Coatings for razor blades

Abstract

The present invention provides a razor blade, comprising: a substrate having a terminal portion including a terminal region, a blade body including a base, and a first outer side and a second outer side arranged opposite to a dividing line of the substrate, wherein the first outer side and the second outer side converge at the terminal, the first outer side includes a first coating substantially arranged thereon and extending from the terminal region toward the base, and a first portion of the second outer side is substantially free of any coating, the first portion extending from the terminal region toward the base or spaced apart from the terminal region and the base. A method for coating the razor blade is also provided.

Description

Technical Field

[0001] The present invention relates generally to coatings of substrates and more particularly to improved coatings on razor components such as razor blades. Background Art

[0002] Razor blades are typically formed from a suitable base material such as stainless steel, wherein the cutting edge is formed with a wedge-shaped configuration having a radius of less than about 1000 angstroms at the final tip. For example, about One or more hard coatings such as diamond, amorphous diamond, diamond-like carbon (DLC) materials, nitrides, carbides, oxides or ceramics can be applied to substrate materials (particularly on cutting edges) to improve strength, corrosion resistance and shaving ability and maintain required strength, while enabling the use of thinner blades with lower cutting forces. One or more soft coatings, usually with polymer materials such as polytetrafluoroethylene (PTFE), can be stacked on top of the hard coating to impart lubricity and reduce friction. Interlayers containing niobium or chromium materials can help improve the combination between substrates and hard carbon coatings such as DLC, which are usually stainless steel. Any suitable method can be used to apply the coating, for example, physical vapor deposition (PVD) technology for hard coatings and dipping, spraying and / or brushing for soft coatings. Examples of razor blades and manufacturing processes are described in U.S. Patents 5,295,305; 5,232,568; 4,933,058; 5,032,243; 5,497,550; 5,940,975; and 5,669,144; EP 0591339; and PCT 92 / 03330, which are incorporated herein by reference.

[0003] Conventional blades typically include generally equal amounts of material on both sides of the substrate, typically applied by vapor deposition parallel to the cutting edge. The coatings on these blades are highly symmetrical and include substantially similar compositions, coverage areas, microstructures, etc. on both sides of the cutting edge. Although current razor blades perform well enough, in order to make the next generation of products perform even better, the interactions between the blade and the skin and between the blade and the hair can be improved. Summary of the invention

[0004] According to one aspect of the present disclosure, a razor blade is provided, the razor blade comprising: a substrate having a terminal portion including a terminal region, a blade body including a base, and a first outer side and a second outer side disposed opposite to a dividing line of the substrate, wherein the first outer side and the second outer side converge at the terminal, the first outer side including a first coating substantially disposed thereon, the first coating extending from the terminal region toward the base, and a first portion of the second outer side being substantially free of any coating, wherein the first portion extends from the terminal region toward the base or is spaced apart from the terminal region and the base.

[0005] According to another aspect of the present disclosure, a method for coating a razor blade is provided, wherein the razor blade includes a substrate having an end portion including an end region, a blade body including a base, and a first outer side and a second outer side arranged opposite to a dividing line of the substrate, wherein the first outer side and the second outer side converge at the end, the method comprising one of the following: (i) applying a first coating only to a portion of the first outer side, the coating extending from the end region toward the base and substantially arranged on the first outer side; or (ii) applying the first coating to a portion of the first outer side, the first coating extending from the end region toward the base and substantially arranged on the first outer side, and applying a second coating to the second outer side, so that the first portion of the second outer side is substantially free of any coating and the second portion of the second outer side includes the second coating, wherein the first portion extends from the end region toward the base or is spaced apart from the end region and the base. BRIEF DESCRIPTION OF THE DRAWINGS

[0006] 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:

[0007] Figure 1 is a front view of a razor system including a handle and a razor cartridge according to the present disclosure;

[0008] Figure 2 is a side view of a razor blade having a symmetrical base according to the present disclosure;

[0009] Figure 3 is a perspective view of a tip portion of another razor blade having a symmetrical base according to the present disclosure;

[0010] Figure 4 , Figure 5 , Figure 6 , Figure 7 , Figure 8 , Fig. 9 , Fig.10 , Fig.11 , Fig.12 , Fig.13 , Fig.14 , Fig.15 , Fig.16 and Fig.17 is a coating comprising one or more coatings according to the present disclosure Figure 3 a side view of a distal portion of a razor blade;

[0011] Fig.18 is a side view of a razor blade having an asymmetric base according to the present disclosure;

[0012] Fig.19 is a side view of another razor blade having an asymmetric base according to the present disclosure;

[0013] Fig. 20A , Fig. 20B , Fig.21A , Fig.21B , Fig.22A , Fig. 22B , Fig.23A , Fig. 23B , Fig.24A , Fig. 24B , Fig.25A , Fig.25B , Fig.26A , Fig.26B , Fig.27A , Fig.27B , Fig.28A , Fig.28B , Fig.29A , Fig.29B , Fig. 30A , Fig. 30B , Fig.31 , Fig.32 and Fig.33 According to the present disclosure, one or more coatings are included Fig.18 a side view of a distal portion of a razor blade;

[0014] Fig.34 yes Figure 4 and a detailed side view of the end region of the razor blade of FIG20;

[0015] Fig.35 , Fig.36 and Fig.37 is a razor blade according to the present disclosure comprising one or more coatings of the end region similar to Fig.34 Additional detailed side view of;

[0016] Fig.38 is a schematic diagram of a chamber showing a razor blade capable of being coated via a deposition technique in accordance with the present disclosure; and

[0017] Fig.39 is a flow chart illustrating an exemplary method of coating a razor blade according to the present disclosure. DETAILED DESCRIPTION

[0018] 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 can be used as a hair cutting surface.

[0019] 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.

[0020] 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 with 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 razor blades 18. Although in Figure 1 1, three 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 razor blades 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 22 located near the rear of the cartridge housing 16 and one or more protective structures 26 located near the front of the cartridge housing 16. The top cover 22 may include one or more lubrication members (not labeled).

[0021] Figure 2 is a side view of a razor blade 8 according to the present disclosure, and Figure 3 and Figure 4 Detailed perspective and side views, respectively, of elements of a razor blade 18 according to the present disclosure. Figures 2 to 4The razor blades 8 and 18 shown in the drawings may each include a substrate 28 including a first portion having a blade body 30 and a second portion having an end portion 34. As used herein, a "substrate" refers to a substance or material that is acted upon by a deposition process in the present disclosure. The exemplary embodiments herein relate to a stainless steel substrate that is typically used for razor blade formation. It is contemplated that the substrate of the present invention may also be made of other metals, plastics, ceramics, or any other material. The blade body 30 may include a base 32, and the end portion 34 may include flanks 36 that converge at an end 40 to define a cutting edge 42 of the substrate 28 that performs cutting hair. As described herein, the flanks 36 may each include one or more bevels or facets 38.

[0022] exist Figures 2 to 4 In the example shown in FIG. 1 , the base 28 is substantially symmetrical and may include a segmentation line SL passing through the end 40 and dividing or splitting the base 28 into substantially equal first and second segments or halves 44 and 46. 28 One outer side 48 (also referred to herein as the first outer side) of the substrate 28 is aligned with the separation line SL relative to the other outer side 50 (also referred to herein as the second outer side). 28 As used herein, the terms "first" and "second" are used for reference only and are not intended to be limiting.

[0023] At least a portion of one outer side (e.g., first outer side 48) of substrate 28 may define a skin contact surface, and at least a portion of another outer side (e.g., second outer side 50) may define a hair cutting surface. It is determined that the two sides of a razor blade generally perform different functions (e.g., a bottom side that contacts the skin and a top side that performs hair cutting, wherein both sides perform hair cutting and the top side (e.g., away from the skin) has a greater impact). Studies have shown that placing Teflon on one bevel and not placing Teflon on the other bevel exhibits completely different cutting forces, depending on whether the Teflon-coated bevel is placed with the skin side facing up (e.g., away from the skin) or with the skin side facing down (e.g., closer to the skin). When a razor blade without Teflon coating on one side is placed so that the side (e.g., without Teflon coating) is skin side facing down, only a small cutting force increase is noted when compared to a blade with Teflon on both sides, but when a razor blade without Teflon coating is placed with the skin side facing up, a very significant cutting force increase is measured when compared to a blade with Teflon on both sides.

[0024] refer to Figure 4, the end portion 34 may include a first wing 36A defined by a portion of the first outer side 48 and a second wing 36B defined by a portion of the second outer side 50, wherein the first wing 36A and the second wing 36B converge at the end 40. The first wing 36A may include one or more first facets, such as the first facet 38A and the third facet 38C, and the second wing 36B may include one or more second facets, such as the second facet 38B and the fourth facet 38D. The first facet 38A is connected to the blade body 30 at the first junction 39-1 and extends between the blade body 30 and the third facet 38C on the first outer side 48 of the base 28. The third facet 38C is connected to the first facet 38A at the second junction 39-2 and extends between the first facet 38A and the end 40 on the first outer side 48. On the second outer side 50 of the base 28, the second facet 38B is connected to the blade body 30 at the third junction 39-3 and extends between the blade body 30 and the fourth facet 38D. The fourth facet 38D is connected to the second facet 38B at the fourth junction 39-4 and extends between the second facet 38B and the end 40 on the second outer side 50. The third facet 38C and the fourth facet 38D (also referred to as the end facet) converge at the end 40 to define the cutting edge 42. In other examples, the side wings 36 may each include a facet 38 (see Figure 2 8) or three or more facets (not shown). Figures 2 to 4 In the razor blades 8 and 18 shown in the drawings, the outer shape or geometry of the first outer side 48 may be substantially the same as the outer shape or geometry of the second outer side 50. For example, the first facet 38A may substantially correspond to the second facet 38B, and may include substantially similar lengths, as defined between the first joint 39-1 and the second joint 39-2 and between the third joint 39-3 and the fourth joint 39-4, respectively. The third facet 38C may similarly substantially correspond to the fourth facet 38D, and may include substantially similar lengths, as defined between the end 40 and the second joint 39-2 and between the end 40 and the fourth joint 39-4, respectively. Therefore, the angles at the joints 39-1 and 39-3 and the angles at the joints 39-2 and 39-4 may also be generally substantially similar.

