Non-fluorinated organic coating material for razor blades

Abstract

A razor blade having a base with a tip portion. A hard coating is deposited on the substrate. A non-fluorinated organic material is deposited in one or more monolayers on the outer bonding surface of the hard coating. The hard coating has an aspect ratio (a) to (b) of at least 1.5: 1, where (a) is a first distance from a tip defined by the hard coating to a tip portion of the substrate, and (b) is a second distance from an outer surface of the hard coating to an underlying surface of the substrate.

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] Typical razor blades for shaving are often produced by grinding a sharp bevel onto a martensitic steel substrate. A hard coating is usually applied to strengthen the blade edge and produce a tip shape suitable for shaving, as well as an upper coating that allows adhesion of polytetrafluoroethylene (PTFE). PTFE is almost always applied to the upper surface of the razor blade edge to produce a low-energy non-stick surface required for low hair cutting force. The PTFE coating also allows good hair engagement and effective cutting and high-quality hair cutting. The razor blade edge without PTFE coating has a hair cutting force that is usually twice as high as the PTFE coated edge. The increase in this cutting force produces a significant sense of discomfort to the user during shaving. The sense of discomfort during shaving increases with the increase in the number of blades being used in the shaving razor. Since the razor blade edge without PTFE coating is not so effective in engaging hair compared to the PTFE coated blade edge, additional strokes may be required during shaving. Similar behavior is seen in the quality of hair cutting, where the non-PTFE coated edge usually thins and cuts the hair, rather than cutting through the hair cleanly.

[0003] The application of PTFE coatings typically requires high sintering temperatures (e.g., close to 400° C.) to allow adequate bonding, which typically softens and potentially damages the steel substrate. This tempering of the steel substrate at such high temperatures reduces hardness, which can limit the durability of the existing edge and the ultimate sharpness of the potential steel edge. In addition, in order to produce a uniformly coated blade, PTFE is typically applied in a very thick layer, which is later thinned. This later thinning allows for comfortable shaving during early use of the razor, but also adds additional cost and complexity during blade edge production. Many current processes for applying PTFE to the blade surface require the blade to be removed from a vacuum chamber to spray an aqueous PTFE dispersion, thereby increasing the cost and time required for manufacturing. In addition, PTFE may be limited to the type of material to which it will be bonded. As a class of materials within a wider range of PFAS chemicals and considering environmental persistence, the production and use of fluorinated polymer coatings (e.g., PTFE) are being reviewed by regulators.

[0004] It is believed that fluorinated polymers are the only lubricating coatings currently used on the blades of multi-blade wet shaving razors. Multi-blade wet shaving razors are the most commonly used wet shaving razors in developed countries such as the United States and European countries. In the past few decades, the technology of fluorinated polymer coated blades has made significant progress. There is currently no known alternative that will not significantly reduce the shaving performance to replace the fluorinated polymer coated blades. Blade coatings have a significant impact on other factors related to the design of shaving razor systems. For example, in the past few decades, shaving razor cartridge designs and blade edge geometries for wet shaving razors are based on blades coated with fluorinated polymers (e.g., PFTE). It is believed that, without being bound by theory, when using blade geometries with a high aspect ratio (e.g., greater than 2:1), PTFE coated blades do not provide comfortable shaving (e.g., causing scratches on the skin). PTFE coatings (fluorinated polymers) can exacerbate the scratching and / or discomfort problems of high aspect ratio blades. Therefore, shaving razor cartridge designs must compensate for nicking the skin, such as by adding additional features (eg, blade guards and wires wrapped around the blades) to protect the skin.

[0005] Prior to the discovery of fluorinated polymer coatings for blade edges, silicone coatings were used. For example, a blade was coated with a silicone gel. It is believed, without being bound by theory, that silicone coatings are generally difficult to control coating thickness and require more stringent processing conditions (e.g., over-cure versus under-cure), which may also be more sensitive to environmental conditions (such as relative humidity and dew point). Therefore, silicone-coated blades tend to have either low durability and low cutting force or high durability and high cutting force, and have a limited processing window to achieve the desired low cutting force and sufficient coating adhesion / durability. High-performance blades ideally have high durability and low cutting force.

[0006] Therefore, there is a need for improved coatings on cutting edges (such as blade edges) that do not utilize PTFE coatings but still have optimal properties for uses such as hair cutting (e.g., cutting force, surface energy, minimal laceration to the skin, etc.), that minimize softening and potential damage to the substrate (e.g., thermal effects), and utilize cost-effective and time-efficient manufacturing processes. Summary of the invention

[0007] The razor blades described herein may include a sharp cutting edge having an outermost layer produced by depositing a lubricating non-fluorinated organic coating material in one or more monolayers. The outer surface of the sharp cutting edge may be coated and / or treated so as to facilitate and / or optimize bonding of the non-fluorinated organic coating material.

