin contacting elements forwardly and rearwardly of said cutting edge of said at least one razor blade, and said blade assembly further comprises a blade support member to which said at least one blade is coupled, said blade support member being configured such that said shoulder of said at least one razor blade is positioned in or adjacent to said shaving plane.

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