[0025] Continue to see Figure 4, the razor blade 18 may include multiple outer surfaces, including a first blade body outer surface 31A and a second blade body outer surface 31B defined by the outer surfaces of the first part 30A and the second part 30B of the blade body 30, respectively; and a first facet outer surface 39A, a second facet outer surface 39B, a third facet outer surface 39C and a fourth facet outer surface 39D defined by the outer surfaces of the first facet 38A, the second facet 38B, the third facet outer surface 38C and the fourth facet 38D, respectively. The first outer side 48 of the base 28 includes the first blade body outer surface 31A and the first facet outer surface 39A and the third facet outer surface 39C. The second outer side 50 includes the second blade body outer surface 31B, the second facet outer surface 39B and the fourth facet outer surface 39D. The first blade body outer surface 31A and the second blade body outer surface 31B may be substantially parallel to each other, and the dividing line SL 28 The first outer side 48 and the second outer side 50 converge at the tip 40 to define the cutting edge 42 of the base 28 .

[0026] Fig.18 and Fig.19 1 is a side view showing an exemplary embodiment of a razor blade 118 and 118' according to the present disclosure. Each razor blade 118, 118' may include a substrate 128, 128' having a first portion including a blade body 130, 130' and a second portion including an end portion 134, 134'. The blade body 130, 130' may include a base 132 ( Fig.19 140, 140') and the end portions 134, 134' may include flanks 136A, 136B and 136A', 136B' that converge at respective ends 140, 140' to define a cutting edge (not labeled) of the respective base 128, 128'. The flanks 136, 136' may each include one or more respective bevels or facets, as described herein. The base 128, 128' may be asymmetrical, wherein the split line SL through the ends 140, 140' 128 , SL 128’ Parallel to the blade body outer surfaces 131A and 131B, and dividing or splitting the base 128, 128' into asymmetrical first sections or halves 144, 144' and second sections or halves 146, 146'. Fig.18 The first outer side 148 of the substrate 128 is opposite to the second outer side 150 and the dividing line SL 128 Relative settings. Fig.19 The first outer side 148' of the substrate 128' is opposite to the second outer side 150' and the separation line SL 128’At least a portion of one outer side (eg, first outer side 148, 148') of each respective base 128, 128' may define a skin contacting surface, and at least a portion of the other outer side (eg, second outer side 150, 150') may define a hair cutting surface.

[0027] exist Fig.18 In the example shown in , the end portion 134 of the base 128 may include a first wing 136A defined by a portion of the first outer side 148 and a second wing 136B defined by a portion of the second outer side 150. The first wing 136A may include one or more first facets, such as the first facet 138A and the third facet 138C, and the second wing 136B may include one or more second facets, such as the second facet 138B and the fourth facet 138D. On the first outer side 148 of the base 128, the first facet 138A is connected to the blade body 130 at the first joint 139-1 and extends between the blade body 130 and the third facet 138C; and the third facet 138C is connected to the first facet 138A at the second joint 139-2 and extends between the first facet 138A and the end 140. On the second outer side 150 of the base 128, the second facet 138B is connected to the blade body 130 at the third junction 139-3 and extends between the blade body 130 and the fourth facet 138D; and the fourth facet 138D is connected to the second facet 138B at the fourth junction 139-4 and extends between the second facet 138B and the end 140. The third facet 138C and the fourth facet 138D (also referred to as the end facet) converge at the end 140 to define the cutting edge of the base 128.

[0028] exist Fig.19In the example shown in , the end portion 134' of the base 128' may include a first flank 136A' defined by a portion of the first outer side 148' and a second flank 136B' defined by a portion of the second outer side 150'. The first flank 136A' may include one or more first facets, such as the first facet 138A and the third facet 138C', and the second flank 136B' may include one or more second facets, such as the second facet 138B'. On the first outer side 148' of the base 128', the first facet 138A' is connected to the blade body 130' at the first joint 139-1' and extends between the blade body 130' and the third facet 138C'; and the third facet 138C' is connected to the first facet 138A' at the second joint 139-2' and extends between the first facet 138A' and the end 140'. On the second outer side 150' of the base 128', the second facet 138B' meets the blade body 130 at the third joint 139-3' and extends between the blade body 130' and the tip 140'. The second facet 138B' and the third facet 138C' (also referred to as the end facet) converge at the tip 140' to define the cutting edge of the base 128'.

[0029] Because the bases 128, 128' are asymmetrical, the outer shape or geometry of the first outer side 148, 148' is different from the outer shape or geometry of the second outer side 150, 150'. Fig.18 , the first facet 138A may include a different length than the second facet 138B, wherein the lengths are defined between the first joint 139-1 and the second joint 139-2 and between the third joint 139-3 and the fourth joint 139-4, respectively. In some examples, the length of the first facet 138A may be greater than the length of the second facet 138B, and in other examples, the length of the first facet 138A may be less than the length of the second facet 138B. The third facet 138C may similarly include a different length than the fourth facet 138D, wherein the lengths are defined between the end 140 and the second joint 139-2 and the fourth joint 139-4, respectively. In some examples, the length of the third facet 138C may be greater than the length of the fourth facet 138D, and in other examples, the length of the third facet 138C may be less than the length of the fourth facet 138D.

[0030] refer to Fig.19, the first outer side 148' includes two facets 138A' and 138C', and the second outer side 150' includes only one facet 138B'. The third facet 138C' may similarly include a different length than the second facet 138B', wherein the length is defined between the end 140' and the second and third joints 139-2', 139-3', respectively. In some examples, the length of the third facet 138C' may be greater than the length of the second facet 138B', and in other examples, the length of the third facet 138C' may be less than the length of the second facet 138B'.

[0031] Each of the razor blades 118, 118' may include a plurality of outer surfaces. Fig.18 The razor blade 118 includes a first blade body outer surface 131A and a second blade body outer surface 131B defined by the outer surfaces of the first portion 130A and the second portion 130B of the blade body 130, respectively; and a first facet outer surface 139A, a second facet outer surface 139B, a third facet outer surface 139C, and a fourth facet outer surface 139D defined by the outer surfaces of the first facet 138A, the second facet 138B, the third facet outer surface 138C, and the fourth facet outer surface 138D, respectively. The first blade body outer surface 131A and the second blade body outer surface 131B may be substantially parallel to each other, and the dividing line SL 128 The first outer side 148 of the base 128 includes the first blade body outer surface 131A and the first facet outer surface 139A and the third facet outer surface 139C, and the second outer side 150 includes the second blade body outer surface 131B and the second facet outer surface 139B and the fourth facet outer surface 139D. The first outer side 148 and the second outer side 150 converge at the end 140 to define the cutting edge of the base 128. The second facet 138B and the fourth facet 138D can be positioned closer to the split line SL than the first facet 138A and the third facet 138C. 128 , such that the first half 144 of the base 128 is larger than the second half 146 .

[0032] refer to Fig.19 The razor blade 118' includes a first blade body outer surface 131A' and a second blade body outer surface 131B' defined by the outer surfaces of the first portion 130A' and the second portion 130B' of the blade body 130', respectively; and a first facet outer surface 139A', a second facet outer surface 139B' and a third facet outer surface 139C' defined by the outer surfaces of the first facet 138A', the second facet 138B' and the third facet 138C', respectively. The first blade body outer surface 131A' and the second blade body outer surface 131B' may be substantially parallel to each other, and the dividing line SL128’ The first outer side 148' of the base 128' includes the first blade body outer surface 131A' and the first facet outer surface 139A' and the third facet outer surface 139C', and the second outer side 150' includes the second blade body outer surface 131B' and the second facet outer surface 139B'. The first outer side 148' and the second outer side 150' converge at the end 140' to define the cutting edge of the base 128'. The second facet 138B' may be positioned closer to the split line SL than the first facet 138A' and the third facet 138C'. 128’ , such that the first half 144 ′ of the base 128 ′ is larger than the second half 146 ′.

[0033] A razor blade according to the present disclosure may include a coating substantially disposed on one or both outer sides of the razor blade, wherein at least a portion of one of the outer sides is free of any coating. As used herein, a "layer" may refer to at least one material on a razor blade that satisfies a variety of factors, including, but not limited to, the composition, morphology, or structure of the layer; the presence of boundaries between layers; whether the process used to manufacture the product is expected to result in one or more layers; and whether there is sufficient compositional or morphological variation to produce one or more layers. As an example, there may be only one type of material on a razor blade, but with distinguishable layers, each with a different morphology. As used herein, a "coating" may refer to one or more layers on a razor blade, wherein each layer includes one or more materials. Thus, the present invention "coating" may be defined by a single layer or multiple layers. The present invention also encompasses the term "coating" to refer to an overall or total coating on one side of a razor blade, which includes all layers on one side of the razor blade.