[0008] According to one aspect of the present disclosure, a razor blade has a sharp cutting edge having an outer bonding surface. A non-fluorinated organic coating material is deposited on the outer bonding surface to form an outermost layer of the sharp cutting edge. The non-fluorinated organic coating is composed of one or more self-assembled monolayers.

[0009] According to one aspect of the present disclosure, a razor blade is provided, comprising a sharp cutting edge; and a non-fluorinated organic coating material, the non-fluorinated organic coating material comprising an organosilane deposited in one or more monolayers on the sharp cutting edge, wherein the deposited organic coating material forms the outermost layer of the razor blade. In some aspects, the sharp cutting edge may include an external bonding surface, and the non-fluorinated organic coating material may be deposited on the external bonding surface. In some specific aspects, the external bonding surface may include a boron-rich material. In other aspects, the sharp cutting edge may include a tip portion, the tip portion including a cutting edge defined by a sharp tip and one or more adjacent facets, wherein the non-fluorinated organic coating material may be deposited on the tip portion to form a non-fluorinated organic coating. In further aspects, the non-fluorinated organic coating material may be selected from the group consisting of: carboxylates, catechols, amines, alkynes, and olefins.

[0010] According to another aspect of the present disclosure, a method of making a razor blade is provided, wherein the method includes: treating a sharp cutting edge of the razor blade to form a treated sharp cutting edge; and depositing a non-fluorinated organic material comprising an organosilane in one or more monolayers on the treated sharp cutting edge, such that the organic coating material forms the outermost layer of the razor blade. In some aspects, the method may include: depositing a first material on the sharp cutting edge of the razor blade to form an outer bonding surface, wherein treating the sharp cutting edge includes treating the outer bonding surface to form a treated outer bonding surface; and depositing the non-fluorinated-organic coating material on the treated outer bonding surface.

[0011] According to another aspect of the present disclosure, a method of making a razor blade is provided, wherein the method includes forming a cutting edge on a substrate having an external bonding surface. A first self-assembled monolayer having a non-fluorinated organic material is deposited on the external bonding surface of the substrate.

[0012] According to another aspect of the present disclosure, a razor blade having a substrate with a tip portion. A hard coating is deposited on the substrate. A non-fluorinated organic material is deposited in one or more monolayers on an outer bonding surface of the hard coating. The hard coating has an aspect ratio (a) to (b) of at least 1.5:1, wherein (a) is a first distance from a tip defined by the hard coating to the tip portion of the substrate, and (b) is a second distance from an outer surface of the hard coating to an underlying surface of the substrate. BRIEF DESCRIPTION OF THE DRAWINGS

[0013] 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:

[0014] Figure 1 is a side view of a razor blade having a symmetrical base in accordance with the present disclosure.

[0015] Figure 2 is a perspective view of a tip portion of another razor blade having a symmetrical base according to the present disclosure.

[0016] Figure 3 is a side view of a razor blade having a symmetrical substrate and coating material according to the present disclosure;

[0017] Figure 4 is a side view of a razor blade having a symmetrical base and coating material on segments of a tip portion and a body portion in accordance with the present disclosure.

[0018] Figure 5 is a detailed view of a tip portion of a razor blade having multiple layers of coating material according to the present disclosure.

[0019] Figure 6 is a side view of a tip portion of an additional razor blade having a symmetric substrate and an asymmetric coating material according to the present disclosure.

[0020] Fig. 7A is a side view of a razor blade having an asymmetric substrate and coating material according to the present disclosure.

[0021] Figure 7B is a side view of another razor blade having an asymmetric substrate and an asymmetric coating in accordance with the present disclosure.

[0022] Figure 8 is a diagrammatic view illustrating a tip area of ​​a razor blade according to the present disclosure.

[0023] Fig. 9 A method of making a razor blade according to the present disclosure.

[0024] Fig.10 A method of making a razor blade according to the present disclosure.

[0025] FIG. 11A to FIG. 11C It is the chemical reaction of the chloroalkylsilane coating according to the present disclosure with the chromium substrate.

[0026] Fig.12 It is the chemical reaction of the ethylalkylsilane coating with the chromium substrate according to the present disclosure.

[0027] Fig.13A and Fig. 13B is a graph comparing the body hardness of a razor blade according to the present disclosure to an uncoated razor blade and a PTFE coated razor blade.

[0028] Fig.14 is a graph comparing the cutting force of a razor blade according to the present disclosure with an uncoated razor blade and a PTFE coated razor blade. DETAILED DESCRIPTION

[0029] For the purpose of the following detailed description, it should be understood that any numerical range described herein is intended to include all subranges subsumed therein. For example, a range of "1 to 10" is intended to include all subranges between the stated minimum value of 1 and the stated maximum value of 10 (and including the end values), i.e., the minimum value is equal to or greater than 1, and the maximum value is equal to or less than 10.

[0030] As used herein, unless specifically stated otherwise, the use of the singular includes the plural and the plural encompasses the singular. Furthermore, in this application, unless specifically stated otherwise, the use of "or" means "and / or", even though "and / or" may be explicitly used in certain circumstances.