[0034] Specifically, "coating" as used herein includes all layers of material applied to one outer side of a razor blade. For example, the coating may include one or more layers as defined herein, such as a first layer substantially disposed on a portion or the entirety of one outer side of the razor blade; a second layer formed on top of at least a portion of the first layer; a third layer formed on top of at least a portion of the second layer; and so on. The coating may also include a plurality of segments substantially disposed on one outer side of the razor blade, wherein each segment may include one or more layers of material. For example, the coating may include a first segment that extends substantially from a first point or position on one outer side of the razor blade to a second point or position on one outer side; a second segment that extends substantially from a second point or position on one outer side to a third point or position; a third segment that extends substantially from a third point or position on one outer side to a fourth point or position; and so on, wherein each segment is substantially different from an adjacent segment, as described in detail herein.

[0035] As used herein, the phrases "substantially disposed on," "substantially extending from," and similar phrases are used to describe the location or orientation of each coating including one or more layers and / or segments thereof, and mean that a majority of the coating / layer / segment is disposed on the indicated outer side and / or surface of the razor blade and / or a majority of the coating / layer / segment extends between two indicated points or locations on the outer side and / or surface of the razor blade. Figure 34 to Figure 37 As described, these phrases may encompass structures in which a portion of the coating / layer / segment extends over the end and onto another outer side or surface; overlaps onto an adjacent outer side or surface; extends slightly beyond two indicated points or locations on the surface; or extends slightly past an identified junction between adjacent facets or between a blade body and a facet, or stops slightly short of that junction.

[0036] According to the present disclosure, one outer side of the razor blade includes a coating and at least a portion of another outer side of the razor blade is free of any coating. Figures 4 to 17 An exemplary coating is shown relative to an asymmetric razor blade 18 having a symmetric substrate 28, and FIGS. 20 to 21 Fig.33 An exemplary coating is shown relative to an asymmetric razor blade 118 having an asymmetric substrate 128. Figures 5 to 17 Figure 20 to Fig.33 Some of the markings in the figure illustrate other aspects of the structure in detail.

[0037] As used herein, the terms "symmetrical," "asymmetrical," and derivatives thereof may refer to the outer shape of a substrate defining a razor blade and / or a coating formed thereon, as determined relative to a dividing line of the substrate. For example, Figure 4 The substrate 28 in the embodiment is substantially symmetrical (ie, the dividing line SL 28 The substrate 28 is divided into substantially equal sections / halves 44 and 46, wherein the substantially similar exterior shapes are generally mirror images of each other), but the coating formed on the substrate 28 in accordance with the present disclosure may be asymmetrical, as described in detail herein, such that the razor blade 18 is asymmetrical. Fig.18 Both the substrate 128 and the coating formed thereon are asymmetrical, as described herein, such that the razor blade 118 is asymmetrical.

[0038] exist Figures 4 to 17 In some examples, one outer side of substrate 28 (e.g., first outer side 48) may include a coating, and at least a portion 51 of another outer side of substrate 28 (e.g., second outer side 50) may be substantially free of any coating. In some examples, at least a portion of first outer side 48 may define a skin contacting surface. Portion 51 may extend from end region 35 toward base 32, such as Figures 4 to 16 As shown, or may be spaced apart from the end region 35 and the base 32, as shown Fig.17 As shown. Again, as used herein, the terms "first" and "second" are used for reference only and are not intended to be limiting. For example, although Figures 4 to 17 The left side of the substrate 28 in FIG. 1 is referred to as the “first” outer side, but it should be understood that the right side of the substrate 28 may also be the “first” outer side.

[0039] refer to Figures 4 to 6 , the razor blade 18 may include a coating 60 disposed substantially on the first outer side 48 of the substrate 28. In some examples, the coating 60 may include a single layer of material, such as Figure 4 In other examples, the coating 60 may include multiple material layers, such as Figure 5 and Figure 6 The coating 60 extends along the first outer side 48 of the substrate 28 from the end region 35 toward the base 32 (see Figure 4 ) extension. Figure 4 As shown in FIG. , the end portion 34 of the substrate 28 includes an end region 35, wherein the end region 35 surrounds (i.e., includes) the end 40 plus a portion of the substrate 28 extending about 1 μM from the end 40 toward the base 32 along the first outer side 48 and the second outer side 50, as shown in FIG. Fig.34 as shown in .

[0040] refer to Figure 5 In some examples, the coating 60 may include a first layer 60A and a second layer 60B, wherein the first layer 60A is substantially disposed on the first outer side 48 and the second layer 60B is formed on top of at least a portion of the first layer 60A. Figure 6 In other examples, the first coating 60 may include a first layer, a second layer, and a third layer 60A-60C, wherein the first layer 60A is substantially disposed on the first outer side 48, the second layer 60B is formed on top of at least a portion of the first layer 60A, and the third layer 60C is formed on top of at least a portion of the second layer 60B. As described herein, the coating 60 and / or any of its layers 60A-60C may be subjected to ion implantation to generate, for example, a coating layer comprising Fig.13 A layer 60' of ion implanted material 61 is shown.

[0041] exist Figures 4 to 6 In the example shown in FIG. 1 , the coating 60 (including all of its layers 60A-60C) is depicted as extending along the first outer side 48 of the substrate 28 from the tip region 35 to the blade body 30 and in some cases extending to the outer side 48 of the substrate 28. Figure 4 The base 32 of the razor blade 18 is shown. In other examples, such as Figure 7 and Figure 8As shown, the coating and / or one or more layers thereof may stop shorter than the blade body 30 and / or the base 32, and in some specific examples, the coating and / or one or more layers thereof may be substantially disposed only on the end portion 34 of the substrate 28, for example, on one or both of the first facet 38A and the third facet 38C.

[0042] refer to Figure 7 and Figure 8 as well as Figure 4 The coating 64, 68 may include one or more layers including a first layer 64A, 68A and a second layer 64B, 68B. The first layer 64A, 68A is substantially disposed on the first outer side 48 of the substrate 28 and extends along a portion of the first outer side from the end region 35 toward the base 32 for a respective first distance D1, D2. 1’ The second layer 64B, 68B is formed on top of at least a portion of the respective first layer 64A, 68B and extends from the end region 35 toward the base 32 by respective second distances D2, D 2’ In some examples, the second distance D2, D 2’ may be smaller than the corresponding first distances D1, D 1’ .exist Figure 7 In the embodiment, the first layer 64A can extend from the end region 35 along the first outer side 48 to the blade body 30 and toward the base 32, and the second layer 64B can be substantially disposed on the first face 38A and the third face 38C, wherein the second layer 64B extends from the end region 35 to the vicinity of the first joint 39-1 between the first face 38A and the blade body 30. Figure 8 In the embodiment, the first layer 68A can extend from the end region 35 along the first outer side 48 to the blade body 30 and toward the base 32, and the second layer 68B can be substantially disposed on the third face 38C, wherein the second layer 68B extends from the end region 35 to the vicinity of the second junction 39-2 between the first face 38A and the second face 38B. 2’ The first distance D1 and D 1’ In some cases, the first layer and the second layer can be disposed on both the first face 38A and the third face 38C, or only on the third face 38C. Figure 7 and Figure 8 In some configurations, the coatings 64 and 68 may include two or more layers, such as a first layer 64A, 68A and a second layer 64B, 68B. In other configurations, the coatings 64 and 68 may include only the second layer 64B and 68B (the first layer 64A and 68A are Figure 7 and Figure 8 are shown with dashed lines in the figure to indicate that they are optional).

[0043] refer to Figures 9 to 11 In other examples, the coating 72 substantially disposed on the first outer side 48 may include two or more segments. Fig. 9 and Fig.10 As shown, the coating 72 may include a first section 72-1 and a second section 72-2. The first section 72-1 of the coating 72 may extend along the first outer side 48 substantially from a first point or position 73-1 on the first outer side 48 that may substantially correspond to the end region 35 of the substrate 28 to a second point or position 73-2. The second section 72-2 may extend substantially from the second position 73-2 on the first outer side 48 to a third point or position 73-3. Fig. 9 as well as Figure 4 The second position 73-2 can be positioned near the junction between the facet and the blade body 30 (e.g., the junction 39-1 between the first facet 38A and the blade body 30) so that the first section 72-1 can be substantially located on the first facet 38A and the third facet 38C on the first outer side 48, and the second section 72-2 can be substantially located on the blade body 30. Fig.10 as well as Figure 4 In the marking of the substrate 28, the second position 73-2 can be located near the junction between two adjacent facets (e.g., the junction 39-2 between the first facet 38A and the third facet 38C), so that the first segment 72-1 is substantially located on the third facet 38C. Fig. 9 and Fig.10 In the depicted example, the third location 73-3 can be spaced apart from the second location 73-2 and can be positioned, for example, toward or near the base 32 of the substrate 28, such as Fig. 9 shown.

[0044] like Fig.11 As shown, the coating 72 may include a first segment 72-1, a second segment 72-2, and a third segment 72-3. The first segment 72-1 may extend along the first outer side 48 substantially from a first point or position 73-1 on the first outer side 48 that may substantially correspond to the end region 35 of the substrate 28 to a second point or position 73-2; the second segment 72-2 may extend substantially from the second position 73-2 on the first outer side 48 to a third point or position 73-3; and the third segment 72-3 may extend substantially from the third position 73-3 on the first outer side 48 to a fourth point or position (not shown). Fig.11 as well as Figure 4The markings of the base 28 in the middle, the second position 73-2 can be positioned near the junction 39-2 between the first facet 38A and the third facet 38C, and the third position 73-3 can be positioned near the junction 39-1 between the first facet 38A and the blade body, so that the first section 72-1 and the second section 72-2 can be substantially disposed on the first facet 38A and the third facet 38C, respectively, and the third section 72-3 can be substantially located on the blade body 30. The fourth position can be spaced apart from the third position 73-3 and can be positioned, for example, toward or near the base 32 of the base 28.

[0045] refer to Fig.12 In another example, substrate 28 can include coating 76 having a thickness that varies along at least a certain section of coating 76 in a direction extending from end region 35 toward base 32, wherein the thickness is measured between outer surface 76A of coating 76 and outer surface 28A of substrate 28. For example, the thickness of coating 76 can increase, such as Fig.12 shown.

[0046] exist Figures 4 to 12 In the examples shown in , the outer shape of coatings 60, 64, 68, 72, and 76 (and all layers or sections thereof) generally conforms to and / or reflects the outer shape of the underlying portion of substrate 28 on which the coatings are formed. Fig.14 As shown, substrate 28 may include coating 80 having one or more sections defining an outer shape that is different from the outer shape of the underlying portion of substrate 28. Coating 80 may include thickened section 80A, wherein coating 80 protrudes outward from substrate 28 and forms a connection with one or more of the underlying portions of substrate 28 (e.g., first facet outer surface and third facet outer surface (not labeled, see Figure 4 The coating 80 may optionally include a second segment 80B having an outer shape that more closely conforms to an underlying portion of the substrate 28 (e.g., the first blade body outer surface (not labeled, see Figure 4 The external shape of the blade body outer surface 31A)).

[0047] exist Figures 4 to 17 In the embodiment, coatings 60, 64, 68, 72, 76, and 80 may be disposed on one or both of the first facets (i.e., first facet 38A and / or third facet 38C) on first outer side 48, and portion 51 of second outer side 50 that is free of any coating may include at least a portion of one or both of the second facets (i.e., second facet 38B and / or fourth facet 38D). Figures 4 to 14In the example shown in , the portion 51 of the second outer side 50 that is substantially free of any coating may substantially include the entire second outer side 50. Figures 15 to 17 In the example shown in , the portion 51 substantially free of any coating may include only a portion (also referred to herein as a first portion or an uncoated portion) of the second outer side 50. The second portion 53 of the second outer side 50 may include a second coating 62 substantially disposed thereon, such that only a portion of the second outer side 50 is uncoated.

[0048] refer to Fig.15 and Fig.16 as well as Figure 4 In the marking of the substrate 28, the first portion 51 of the second outer side 50 that is substantially free of any coating can extend from the end region 35 toward the base 32, and the second coating 62 can substantially extend from the first position 75-1 to the second position 75-2, wherein the first position 75-1 is spaced apart from the end region 35 and the second position 75-2 is located toward the base 32. Fig.15 In the embodiment, the first position 75-1 may substantially correspond to the joint 39-3 between the blade body 30 and the fourth facet 38D, so that the uncoated portion 51 of the second outer side 50 may substantially include the entire second facet 38B and the fourth facet 38D. Fig.16 , the first position 75-1 can substantially correspond to the junction 39-4 between the second facet 38B and the fourth facet 38D, so that the uncoated portion 51 of the second outer side 50 can substantially include the entire fourth facet 38D. It can be understood that the second coating 62 can be provided so that the uncoated portion 51 of the second outer side 50 is located at any desired position within these parameters.

[0049] refer to Fig.17 and Figure 4 In another example, the second coating 62 may include a first segment 62-1 and a second segment 62-2, and the uncoated portion 51 of the second outer side 50 may be located between the first segment 62-1 and the second segment 62-2 of the second coating 62, so that the uncoated portion 51 is spaced apart from the end region 35 and the base 32. For example, the first segment 62-1 of the second coating 62 may extend substantially from the first position 75-1 to the second position 75-2, and the second segment 62-2 may extend substantially from the third position 75-3 to the fourth position 75-4. The first position 75-1 may substantially correspond to the end region 35 of the substrate 28, and the second position 75-2 may be spaced apart from the third position 75-3. Fig.17In the example shown, the second position 75-2 can substantially correspond to the junction 39-4 between the second facet 38B and the fourth facet 38D; the third position 75-3 can substantially correspond to the junction 39-3 between the blade body 30 and the fourth facet 38D; and the fourth position 75-4 can be positioned toward the base 32 of the substrate 28 so that the uncoated portion 51 of the second outer side 50 can substantially include the entire second facet 38B. It should be understood that the sections 62-1 and 62-2 of the second coating 62 can be arranged so that the uncoated portion 51 of the second outer side 50 is located at any desired position within these parameters.

[0050] In all examples, each coating may include one or more materials. Figures 5 to 8 In the example of a coating with multiple layers shown, the layers can include the same material or one or more different materials compared to each other. For example, a first layer of the coating can include one or more first materials, and a second layer of the coating can include one or more second materials, wherein at least one of the second materials is different from at least one of the first materials. ... Figures 9 to 11 In the example of a coating of two or more segments shown, each segment may contain a different material than an adjacent or neighboring segment. Figures 15 to 17 In the examples of the first coating and the second coating shown, the coatings can include the same material or one or more different materials compared to each other. For example, the first coating can include one or more first materials, and the second coating can include one or more second materials, wherein at least one of the second materials is different from at least one of the first materials.

[0051] The material may include one or more carbon-containing materials (e.g., diamond, amorphous diamond, nanocrystalline diamond, or diamond-like carbon (DLC)); nitrides (e.g., boron nitride, niobium nitride, chromium nitride, titanium nitride, aluminum nitride, titanium carbon nitride), carbides (e.g., silicon carbide or chromium carbide), oxides (e.g., aluminum oxide, zirconium oxide), titanium diboride, one or more ceramic materials, fluorinated polymers (e.g., polytetrafluoroethylene (PTFE)), polyolefins (e.g., polypropylene), niobium, chromium, and platinum chromium. The carbon-containing material may be doped with other elements such as tungsten, titanium, or chromium by, for example, including these additives in the target during coating by sputtering. These materials may also contain hydrogen, such as hydrogenated DLC. The material may include one or more nanocomposites, such as carbon-based nanocomposites, metal-based nanocomposites, and / or ceramic-based nanocomposites; for example, diamond and carbon and nanocomposites.

[0052] The materials may be selected based at least in part on their coefficient of friction, wherein the materials of the various coatings and / or layers and / or sections thereof comprise one or more materials having different coefficients of friction than one another. Figure 4 The coating 60 or its Figures 5 to 7 The outer layers 60B, 60C, 64B, 68B in the embodiment of the present invention may comprise a material having a low coefficient of friction, such as PTFE, particularly when the first outer side 48 of the substrate 28 at least partially defines the skin contacting surface. When present, the second coating 62 (see Figures 15 to 17 ) may comprise a material having a higher coefficient of friction than PTFE, such as polypropylene.

[0053] The material of the coating and / or its layers and / or sections can also be selected based at least in part on the morphology, which can include a microstructure (e.g., amorphous, columnar, crystalline, dense, porous, etc.). The porous microstructure can improve the adhesion of subsequent polymer coatings. As described herein, the desired morphology can be obtained, for example, by applying the coating and / or its layers and / or sections via different application techniques or via the same application technique with different application speeds.

[0054] The material of the coating and / or its layers and / or sections may be further selected based at least in part on the hardness of the material. One coating and / or its layers and / or sections may have a first hardness, and another coating and / or its layers and / or sections may have a second hardness. In some examples, the first hardness may be greater than about 7 GPa, and the second hardness may be greater than about twice the first hardness, for example, greater than about 15 GPa. In other examples, the first hardness may be between about 7 GPa and about 10 GPa, and the second hardness may be between about 15 GPa and about 60 GPa. As used herein with respect to hardness, the term "about" may mean ± 0.5 GPa.

[0055] The texture of the coating and / or its layers and / or sections may also be selected. Figure 4 The coating 60 or its Figures 5 to 7 The outer layers 60B, 60C, 64B, 68B in the embodiment of the present invention may include a substantially smooth texture, particularly when the first outer side 48 of the substrate 28 at least partially defines the skin contacting surface. When present, the second coating 62 (see Figures 15 to 17 ) may include a discontinuous or rougher texture, which may include protrusions. As described herein, the desired texture may be obtained, for example, by applying the coating and / or its layers and / or sections via different application techniques or via the same application technique with different application speeds. The texture may also be altered via one or more post-application treatment methods, as described herein.

[0056] In further examples, at least certain sections of the coating and / or its layers and / or sections may be subjected to one or more post-application treatments (e.g., modification of the coating surface and / or modification of one or more layers of the coating). For example, one or more sections of the coating and / or its layers and / or sections may be subjected to ion implantation. Fig.13 , at least a certain section of the coating 60' may include an ion implanted material 61. The ion implanted material 61 may include, for example, a plasma nitrided material or a plasma borided material. The ion implantation may be performed as described herein, and the ion implantation may be performed on all or part of the coating 60'. One or more post-application treatments may also include changing the texture of the coating and / or its layers and / or sections. For example, the coating and / or its layers and / or sections may be subjected to chemical modification (e.g., solvent treatment) and / or mechanical modification (e.g., ion etching, ion implantation, grinding, rubbing, polishing, etc.) to change the surface texture.