[0031] As used herein, the term "asymmetric blade" means a blade defined by a base having a first portion including a blade body and a second portion including a tip portion, wherein a split line passes through the tip of the tip portion, extends through the first portion and the second portion and separates the second portion into a substantially asymmetric first section and a second section. The outer surface of the first section of the second portion is asymmetric relative to the outer surface of the second section. The outer surface of the first section of the second portion can be used as a skin contact surface, and the outer surface of the second section can be used as a hair cutting surface.

[0032] As used herein, "partition line" means a line extending through the tip of the tip portion of the substrate that is generally parallel to the generally parallel first and second outer surfaces of the first portion of the blade body defining the substrate and that separates or divides the substrate into a first half or segment and a second half or segment.

[0033] As used herein, the term "gel" means a semisolid structure consisting of a dilute cross-linked polymer chain having an insoluble, infusible, coherent three-dimensional network containing a relatively low molecular weight fluid material therein. The gel can exhibit little or no flow when in a stable state. The fluid material in the gel can include various liquids, including water and water-based solutions (i.e., hydrogels). The fluid material of the gel is, for example, usually fully contained in the polymer chain network of the gel by surface tension and hydrogen bonding.

[0034] As used herein, the term "self-assembled monolayer" and its variants (e.g., self-assembled monolayer, SAM) means an ordered molecular assembly of organic molecules that are spontaneously deposited on a surface by adsorption. Typically, a self-assembled monolayer is formed by reacting the head groups of molecules in a liquid or gas phase with a substrate on the surface. Examples of molecules in a liquid or gas phase that can form a self-assembled monolayer in the present disclosure include non-fluorinated organic compounds, such as organosilanes, carboxylates, catechols, amines, alkynes, and olefins. The head groups of molecules that react with a substrate to form a self-assembled monolayer can be a variety of reactive functional groups, such as silanes, amines, carboxyl groups, alcohols, and hydrolyzable groups. Examples of substrates on which a self-assembled monolayer can be deposited on a surface in the present disclosure include metals, alloys, or ceramics, such as chromium, platinum, boron, chromium diboride, titanium, titanium diboride, vanadium, aluminum, silicon, tin, tantalum, zirconium, niobium, magnesium, manganese, iron, cobalt, copper, silver, zinc, hafnium, tungsten, molybdenum, or nickel, and their oxides, nitrides, and nitrogen oxides.

[0035] Now referring to the accompanying drawings, Figure 1 , Figure 3 and Figure 4 is a side view of a cutting member 8 according to aspects of the present disclosure, and Figure 2 is a detailed perspective view of elements of the cutting member 18 according to aspects of the present disclosure. Figures 1 to 4 The razor blades 8 and 18 shown in the drawings may each include a substrate 28 and a coating 60 (in Figure 1 and Figure 2 Not visible in; see Figure 3 and Figure 4 ). As used herein, "substrate" may refer to a substance or material that is acted upon by a deposition process in the present disclosure. Substrate 28 may include one or more metals, alloys, or ceramics. In some examples, substrate 28 may be stainless steel. Razor blades 8 and 18 may include a first portion having a blade body 30 and a second portion having a tip portion 34. Blade body 30 may include a base 32, and tip portion 34 may include flanks 36 that converge at a sharp tip 40 to define a sharp cutting edge 42 for performing hair cutting. Flanks 36 may each include one or more bevels or facets 38. Figure 2 The base 28 is described in more detail in US Pat. No. 9,751, 230. Razor blades 8 and 18 may be incorporated into a razor cartridge (not shown).

[0036] exist Figures 1 to 4 In the example illustrated in FIG. 1 , the base 28, and in particular the tip portion 34, is substantially symmetrical and may include a dividing line SL passing through the tip 40 and dividing or separating the base 28 into substantially equal first and second segments or halves. 28 . Dividing line SL 28may coincide with the centerline (not shown) of the coating 60 as described herein, such that the segmentation line SL 28 The coating 60 may also be divided or separated into a first segment or half and a second segment or half that are substantially equal. 28 The outer side 48 of the base 28 (also referred to herein as the first outer side) is substantially parallel to the generally planar outer surface (not labeled) of the blade body 30. The outer side 50 of the base 28 (also referred to herein as the second outer side) is substantially parallel to the generally planar outer surface (not labeled) of the blade body 30. 28 As used herein, the terms "first" and "second" (ie, used to refer to structures such as sections) are used for reference only, and are not intended to be limiting.

[0037] At least a portion of one outer side (e.g., first outer side 48) of base 28 may define a skin contacting surface, and at least a portion of another outer side (e.g., second outer side 50) may define a hair cutting surface. The two sides of razor blades 8 and 18 may 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).