[0057] One or more post-application treatments may also include, for example, partially removing the coating and / or its layers and / or sections by solvent treatment, ion etching, etc. Partial removal may include, for example, removing all or part of the thickness of the coating along one or more sections of the second coating (i.e., in a direction substantially perpendicular to the lower portion of the substrate), wherein at least a portion of the coating remains intact. In some examples, the partial removal of one or more portions of the first coating and / or the second coating may be followed by one or more additional post-application treatments, including selectively applying material to the first coating and / or the second coating, partially removing material from the first coating and / or the second coating. The selectively applied material may be applied using any suitable method. The selectively applied material may include, for example, a polymer or organic compound, such as a fluoropolymer, PTFE, or polypropylene. In some specific examples, the portion of the coating to which the material is selectively applied may define the skin contact surface of the razor blade.

[0058] Now refer to Figures 20 to Fig.33 , the razor blade 118 may include one or more coatings that are substantially similar to Figures 4 to 17 1 and described in detail herein, wherein one of the first outer side 148 or the second outer side 150 of the substrate 128 may include a coating, and at least a portion 149 or 151 of the other of the first outer side 148 or the second outer side 150 of the substrate 128 may be substantially free of any coating. In some specific examples where the first outer side 148 includes a coating, at least a portion of the first outer side 148 may define a skin contacting surface. Portions 149, 151 may extend from the end region 135 toward the base 132, as shown in FIGS. 20 to 21. Fig.32 As shown, or may be spaced apart from the end region 135 and the base 132, as shown Fig.33 shown.

[0059] like Fig. 20A , Fig.21A and Fig.22A As shown, the razor blade 118 may include a coating 160 that is substantially disposed on the first outer side 148 of the substrate 128 and along the first outer side 148 from the end region 135 toward the base (not shown; see Fig.18 The portion 151 of the second outer side 150 that is substantially free of any coating may extend from the end region 135 toward the base. The coating 160 may include a single material layer, such as Fig. 20A or multiple material layers, such as a first layer 160A, a second layer 160B and / or a third layer 160C, such as Fig.21A and Fig.22A A first layer 160A is substantially disposed on the first outer side 148; a second layer 160B is formed on top of at least a portion of the first layer 160A; and when present, a third layer 160C is formed on top of at least a portion of the second layer 160B. Fig. 20B , Fig.21B and Fig. 22B Depicted Fig. 20A , Fig.21A and Fig.22A 1, wherein the razor blade 118 includes a coating 162 disposed substantially on the second outer side 150 of the substrate 128, and the first outer side 148 includes a portion 149 substantially free of any coating. The coating 162 extends along the first outer side 150 from the end region 135 toward the base (not shown; see Fig.18 The portion 149 that is substantially free of any coating may extend from the end region 135 toward the base. The coating 162 may include a single layer of material, such as Fig. 20B or multiple material layers, such as a first layer 162A, a second layer 162B and / or a third layer 162C, such as Fig.21B and Fig. 22B As described herein, any of the coatings 160, 162 and / or layers 160A-160C, 162A-162C thereof may be subjected to ion implantation to generate, for example, Fig.29A and Fig.29B A layer 160 ′ or 162 ′ of ion implanted material 161 or 163 is shown.

[0060] In the examples shown in FIGS. 20-22 , coatings 160 and 162 (including all of their layers 160A-160C and 162A-162C) are depicted extending from the tip region 135 onto the blade body along the respective outer sides 148 or 150 of the substrate 128 (not labeled; see FIG. Fig.18130) and in some cases may extend all the way to the base of the razor blade 118 (not shown, see Fig.18 In other examples, the coating and / or one or more layers thereof may stop at a position shorter than the blade body and / or the base, and in some specific examples, the coating and / or one or more layers thereof may be disposed substantially only at the distal end portion of the substrate 128 (not labeled, see Fig.18 134), for example, on one or both of the first and third facets or one or both of the second and fourth facets (not labeled; see Fig.18 On the small faces 138A to 138D).

[0061] refer to Fig.23A and Fig.24A as well as Fig.18 The coating 164, 168 may include one or more layers including a first layer 164A, 168A substantially disposed on the first outer side 148 of the substrate 128 and extending along a portion of the first outer side from the end region 135 toward the base 132 for a first distance D 10 , D 10’ and a second layer 164B, 168B formed on top of at least a portion of the respective first layer 164A, 168B and extending from the end region 135 toward the base 132 by a respective second distance D 20 , D 20’ In some examples, the second distance D 20 , D 20’ Can be less than the corresponding first distance D 10 , D 10’ .exist Fig.23A In the embodiment, the first layer 164A may extend from the end region 135 along the first outer side 148 to the blade body 130 and toward the base 132, and the second layer 164B may be substantially disposed on the first face 138A and the third face 138C, wherein the second layer 164B extends from the end region 135 to the vicinity of the first joint 139-1 between the first face 138A and the blade body 130. Fig.24A In the embodiment, the first layer 168A can extend from the end region 135 along the first outer side 148 onto the blade body 130 and toward the base 132, and the second layer 168B can be substantially disposed on the third face 138C, wherein the second layer 168B extends from the end region 135 to the vicinity of the second junction 139-2 between the first face 138A and the second face 138B. In other examples, the second distance D 20 , D 20’ The first distance D 10 , D10’ In some cases (not shown), the first layer and the second layer can be disposed on both first facet 138A and third facet 138C, or only on third facet 138C.

[0062] Fig. 23B and Fig. 24B Depicted separately Fig.23A and Fig.24A 1, wherein the second outer side 150 includes a coating 166, 170 substantially disposed thereon, wherein each coating 166, 170 may include one or more layers, including a respective first layer 166A, 170A and a second layer 166B, 170B. Each first layer 166A, 170A extends along a portion of the second outer side 150 from the end region 135 toward the base (not shown; see Fig.18 The base 132 in the embodiment extends a corresponding third distance D 30 , D 30’ and each second layer 166B, 170B extends from the end region 135 toward the base to a respective fourth distance D 40 , D 40’ In some examples, the fourth distance D 40 , D 40’ can be less than the corresponding third distance D 30 , D 30’ ,For example, Fig. 23B The second layer 166B of the coating 166 is substantially disposed on the second and fourth facets (not labeled; see Fig.18 on the small faces 138B and 138D in the Fig. 24B The second layer 170B of the coating 170 is substantially disposed on the fourth face. In other examples, the fourth distance D 40 , D 40’ The corresponding third distance D 30 , D 30’ In the example depicted in Figures 23 and 24, coatings 164, 166, 168, and 170 may include two layers, for example, respective first layers 164A, 166A, 168A, and 170A and second layers 164B, 166B, 168B, and 170B. In other configurations, coatings 164, 166, 168, and 170 may include only second layers 164B, 166B, 168B, and 170B (first layers 164A, 166A, 168A, and 170A are shown in dashed lines in Figures 23 and 24, indicating that they are optional).

[0063] refer to Fig.25A , Fig.26A and Fig.27AIn another example, the coating 172 may include two or more segments, including a first segment 172-1, a second segment 172-2, and a third segment 172-3. The first segment 172-1 may extend along the first outer side 148 substantially from a first point or position 173-1 that may substantially correspond to the end region 135 of the substrate 128 to a second point or position 173-2; the second segment 172-2 may extend substantially from the second position 173-2 to a third point or position 173-3; and when present, the third segment 172-3 may extend substantially from the third position 173-3 to a fourth point or position (not shown). Reference Fig.25A as well as Fig.18 The second position 173-2 can be positioned near the junction 139-1 between the first facet 138A and the blade body 130, so that the first section 172-1 can be substantially located on the first facet 138A and the third facet 138C, and the second section 172-2 can be substantially located on the blade body 130. Fig.26A as well as Fig.18 In the marking of the substrate 118, the second position 173-2 can be located near the junction 139-2 between the first facet 138A and the third facet 138C, so that the first section 172-1 can be substantially located on the third facet 138C. Fig.25A and Fig.26A In the depicted example, the third location 173-3 can be spaced apart from the second location 173-2 and can be positioned, for example, toward or near the base 132 of the substrate 128, such as Fig.25A Reference Fig.27A as well as Fig.18 In the marking of the base 118, the second position 173-2 can be positioned near the junction 139-2 between the first facet 138A and the third facet 138C, and the third position 173-3 can be positioned near the junction 139-1 between the first facet 138A and the blade body 130, so that the first section 172-1 and the second section 172-2 can be substantially disposed on the first facet 138A and the third facet 138C, respectively, and the third section 172-3 can be substantially located on the blade body 130. The fourth position (not shown) can be spaced apart from the third position 173-3 and can be positioned, for example, toward or near the base 132 of the base 128.

[0064] Fig.25B , Fig.26B and Fig.27B Depicted separately Fig.25A , Fig.26A and Fig.27AAn alternative configuration in which the second outer side 150 includes a coating 174 that includes two or more segments, including a first segment 174-1, a second segment 174-2, and a third segment 174-3. The first segment 174-1 may extend along the second outer side 150 substantially from a first point or position 175-1 (which may substantially correspond to the end region 135 of the substrate 128) to a second point or position 175-2; the second segment 174-2 may extend substantially from the second position 175-2 to a third point or position 175-3, and when present, the third segment 174-3 may extend substantially from the third position 175-3 to a fourth point or position (not shown).

[0065] refer to Fig.28A and Fig.28B In another example, one of the first outer side 148 or the second outer side 150 of the substrate 128 may include a respective coating 176 or 178 having a thickness that varies along at least a certain section of the coating 176 or 178 in a direction extending from the end region 135 toward the base 132. The thickness of the coatings 176 and 178 may be measured between the outer surfaces 176A, 178A of the respective coatings 176 and 178 and the outer surface 128A of the substrate 128. For example, the thickness of the coatings 176 and 178 may increase, as shown in FIG. Fig.28A and Fig.28B shown.

[0066] In the examples shown in FIGS. 20-28 , the outer shape of coatings 160, 162, 164, 166, 168, 170, 172, 174, 176, and 178 (and all layers or segments thereof) generally conforms to and / or reflects the outer shape of the underlying portion of substrate 128 on which the coating is formed. Fig. 30A and Fig. 30B As shown, substrate 128 may include coating 180 or 182 having one or more sections defining an outer shape that is different from the outer shape of an underlying portion of substrate 128. Fig. 30A As shown, coating 180 can be substantially disposed on first outer side 148 and can include thickened section 180A, wherein coating 180 protrudes outward from substrate 128 and forms a bond with one or more underlying portions of substrate 128 (e.g., at least a portion of the third facet outer surface and the first facet outer surface (not labeled, see Fig.18 The outer shapes of the facet outer surfaces 139A and 139C) are different from each other. Fig. 30BAs shown, coating 182 can be substantially disposed on second outer side 150 and can include thickened section 182A, wherein coating 182 protrudes outward from substrate 128 and forms a connection with one or more of the lower portions of substrate 128 (e.g., the fourth facet outer surface and at least a portion of the second facet outer surface (not labeled, see Fig.18 The coatings 180 and 182 may optionally include respective second segments 180B and 182B having an outer shape that more closely conforms to an underlying portion of the substrate 128 (e.g., a first blade body outer surface or a second blade body outer surface (not shown, see Fig.18 The external shape of the blade body outer surface 131A, 131B).

[0067] exist Fig. 20A , Fig.21A , Fig.22A , Fig.23A , Fig.24A , Fig.25A , Fig.26A , Fig.27A , Fig.28A , Fig.29A and Fig. 30A , coatings 160, 164, 168, 172, 176, and 180 may be disposed on a first facet (ie, Fig.18 On one or both of the first facet 138A and / or the third facet 138C in the second outer side 150, and the portion 151 of the second outer side 150 that does not contain any coating may include the second facet (ie, Fig.18 At least a portion of one or both of the second facet 138B and / or the fourth facet 138D). Fig. 20B , Fig.21B , Fig. 22B , Fig. 23B , Fig. 24B , Fig.25B , Fig.26B , Fig.27B , Fig.28B , Fig.29B and Fig. 30B In the embodiment, coatings 162, 166, 170, 174, 178 and 182 may be disposed on a second facet (ie, Fig.18 The coating may be applied to one or both of the second facet 138B and / or the fourth facet 138D in the first outer side 148, and the portion 149 of the first outer side 148 that does not contain any coating may include the third facet (ie, Fig.18In the example shown in Figures 20 to 30, the portion 149 or 151 of the outer side 148 or 150 that is substantially free of any coating may substantially include the entire corresponding outer side 148 or 150. Figure 31 to Figure 33 In the example shown in , the portion 151 that is substantially free of any coating may include only a portion (also referred to herein as a first portion or an uncoated portion) of the second outer side 150. The second portion 153 of the second outer side 150 may include a second coating 162 substantially disposed thereon, such that only a portion of the second outer side 150 is uncoated.

[0068] refer to Fig.31 and Fig.32 as well as Fig.18 In the marking of the substrate 128, the first portion 151 of the second outer side 150 that is substantially free of any coating may extend from the end region 135 toward the base 132, and the second coating 162 may substantially extend from a first position 175-1 to a second position 175-2, wherein the first position 175-1 is spaced apart from the end region 135 and the second position 175-2 is positioned toward the base 132. Fig.31 In the embodiment, the first position 175-1 may substantially correspond to the joint 139-3 between the blade body 130 and the fourth facet 138D, so that the uncoated portion 151 of the outer side 150 may substantially include the entire second facet 138B and the fourth facet 138D. Fig.32 , first position 175-1 may substantially correspond to junction 139-4 between second facet 138B and fourth facet 138D, such that uncoated portion 151 of outer side 150 may substantially include entire fourth facet 138D. It will be appreciated that second coating 162 may be provided such that uncoated portion 151 of outer side 150 is located at any desired position within these parameters.

[0069] refer to Fig.33 and Fig.18In another example, the second coating 162 may include a first segment 162-1 and a second segment 162-2, and the uncoated portion 151 of the second outer side 150 may be located between the first segment 162-1 and the second segment 162-2 of the second coating 162, such that the uncoated portion 151 is spaced apart from the end region 135 and the base 132. For example, the first segment 162-1 of the second coating 162 may extend substantially from the first position 175-1 to the second position 175-2, and the second segment 162-2 may extend substantially from the third position 175-3 to the fourth position 175-4. The first position 175-1 may substantially correspond to the end region 135 of the substrate 128, and the second position 175-2 may be spaced apart from the third position 175-3. Fig.33 In the example shown, the second position 175-2 can substantially correspond to the junction 139-4 between the second facet 138B and the fourth facet 138D; the third position 175-3 can substantially correspond to the junction 139-3 between the blade body 130 and the fourth facet 138D; and the fourth position 175-4 can be positioned toward the base 132 of the substrate 128 so that the uncoated portion 151 of the outer side 150 can substantially include the entire second facet 138B. It should be understood that the sections 162-1 and 162-2 of the second coating 162 can be arranged so that the uncoated portion 151 of the second outer side 150 is located at any desired location within these parameters. In addition, although the uncoated portion 151 is located at Figure 31 to Figure 33 14. Although depicted as being located on the second outer side 150, it should be understood that the uncoated portion 151 may also be located on the first outer side 148 (not shown).

[0070] Figure 20 to Fig.33 The coating and / or its layers and / or sections depicted in the drawings may comprise one or more materials, as described herein with respect to Figures 4 to 17 The materials may be selected for any of the properties and characteristics described herein (e.g., coefficient of friction, morphology, texture, hardness, etc.), and at least certain sections of the coating and / or its layers and / or sections may be subjected to one or more post-application treatments, as described in detail herein. For example, one or more sections of the coating and / or its layers and / or sections may be subjected to ion implantation, such as Fig.29A and Fig.29B As shown, at least certain sections of the coatings 160 ′, 162 ′ may contain ion implantation materials 161 , 163 .

[0071] Figure 34 to Figure 37 is a detailed view of the end region 35 of the substrate 28, which can be seen Figures 4 to 17 Figure 20 to Fig.33 Any of the substrates 28 and 128 in. Fig.34An idealized representation of the end region 35 is depicted in which the coating 60 is disposed only on the first outer side 48 of the substrate 28 (ie, at the separation line S of the substrate 28). 28 ), and at least a portion 51 of the second outer side 50 of the substrate 28 (ie, on the dividing line S 28 does not contain any coating.

[0072] However, if Figure 35 to Figure 37 As shown, applying the material to the substrate 228 may produce an end region 235 having slight defects. Figure 35 to Figure 37 In the embodiment, the first outer side 248 of the substrate 228 (as indicated by the dividing line SL 228 ) may include a coating 260 having a first layer 260A and a second layer 260B, and a portion 251 of the second outer side 250 may be substantially free of any coating. Fig.35 and Fig.36 As shown, in some examples, a small portion of coating 260 (which may include one or both of layers 260A and 260B) may be disposed on first outer side 250 of substrate 228 at end region 235, i.e., a small portion of coating 260 (extending less than or equal to about 1 μM from end 240 back toward the base) may be located at segmentation line SL 228 on the right side. Fig.37 Another example is provided in which the coating 260 stops shorter than the tip 240 , such that a small gap (less than or equal to about 1 μM) exists between the coating 260 and the tip 240 .

[0073] In the examples described herein, although there is a small amount of overlap (less than or equal to about 1 μM extending back from the tip 240 toward the base) of the coating 260 on the second outer side 250 or the gap between the coating 260 and the tip 240 in the tip region 235, the coating 260 including all of its layers 260A and 260B is considered to be "substantially" disposed on the first outer side 248 of the substrate 228, and "extends from the tip region" when the majority of the coating 260 is disposed on the first outer side 248 of the substrate 228. In addition, in Fig.35 and Fig.36 In the embodiment of the present invention, although the coating 260 overlaps the second outer side 250 by a small amount, the portion of the second side 250 that "extends from the end region toward the base" is considered to be "substantially free of any coating." Figure 34 to Figure 37 The example shown in illustrative embodiments depicts the coating being located on the first outer side 248 of the substrate 228 , but it should be understood that the coating may be located on the second outer side 250 as well.

[0074] In examples where the first coating and / or the second coating comprises two or more layers (see Figures 5 to 8and Figures 21 to 24) and / or two or more segments (see Figures 9 to 11 25 to 27 ), each layer or segment is described as extending from one point or location on the substrate to another point or location (e.g., a junction between adjacent facets in a facet or a junction between a blade body and one of the facets), and in some examples, a segment may abut and contact at least a portion of an adjacent segment.

[0075] Similar to Figure 35 to Figure 37 In the structures depicted in , layers and / or segments may extend slightly beyond (less than or equal to about 1 μM) one or both of the identified locations, or stop slightly shorter than (less than or equal to about 1 μM) the one or both of the identified locations. In some cases, there may be a small amount of material mixing at the interface between two adjacent segments or at a small gap (less than or equal to about 1 μM) between adjacent segments. Despite these slight imperfections, a layer or segment of a coating can be considered to extend "substantially" from one location to another when the majority of the layer / segment is disposed between two identified locations.