[0038] like Figure 3 and Figure 4 As shown, the razor blades 8 and 18 may include a coating 60 disposed substantially on at least a portion of the first outer side 48 and the second outer side 50 of the substrate 28. The coating 60 may include a single layer, such as Figure 3 and Figure 4 As shown, or may include two or more layers (see Figure 5 ). As used herein, the term "coating" means a covering applied to an object or substrate, including a monolayer, a free film, an impregnation, etc., such that the covering may be continuous, discontinuous, may have a single thickness or varying thicknesses, or may exist in a single plane or multiple planes. The coating 60 may include one or more layers, wherein each layer comprises one or more materials. The term "coating" may be used to refer to the overall or entire coating on one or both sides of the razor blade 8, 18, such as the first outer side 48 and the second outer side 50.

[0039] exist Figure 3 and Figure 4 In the example shown, the coating 60 is depicted as extending from the tip region 35 toward the base 32 along the first outer side 48 and the second outer side 50 of the substrate 28. In some examples, the coating 60 may not reach the blade body 30 and / or the base 32, and in some specific examples, the coating 60 may be substantially only disposed on the tip portion 34 of the substrate 28, such as Figure 3 In other examples, the coating 60 may be disposed on the tip portion 34 of the substrate 28 and at least a portion of the blade body 30, such as Figure 4. The coating of the blade body 30 may allow for easier rinsing and debris removal, which may allow for less water usage during cartridge rinsing and cleaning, and may result in a cleaner, more aesthetically pleasing shaving cartridge over the life of the product. In some specific examples (not shown), the coating 60 may extend from the tip region 35 all the way to the base 32. In some aspects (not shown), the coating 60 may be disposed only on the first outer side 48 or the second outer side 50. In other aspects (not shown), the coating 60 may be disposed on the first outer side 48 and the second outer side 50, but may extend different distances along the first outer side 48 and the second outer side 50.

[0040] Figure 5 A detailed view of the tip region 35 of substrate 28 having a multilayer coating 60' is provided, which can be any substrate according to the present disclosure. Coating 60' can include two or more layers, including an outermost layer 76 and one or more of interlayer 70, hard coating 72, protective layer 74, and outer layer 76.

[0041] The interlayer 70 can be used to facilitate bonding of the hard coating 72 to the substrate 28. Examples of suitable materials for the interlayer 70 may include materials containing niobium, titanium, and chromium. A particular interlayer is made of niobium greater than about 100 angstroms thick and preferably less than about 500 angstroms thick. In some examples, the interlayer 70 may have a thickness of about 150 angstroms to about 350 angstroms.

[0042] The hard coating 72 can provide improved strength, corrosion resistance and shaving ability, and can be used to obtain a desired tip shape. The hard coating 72 can be made of materials such as fine crystalline carbon, micron crystalline carbon or nanocrystalline carbon (e.g., diamond, amorphous diamond or diamond-like carbon (DLC)), nitrides (e.g., boron nitride, niobium nitride, chromium nitride, zirconium nitride, or titanium nitride), carbides (e.g., silicon carbide), oxides (e.g., aluminum oxide, zirconium oxide) or ceramic materials (including nanolayers or nanocomposites). Carbon-containing materials can be doped with other elements such as tungsten, titanium, silver or chromium by including these additives in, for example, a target during application by sputtering. These materials can also contain hydrogen, such as hydrogenated DLC. Preferably, the hard coating 72 is made of diamond, amorphous diamond or DLC. Specific examples include DLC less than about 3000 angstroms thick, preferably about 500 angstroms to about 1500 angstroms thick. DLC layers and deposition methods are described in U.S. Pat. No. 5,232,568. As stated in the "Handbook of Physical Vapor Deposition (PVD) Processing," "DLC is an amorphous carbon material that exhibits many of the desirable properties of diamond but does not have the crystalline structure of diamond."

[0043] The protective layer 74 may optionally be used to reduce the tip rounding of the hard coating edge and facilitate bonding of the outer layer 76 to the hard coating 72 while still maintaining the benefits of both. The protective layer 74 is preferably made of a chromium-containing material, such as chromium or a chromium alloy or chromium compound (e.g., CrPt) that is compatible with the hard coating 72 and the outer layer 76. A specific protective layer 74 is about 100 angstroms thick-200 angstroms thick chromium. The protective layer 74 may include materials similar to the interlayer 70 and / or the hard coating 72, such as niobium or boron. In some examples, the protective layer 74 may have a thickness of about 50 angstroms to about 500 angstroms, preferably about 100 angstroms to about 300 angstroms.

[0044] The outermost layer 76 can be used, for example, to provide reduced friction. The outermost layer 76 can be a non-fluorinated organic coating material, as described herein. As used herein, the term "non-fluorinated" refers to a material that does not contain fluorine or lacks fluorine. The outermost layer 76 is preferably continuous, which can allow for reduced coating thickness and improved first shave results.

[0045] exist Figures 3 to 5 In the example shown, coatings 60 and 60 ′ may generally conform to and / or mirror the outer shape of an underlying portion of substrate 28 and may include a substantially uniform thickness. Figure 6 An example of a coating 160 that does not conform to and / or mirror the outer shape of an underlying portion of substrate 128 (referred to herein as an asymmetric coating) is illustrated. Asymmetric coating 160 may include a variable thickness that varies along at least a portion of substrate 128. Asymmetric coating 160 may include at least an outermost layer 176, which may include a non-fluorinated organic coating material as described herein; and optionally one or more additional layers 174, which may include Figure 5 One or more of layers 70, 72 and 74 in.

[0046] Figure 6 The base 128 in the embodiment of the present invention may include a dividing line 180 (also referred to as a centerline) that passes through the tip 140 and divides or separates the base 128 into a first substantially equal section or half (not labeled) and a second section or half. The centerline 180 may be generally aligned with the blade body (not shown; see Figures 1 to 4). The asymmetric coating 160 (including the outermost layer 176) may include a centerline 182 that may be offset from the centerline 180 of the substrate 128, as indicated by 184. The asymmetric coating 160 may be deposited on the substrate 128 at an angle relative to the centerline 180 of the substrate 128, wherein the centerline 182 of the asymmetric coating 160 is determined by, for example, the angle at which the asymmetric coating 160 is deposited. In some examples, the centerline 182 of the asymmetric coating 160 may be offset from the centerline 180 of the substrate 128 by at least 3 degrees, and in other examples, by at least 5 degrees, at least 8 degrees, or at least 10 degrees. In all examples, the centerlines 180 and 182 may be offset by up to 30 degrees. Figure 6 1 and asymmetric coating 160 are illustrated relative to a skin surface. As described herein, a first outer side 148 of the substrate 128 may define a skin contacting surface, and at least a portion of another outer side (e.g., second outer side 150) may define a hair cutting surface. The asymmetric coating 160, particularly when the outermost layer 176 comprises a non-fluorinated organic coating material as described herein, can help improve shaving comfort and safety by reducing cutting forces and improving skin management, and can also help improve durability by reducing shear forces and wear on critical surfaces (i.e., hair cutting surfaces) due to peak cutting forces of the hair.

[0047] refer to Figure 8 , the substrate 28 may include a thickness T1 between about 1.3 microns and 2.0 microns measured at a distance D1 of four microns from the sharp tip 40, a thickness T2 between about 2.3 microns and 3.5 microns measured at a distance D2 of eight microns from the sharp tip 40, a thickness T3 between about 3.8 microns and 6.4 microns measured at a distance D3 of sixteen microns from the sharp tip 40, and / or a thickness T4 between about 9.3 microns and 16.2 microns measured at a distance D4 of forty microns from the sharp tip 40. Alternatively or in addition, the substrate 28 may include a ratio of at least 0.55 of the thickness T1 measured at four microns to the thickness T2 measured at eight microns, and / or a ratio of at least 0.28 of the thickness T1 measured at four microns to the thickness T3 measured at sixteen microns.

[0048] Fig. 7A and Figure 7B An example of a cutting member 218 and 318 (here a razor blade) comprising an asymmetric base 228 and 328 is illustrated. Fig. 7A, the razor blade 218 may include a first portion having a blade body 230 and a second portion having a tip portion 234, wherein the blade body may include a base (not shown) and the tip portion 234 may include flanks (not labeled) that converge at a sharp tip 240. These flanks may each include one or more bevels or facets (not labeled) of unequal lengths, such that the tip portion 234 is asymmetrical. Although the tip portion 234 is depicted as including two facets on each of the first outer side 248 and the second outer side 250, it is understood that the first outer side 248 and the second outer side 250 may include different numbers of facets, and in some examples, one of the outer sides (e.g., the second outer side 250) may not include a facet.

[0049] The razor blade 218 may include a coating 260 extending from the tip region 235 toward the base (not shown) along the first outer side 248 and the second outer side 250. As described herein, the first outer side 248 may define a skin contacting surface and the second outer side 250 may define a hair cutting surface. Also as described herein, the coating 260 may be disposed on the tip portion 234 and at least a portion of the blade body 230, such as Fig. 7A As shown, or only provided on the tip portion 234 (not shown; see Figure 3 ). Although a single layer is depicted for convenience, coating 260 may include an outermost layer and at least one additional layer, as described herein (see Figure 5 and Figure 6 ).

[0050] Continue to refer Fig. 7A , coating 260 may generally conform to and / or mirror the outer shape of the underlying portion of substrate 228 and may include a substantially uniform thickness. 228 The coating 260 may pass through the tip 240 and may be generally parallel to an outer surface (not labeled) of the blade body 230. Because the coating 260 generally conforms to the outer shape of the substrate 228, the separation line SL of the substrate 228 228 May coincide with a centerline (not shown) of coating 260, as described herein.