[0076] One or more techniques may be used to apply or selectively remove the coatings described herein. Fig.38 302-1 to 302-n, which can be used to apply one or more coatings to one or more portions of a plurality of razor blades 318 and / or perform one or more post-application treatments after applying the one or more coatings. As shown, the razor blades 318 can be positioned within a first chamber 302-1 for applying the one or more coatings using one or more techniques, such as vacuum deposition, spraying, dipping, brushing, molding, sintering, printing, etching, application via a pad or lacquer, inkjet nozzles, or any combination thereof, any of which may or may not include masking one or more portions of the razor blades 318. In some examples, chamber 302-1 can include a vacuum chamber with a vacuum pump 390. The system 300 can optionally include one or more additional chambers 302-n for performing different coating techniques and / or performing different post-application treatments.

[0077] Razor blade 318 can represent any razor blade described herein.Razor blade 318 can be arranged in chamber 302-1 in any way.As shown, razor blade 318 can be positioned adjacent to each other with the arrangement that can be called razor blade main axis.Blade 318 can also be arranged to have interval (not shown) between each other using spacer, and this can allow the coating coverage on blade body 330 of razor blade 318 to increase.Blade 318 can also be arranged to face opposite direction or different angles (not shown) from each other with edge (not marked) and end 340.Any feasible orientation of razor blade 318 is all contained in the present disclosure.

[0078] System 300 can be used to apply a coating to a razor blade, wherein the razor blade includes a substrate having a first outer side and a second outer side disposed opposite a parting line. The first coating and the second coating are applied to at least a portion of the first outer side and the second outer side, wherein the first coating and the second coating extend from an end region of the substrate toward the base and are substantially disposed on the respective first outer side or the second outer side. The coatings can each include one or more layers.

[0079] As described herein, the system 300 can be configured to accommodate the application of a variety of different types of materials, including metals, fluorinated polymers, etc. The first coating and the second coating can be applied simultaneously or sequentially, and can be applied using the same or different techniques. In some examples, the selective application of one or more materials can be achieved by, for example, masking one or more portions of the substrate and applying the materials to the unmasked portions of the substrate. The system 300 can also be configured to apply the first coating and the second coating to generate one or more desired characteristics for each coating, having a specific thickness, external shape, morphology, texture, etc. as described herein. The system 300 can also be configured to perform one or more post-application treatments on at least one section of the first coating or the second coating, including ion implantation and / or changing the texture of the coating.

[0080] Fig.39 is a flow chart illustrating an exemplary method 400 of coating a razor blade according to the present disclosure. Figure 4 and Fig.18 The razor blade 18, 118 may include a substrate 28, 128 having an end portion 34, 134 including an end region 35, 135, a blade body 30, 130 including a base 32, 132, and a separation line SL from the substrate 28, 128. 28 , SL 128 A first outer side 48, 148 and a second outer side 50, 150 are disposed oppositely, wherein the first outer side 48, 148 and the second outer side 50, 150 converge at the tip 40, 140. The method 400 includes either step 410, which includes applying a first coating only to a portion of the first outer side, wherein the coating extends from the tip region toward the base and is substantially disposed on the first outer side, or step 420, which includes applying the first coating to a portion of the first outer side, wherein the first coating extends from the tip region toward the base and is substantially disposed on the first outer side, and applying a second coating to the second outer side, such that a first portion of the second outer side is substantially free of any coating and a second portion of the second outer side includes the second coating, wherein the first portion extends from the tip region toward the base or is spaced apart from the tip region and the base, after which the method 400 may end.

[0081] In some specific examples, the substrate may include a second coating. In some cases, the second coating may extend substantially from a first position to a second position, the first position being spaced apart from the end region, and the second position being positioned toward the base. In other cases, the second coating may include a first section extending substantially from the first position to the second position and a second section extending substantially from the third position to the fourth position, wherein the first position may include the end region, the second position may be spaced apart from the third position, and a first portion of the second outer side substantially free of any coating may be located between the first section and the second section of the second coating. The first coating may include one or more first materials, and the second coating may include one or more second materials, wherein at least one of the second materials may be different from at least one of the first materials. The first coating and the second coating may be applied simultaneously or sequentially using the same technique or different techniques.

[0082] The first coating can be applied so that at least a certain section of the first coating defines an external shape that is different from the external shape of the underlying portion of the substrate, or so that the first coating has a thickness that varies along at least a certain section of the first coating in a direction extending from the end region toward the base of the razor blade.

[0083] In some examples, step 410 of applying a first coating may also include applying multiple material layers. Applying multiple material layers may include: applying a first layer to a portion of the first outer side, wherein the first layer extends a first distance from the end region toward the base; and applying a second layer on top of at least a certain section of the first layer, wherein the second layer extends a second distance from the end region toward the base, the second distance being the same as or less than the first distance. The first layer may include a first material, and the second layer may include a second material different from the first material.

[0084] In other examples, the first outer side of the substrate may include one or more first facets, and the second outer side may include one or more second facets. The first coating may be disposed on at least one of the first facets, and the first portion of the second outer side that is substantially free of any coating may include at least a portion of at least one of the second facets. The first coating may be applied so that the first coating includes: a first segment that extends substantially from a first position on the first outer side to a second position; and a second segment that extends substantially from a second position on the first outer side to a third position, wherein the first position may include an end region and the second position may include (i) a junction between two adjacent first facets in the first facet or (ii) a junction between the blade body and one of the first facets in the first facets. The second position may include a junction between two adjacent first facets in the first facet, and the third position may include a junction between the blade body and one of the first facets in the first facets, wherein the first coating may be applied so that the first coating also includes a third segment that extends substantially from the third position toward the base.

[0085] In another example, the method may further include an optional step 430, which includes performing one or more post-application treatments on at least one section of the first coating and / or performing one or more post-application treatments on at least one section of the second coating when the substrate includes a second coating. In some cases, the one or more post-application treatments may include one or more of the following: subjecting at least one section of the first coating or the second coating to ion implantation; or partially removing one or more sections of the first coating and / or the second coating. In some cases, the one or more post-application treatments may also include selectively applying a material to the first coating and / or the second coating after partially removing one or more sections of the first coating and / or the second coating. At least a portion of the first outer side or the second outer side having the selectively applied material may define a skin contact surface.

[0086] The representative embodiments of the present disclosure described above can be described as follows:

[0087] A. A razor blade, comprising:

[0088] a substrate having an end portion including an end region, a blade body including a base, and a first outer side and a second outer side disposed opposite a dividing line of the substrate, wherein the first outer side and the second outer side converge at the end,

[0089] wherein the first outer side comprises a first coating disposed substantially thereon, the first coating extending from the terminal region towards the base, and

[0090] • wherein a first portion of the second outer side is substantially free of any coating, wherein the first portion extends from the terminal region towards the base or is spaced apart from the terminal region and the base.

[0091] B. The razor blade of paragraph A, wherein the second portion of the second outer side includes a second coating substantially disposed thereon, the second coating substantially extending from the first location to the second location, wherein the first location is spaced apart from the end region and the second location is positioned toward the base.

[0092] C. The razor blade of paragraph A or B, wherein the first portion includes substantially the entire second outer side.

[0093] D. A razor blade according to any of paragraphs A or C, wherein the second portion of the second outer side includes a second coating substantially disposed thereon, the second coating including a first segment extending substantially from the first position to the second position and a second segment extending substantially from the third position to the fourth position, wherein the first position includes a terminal region, the second position is spaced apart from the third position, and the first portion of the second outer side that is substantially free of any coating is located between the first segment and the second segment of the second coating.

[0094] E. The razor blade of any of paragraphs A to D, wherein at least a portion of the first outer side or defines a skin contacting surface.

[0095] F. The razor blade of any of paragraphs A to E, wherein the dividing line divides the substrate into two substantially equal halves.

[0096] G. The razor blade of any of paragraphs A to F, wherein the dividing line divides the substrate into two asymmetrical halves.

[0097] H. The razor blade of any of paragraphs A to G, wherein the first coating comprises multiple layers of material.

[0098] I. The razor blade according to paragraph H, wherein the first coating comprises:

[0099] a first layer disposed substantially on the first outer side and extending a first distance from the end region towards the base; and

[0100] • A second layer disposed on top of at least a section of the first layer and extending from the end region toward the base a second distance that is the same as or less than the first distance.

[0101] J. The razor blade of paragraph I, wherein the first layer comprises a first material and the second layer comprises a second material different from the first material.

[0102] K. The razor blade of any of paragraphs A to J, wherein the first coating has a thickness that varies along at least a section of the first coating in a direction extending from the end region toward the base of the razor blade.

[0103] L. The razor blade of any of paragraphs A to K, wherein the first coating comprises an ion implanted material.

[0104] M. The razor blade of any of paragraphs A to L, wherein at least a section of the first coating defines an outer shape that is different than an outer shape of an underlying portion of the substrate.

[0105] N. The razor blade of any of paragraphs A, C, or E to M, wherein the second portion of the second outer side includes the second coating substantially disposed thereon.

[0106] O. The razor blade of paragraph N, wherein the first coating comprises one or more first materials and the second coating comprises one or more second materials, at least one of the second materials being different from at least one of the first materials.

[0107] P. The razor blade of any of paragraphs A to O, wherein the first outer side includes one or more first facets and the second outer side includes one or more second facets.