[0051] refer to Figure 7B , the substrate 328 may be substantially similar to Fig. 7A 328, except that coating 360 is asymmetric, i.e., coating 360 does not conform to and / or mirror the outer shape of the underlying portion of substrate 328. Asymmetric coating 360 may include a variable thickness that varies along at least a portion of substrate 328. Substrate 328 may include a thickness that may be symmetrical to the substrate 328. Fig. 7A The dividing line SL shown 228A substantially similar split line 380 (also referred to as a centerline). The asymmetric coating 360 may include a centerline 382 that may be offset from the centerline 380 of the substrate 328, as indicated by 384. As described above, the centerline 382 of the asymmetric coating 360 may be determined by the angle at which the asymmetric coating 360 is deposited relative to the centerline 380 of the substrate 328. In some examples, the centerline 382 of the asymmetric coating 360 may be offset from the centerline 380 of the substrate 328 by at least 3 degrees, and in other examples, at least 8 degrees. In other examples, the centerlines 380 and 382 may be offset by up to 30 degrees. As described above, the asymmetric coating 360, particularly when the outermost layer (not shown) includes a non-fluorinated organic coating material as described herein, may help improve shaving comfort and safety, as well as durability.

[0052] According to the present disclosure, a cutting member is provided, which may include Figures 1 to 6 , Fig. 7A and Figure 7BRazor blades 8, 18, 118 and 218. The blade may include a substrate having a sharp cutting edge, and a non-fluorinated organic coating material deposited on the substrate, particularly on the sharp cutting edge and / or on the body, wherein the non-fluorinated organic coating material forms the outermost layer of the razor blade. The non-fluorinated organic coating material may be directly or indirectly adhered to the substrate. The non-fluorinated organic coating material may be deposited in one or more monolayers (e.g., self-assembled monolayers). A self-assembled monolayer (SAM) is a one-molecule thick material layer that is bonded to a surface in an orderly manner due to physical or chemical forces during the deposition process. Silanes may form SAMs by solution or vapor deposition processes. In certain embodiments, a first self-assembled monolayer (SAM) may be directly or indirectly adhered to a substrate, and a second self-assembled monolayer (SAM) may be directly adhered to the first self-assembled monolayer (SAM) and / or the substrate (e.g., an external bonding surface). Additional self-assembled monolayers (SAMs) may be added to fill any gaps on the substrate and / or to build layers on top of existing self-assembled monolayers (SAMs), such as the first self-assembled monolayer (SAM). For example, a third self-assembled monolayer (SAM) may be directly adhered to the first self-assembled monolayer (SAM), the second self-assembled monolayer (SAM), and / or the substrate. In some examples, a razor blade may include a tip portion having a cutting edge defined by a sharp tip and one or more adjacent facets, as described herein, and a non-fluorinated organic coating material may be deposited on the tip portion to form a non-fluorinated organic coating. It is believed that, without being bound by theory, coating thickness and uniformity are important for lubricating blade coatings, especially silicone-based coatings. Therefore, for typical coatings, thicker coatings may be required to ensure complete surface coverage to compensate for inconsistencies. The self-assembled monolayer can provide a complete surface (of a desired area) of a coated blade without over-applying benefits exceeding the desired thickness and target surface (e.g., exceeding the tip portion). For example, a self-assembled monolayer can be applied to a blade in very thin layers at a time, providing better thickness control and consistency as well as uniformity of coverage.

[0053] The substrate, including the sharp cutting edge, may include a metal, alloy or ceramic, such as stainless steel. In some examples, the substrate, in particular the sharp cutting edge, may include one or more of the following materials, for example as at least one additional material layer disposed between the sharp cutting edge and the non-fluorinated organic coating material (see Figure 5 and Figure 6): (i) diamond, amorphous diamond or diamond-like carbon (DLC); or (ii) chromium, platinum, boron, chromium diboride, titanium, titanium diboride, vanadium, aluminum, silicon, tin, tantalum, zirconium, niobium, magnesium, manganese, iron, cobalt, copper, silver, zinc, hafnium, tungsten, molybdenum or nickel and their oxides, nitrides and oxynitrides. In one example, one or more additional material layers may include chromium. In a specific example, the additional layer may include a niobium layer, a DLC layer, a chromium layer and an outermost layer including a non-fluorinated organic coating material, as described herein. In another example, one or more additional material layers may include boron, including a metal boride (such as chromium diboride), a metal boride alloy or a boron-rich mixture or alloy. As used herein, the term "boron-rich" may refer to a material containing at least 50 atomic % boron. In a specific example, the additional layer may include a niobium layer, a DLC layer, a boron layer or a boron-rich material and an outermost layer including a non-fluorinated organic coating material, as described herein.

[0054] Non-fluorinated organic coatings containing organosilanes

[0055] In some examples, the non-fluorinated organic coating material may include an organosilane. Examples of organosilanes may include a compound or mixture of compounds having the following general formula:

[0056] S i n X m

[0057] Wherein R is an alkyl group; X is a leaving group such as chloride, alkoxy or hydride; n = 1-3; and m = 1-3; n + m = 4. The alkyl groups R may be the same as each other, or may be different alkyl groups. The alkyl groups R may be substituted or unsubstituted, linear or branched, saturated or unsaturated, etc.

[0058] In some examples, the organosilane may be derived from a compound having a hydrolyzable group. In other examples, the organosilane may be derived from a compound selected from the group consisting of chlorosilanes, alkoxysilanes, hydroxysilanes, and hydrogensilanes.

[0059] In a specific example, the organosilane may be derived from an alkoxysilane, wherein the alkoxysilane may be selected from the group consisting of trimethoxysilane, dimethoxysilane, and ethoxysilane. The alkoxysilane may include one or more alkyl side chains, wherein the one or more alkyl side chains have saturated carbon-carbon bonds. In certain aspects, the one or more alkyl side chains having saturated carbon-carbon bonds may be composed of the following general formula:

[0060] CH3(CH2) n

[0061] Where n = 0-18. In some examples, n = 0-17 or n = 0-10. In other examples, n = 0-8.

[0062] In further examples, the non-fluorinated organic coating material may include an organosilane derived from bis(trimethylsilyl)amine or derived from hexamethyldisiloxane.

[0063] The non-fluorinated organic coating material may include an organosilane derived from a chlorosilane. Examples of chlorosilanes may include a compound or mixture of compounds having the following general formula:

[0064] S i n Cl m

[0065] wherein R is an alkyl group, n = 1-3, and m = 1-3, and n+m = 4. The alkyl groups R may be the same as each other, or may be different alkyl groups.

[0066] The alkyl group R can be saturated or unsaturated, substituted or unsubstituted, linear or branched, etc. The organosilane can be derived from a chlorosilane consisting of one, two, or three chlorine atoms. In some examples, the organosilane can be derived from a chlorosilane selected from the group consisting of methyltrichlorosilane, dimethyldichlorosilane, tert-butyltrichlorosilane, 3,3-dimethylbutyltrichlorosilane, dodecyltrichlorosilane, and mixtures thereof. In certain aspects, one or more alkyl side chains having a saturated carbon-carbon bond can be composed of the following general formula:

[0067] CH3(CH2) n

[0068] Where n = 0-18. In some examples, n = 0-10. In other examples, n = 0-8.

[0069] The use of disiloxanes such as 1,2-bis(trimethoxysilyl)decane or 1,2-bis(trichlorosilyl)decane and other trialkoxysilanes and / or trichlorosilanes may have the advantage of allowing better bonding to the substrate and to each other.

[0070] Non-fluorinated organic coatings containing other materials

[0071] In other examples, the non-fluorinated organic coating material can be selected from the group consisting of carboxylates, catechols, amines, alkynes, and olefins. In some aspects, the non-fluorinated organic coating material is not an organophosphorus compound. In other aspects, the non-fluorinated organic coating material is not an organophosphoric acid or a derivative thereof.

[0072] Properties of non-fluorinated organic coating materials and substrates coated therewith

[0073] The surface energy may correspond to the cutting force of a cutting member (such as a razor blade). In general, it is desirable to provide a coating material having a relatively low surface energy while still maintaining a desired level of durability to withstand shaving applications. According to the present disclosure, the non-fluorinated organic coating material may have a surface energy of less than 40 dyne / cm. In various aspects, the non-fluorinated organic coating material has a surface energy of less than 37 dyne / cm, less than 35 dyne / cm, less than 33 dyne / cm, or less than 31 dyne / cm. Surface energy is a measure of the excess energy present at the surface of a material compared to that at the bulk of the material, and is typically given in dynes / cm (i.e., dyne / cm). The surface energy may be determined by a dyne test, in which a liquid (e.g., water, diiodomethane, ink, etc.) is applied to a surface, and the amount of liquid spread or beaded on the surface is measured, for example, by measuring the contact angle between the droplet and the material surface. For materials with high surface energy, the applied droplets typically spread and form a film on the material surface. In contrast, for materials with low surface energy, the applied droplets typically form beads.

[0074] The non-fluorinated organic coating material can be deposited on a substrate including a sharp cutting edge and / or a body in one or more monolayers. In some examples, each monolayer in one or more monolayers can be a self-assembled monolayer. In other examples, the non-fluorinated organic coating is not a gel. The non-fluorinated organic coating material can form a layer less than 500 angstroms thick. In various aspects, the non-fluorinated organic coating material forms a layer less than 100 angstroms thick or less than 30 angstroms thick. The thickness of the non-fluorinated organic material layer can be as small as 7 angstroms-10 angstroms. These relatively thin coatings are expected to be uniform in thickness and continuous in coverage, which can affect coating quality and consistency, and allow the generation of reduced cutting forces and more comfortable shaving, as well as having a small tip radius because the coating is more conformable to the blade edge substrate surface. A thicker outermost coating (e.g., a coating derived from a polymer precursor, including a cross-linked or gel coating) can result in a larger edge cross section and tip radius, which can increase cutting forces and / or reduce hair engagement and cutting efficiency. The increased coating thickness also increases surface shear forces and contributes to unacceptable wear of the outermost coating.