[0108] Q. A razor blade according to paragraph P, wherein the first coating is disposed on at least one of the first facets and the first portion of the second outer side that is substantially free of any coating includes at least a portion of at least one of the second facets.

[0109] R. The razor blade of paragraph P, wherein the first coating comprises:

[0110] a first section extending substantially from a first position on the first outer side to a second position; and

[0111] a second section extending substantially from a second position on the first outer side to a third position, wherein the first position includes the end region and the second position includes (i) a junction between two adjacent ones of the first facets or (ii) a junction between the blade body and one of the first facets.

[0112] S. A razor blade according to paragraph R, wherein the second position includes a junction between two adjacent first facets of the first facets, and the third position includes a junction between the blade body and one of the first facets of the first facets, and the first coating further includes a third segment extending substantially from the third position toward the base.

[0113] T. A method of coating a razor blade, the razor blade comprising a substrate having a tip portion including a tip region, a blade body including a base, and a first outer side and a second outer side disposed opposite a parting line of the substrate, wherein the first outer side and the second outer side converge at the tip, the method comprising one of the following:

[0114] (i) applying the first coating to only a portion of the first outer side, the coating extending from the terminal region towards the base and being substantially disposed on the first outer side; or

[0115] (ii) applying a first coating to a portion of the first outer side, the first coating extending from the terminal region toward the base and being substantially disposed on the first outer side, and applying a second coating to the second outer side, such that the first portion of the second outer side is substantially free of any coating and the second portion of the second outer side comprises the second coating, wherein the first portion extends from the terminal region toward the base or is spaced apart from the terminal region and the base.

[0116] U. The method of paragraph T, wherein the substrate includes a second coating.

[0117] V. The method of paragraph U, wherein the second coating extends substantially from a first location to a second location, the first location being spaced apart from the end region, and the second location being positioned toward the base.

[0118] W. A method according to paragraph U, wherein the second coating includes a first segment extending substantially from a first position to a second position and a second segment extending substantially from a third position to a fourth position, the first position including an end region and the second position being spaced apart from the third position, wherein a first portion of the second outer side substantially free of any coating is located between the first segment and the second segment of the second coating.

[0119] X. The method of any of paragraphs U to W, wherein the first coating comprises one or more first materials and the second coating comprises one or more second materials, at least one of the second materials being different from at least one of the first materials.

[0120] Y. The method of any of paragraphs U to X, wherein the first coating and the second coating are applied simultaneously.

[0121] Z. The method of any of paragraphs U to X, wherein the first coating and the second coating are applied sequentially.

[0122] AA. The method of any of paragraphs U to Z, wherein the first coating and the second coating are applied using the same technique.

[0123] BB. The method of any of paragraphs U to Z, wherein the first coating is applied using a first technique and the second coating is applied using a second technique different from the first technique.

[0124] CC. The method of any of paragraphs T to BB, wherein the first coating is applied such that at least certain sections of the first coating define an outer shape that is different than an outer shape of an underlying portion of the substrate.

[0125] DD. The method of any of paragraphs T to CC, wherein the first coating is applied such that the first coating has a thickness that varies along at least a section of the first coating in a direction extending from the tip region toward the base of the razor blade.

[0126] EE. The method of any of paragraphs T to DD, wherein applying the first coating further comprises applying multiple layers of material.

[0127] FF. The method of paragraph EE, wherein applying a plurality of material layers comprises:

[0128] applying a first layer to a portion of the first outer side, the first layer extending a first distance from the end region towards the base; and

[0129] - Applying a second layer on top of at least a certain section of the first layer, the second layer extending from the end region towards the base a second distance which is the same as or smaller than the first distance.

[0130] GG. The method of paragraph FF, wherein the first layer comprises a first material and the second layer comprises a second material different from the first material.

[0131] HH. The method of any of paragraphs T to GG, wherein the first outer side of the substrate includes one or more first facets and the second outer side includes one or more second facets.

[0132] II. The method of paragraph HH, wherein the first coating is disposed on at least one of the first facets and the first portion of the second outer side substantially free of any coating includes at least a portion of at least one of the second facets.

[0133] JJ. A method according to paragraph HH, wherein the first coating is applied such that the first coating comprises:

[0134] a first section extending substantially from a first position on the first outer side to a second position; and

[0135] a second section extending substantially from a second position on the first outer side to a third position, wherein the first position includes the end region and the second position includes (i) a junction between two adjacent ones of the first facets or (ii) a junction between the blade body and one of the first facets.

[0136] KK. The method of paragraph JJ, wherein the second location includes a junction between two adjacent ones of the first facets, and the third location includes a junction between the blade body and one of the first facets, and the first coating is applied such that the first coating further includes:

[0137] • A third section extending substantially from the third position towards the base.

[0138] LL. The method according to any one of paragraphs T to JJ, further comprising:

[0139] • Performing one or more post-application treatments on at least a section of the first coating.

[0140] MM. The method according to paragraph MM, wherein the one or more post-application treatments include one or more of the following:

[0141] subjecting at least a section of the first coating to ion implantation; or

[0142] • Partially removing one or more sections of the first coating.

[0143] NN. The method of paragraph MM, wherein the one or more post-application treatments further comprise selectively applying a material to the first coating after partially removing one or more sections of the first coating.

[0144] OO. The method of paragraph NN, wherein at least a portion of the first outer side having material defines a skin-contacting surface.

[0145] PP. The method of any one of paragraphs TT to JJ, wherein the substrate comprises a second coating, the method further comprising:

[0146] • Performing one or more post-application treatments on at least a section of the second coating.

[0147] QQ. The method of paragraph PP, wherein the one or more post-application treatments include partially removing one or more sections of the second coating.

[0148] 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.

[0149] 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".

[0150] 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.

[0151] 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, comprising: a substrate having an end portion including an end region, a blade body including a base, and a first outer side and a second outer side disposed opposite a dividing line of the substrate, wherein the first outer side and the second outer side converge at the end, wherein the first outer side includes a first coating disposed substantially thereon, the first coating extending from the terminal region toward the base, and wherein a first portion of the second outer side is substantially free of any coating, wherein the first portion is spaced apart from the terminal region and the base, wherein the second portion of the second outer side includes a second coating substantially disposed thereon, the second coating including a first segment extending substantially from a first position to a second position and a second segment extending substantially from a third position to a fourth position, wherein the first position includes the end region, the second position is spaced apart from the third position, and the first portion of the second outer side substantially free of any coating is located between the first segment and the second segment of the second coating.

2. The razor blade of claim 1, wherein at least a portion of the first outer side defines a skin contacting surface.

3. The razor blade of claim 1, wherein the dividing line divides the substrate into two substantially equal halves, or wherein the dividing line divides the substrate into two asymmetric halves.

4. The razor blade of claim 1, wherein the first coating comprises: a first layer disposed substantially on the first outer side and extending a first distance from the end region toward the base; and A second layer is disposed on top of at least a section of the first layer and extends from the end region toward the base a second distance, the second distance being the same as or less than the first distance.

5. The razor blade of claim 4, wherein the first layer comprises a first material and the second layer comprises a second material different from the first material.

6. The razor blade of claim 1, wherein the first coating has a thickness that varies along at least a section of the first coating in a direction extending from the end region toward the base of the razor blade.

7. The razor blade of claim 1 wherein said first coating comprises an ion implanted material.

8. The razor blade of claim 1, wherein at least a section of the first coating defines an outer shape that is different than an outer shape of an underlying portion of the substrate.

9. The razor blade of claim 1 , wherein the first outer side comprises one or more first facets and the second outer side comprises one or more second facets, and wherein the first coating is disposed on at least one of the first facets, and the first portion of the second outer side that is substantially free of any coating comprises at least a portion of at least one of the second facets.

10. The razor blade of claim 9, wherein the first coating comprises: a first section extending substantially from a first position on the first outer side to a second position; and a second section extending substantially from the second position on the first outer side to a third position, wherein the first position includes the end region and the second position includes (i) a junction between two adjacent first facets in the first facets or (ii) a junction between the blade body and one of the first facets in the first facets.

11. A razor blade according to claim 10, wherein the second position includes the junction between two adjacent first facets of the first facets, and the third position includes the junction between the blade body and one of the first facets, and the first coating further includes a third segment extending substantially from the third position toward the base.

12. A method of coating a razor blade, the razor blade comprising a substrate having a tip portion including a tip region, a blade body including a base, and a first outer side and a second outer side disposed opposite a parting line of the substrate, wherein the first outer side and the second outer side converge at a tip, the method comprising: A first coating is applied to a portion of the first outer side, the first coating extending from the terminal region toward the base and being substantially disposed on the first outer side, and a second coating is applied to the second outer side, such that a first portion of the second outer side is substantially free of any coating and a second portion of the second outer side includes the second coating, wherein the first portion is spaced apart from the terminal region and the base, wherein the second coating includes a first segment extending substantially from a first position to a second position and a second segment extending substantially from a third position to a fourth position, wherein the first position includes the terminal region, the second position is spaced apart from the third position, and the first portion of the second outer side substantially free of any coating is located between the first segment and the second segment of the second coating.

13. The method of claim 12, wherein the first coating is applied using a first technique and the second coating is applied using a second technique different from the first technique.

14. The method according to claim 12, further comprising: performing one or more post-application treatments on at least one section of the first coating or the second coating, wherein the one or more post-application treatments include one or more of the following: subjecting one of the coatings to a step of ion implantation; or The step of partially removing one or more sections of the first coating or the second coating or both.

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