[0075] Coatings, including non-fluorinated organic coatings, may have an aspect ratio (a) to (b), such as Figure 3 , where (a) is a first thickness 80 of the sharp tip 40 from the tip 41 defined by the non-fluorinated organic coating 60 (defining the outermost layer) to the substrate 28, and (b) is a second thickness 82 from the outer surface (not labeled) of the non-fluorinated organic coating 60 to the lower surface (not labeled) of the substrate 28. The thickness 82 can be measured at a distance of four microns from the sharp tip 40 (e.g., see Figure 8In some examples, the aspect ratio (a) to (b) can be at least about 1.5:1, at least 2:1, or at least 2.5:1, with (a) ±0.5. In some specific examples, the aspect ratio (a) to (b) can be up to 3.5:1, and in other specific examples, the aspect ratio (a) to (b) can be up to 4:1. Generally speaking, a higher aspect ratio means a sharper cutting edge and lower cutting force.

[0076] As described herein, coatings comprising non-fluorinated organic materials require lower processing temperatures (less than 300°C, and preferably less than 150°C) compared to the processing temperatures required for PTFE (typically about 400°C). Fig.13A and Fig. 13B is a graph comparing the body hardness of a razor blade according to the present disclosure (Standard DMS Coated) with an uncoated razor blade (Standard Uncoated) and a razor blade having a PTFE coating (Standard PTFE Coated). Fig.13A Provides the average Vickers hardness of razor blades, and Fig. 13B The percentage hardness as measured relative to an uncoated razor blade is provided. The uncoated "control" razor blade (standard no coating) includes a stainless steel razor blade having a niobium layer, a DLC layer, and a chromium layer, and no additional lubricating coating. The standard PTFE coated razor blade includes a razor blade from the same batch with an additional PTFE coating on chromium, wherein the razor blade undergoes sintering at a temperature above the melting point of PTFE. The standard DMS coated razor blade includes a razor blade from the same batch with an additional organosilane coating, i.e., dimethylsiloxane (DMS), on chromium (e.g., such as Fig.11A shown).

[0077] exist Fig.13A and Fig. 13B As can be seen in the figure, the standard PTFE coated razor blades show a significantly reduced body hardness compared to the standard uncoated razor blades, and the hardness of the standard PTFE coated razor blades is about 18% lower than the hardness of the standard uncoated razor blades. It is believed that the reduction in the hardness of the standard PTFE coated razor blades is at least partially due to the higher processing temperature, that is, the sintering temperature of> 300°C, which can significantly reduce the hardness of the razor blades by thermal tempering. In contrast, the standard DMS coated razor blades show a body hardness similar to that of the standard uncoated razor blades, and the hardness is almost not reduced. It is believed that this retention of hardness in the standard DMS coated razor blades is at least partially due to the lower processing temperature allowed by the non-fluorinated organic coating material described herein, which reduces the softening of the stainless steel substrate and thus reduces the possibility of damage to the stainless steel substrate and reduces the possibility of damage to the blade edge during shaving.

[0078] flow chart

[0079] Fig. 9 and Fig.10 4 and 5, respectively, are flow charts illustrating exemplary methods 400 and 500 of making a razor blade according to the present disclosure. Fig. 9 As shown, method 400 may include treating a sharp cutting edge (coated or uncoated) of a razor blade at 410 to form a treated sharp cutting edge, and depositing a non-fluorinated organic material in one or more monolayers on the treated sharp cutting edge at 420, such that the organic coating material forms the outermost layer of the sharp cutting edge. In some examples, the non-fluorinated organic material includes an organosilane. In other examples, the non-fluorinated organic material is selected from the group consisting of: carboxylates, catechols, amines, alkynes, and olefins. In both examples, the monolayer may be a self-assembled monolayer.

[0080] The non-fluorinated organic material can be deposited using any suitable technique or combination of techniques, including vapor deposition (such as PVD and atomic layer deposition), dipping, flooding, spraying, or soaking. Brushing can also be used for soft coatings. In some examples, depositing the non-fluorinated organic material may include vapor deposition in a vacuum. Examples of razor blades and methods of manufacture 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.

[0081] In various aspects, the temperature, such as the processing temperature during method 400, does not exceed 300° C. In particular aspects, the temperature does not exceed 200° C., does not exceed 160° C., does not exceed 150° C., does not exceed 100° C., or does not exceed 50° C., or does not exceed 45° C.

[0082] Method 400 may also include curing the sharp cutting edge after depositing the non-fluorinated organic material at 425, for example to improve bonding and adhesion of the non-fluorinated organic material to the sharp cutting edge. Curing may include curing by ultraviolet (UV) light, thermal curing, or one or more of non-oxidative plasma treatment. When curing includes UV curing, UV light having a wavelength between 100 nm and 400 nm may be used for curing. The outer side or surface of the razor blade (i.e., the skin contact surface and the hair cutting surface) may be cured independently using light of different wavelengths and / or curing times. For example, the skin contact surface may be made durable and not too hydrophobic, thereby increasing edge slip on the skin in a wet shaving environment. Such UV modification of the skin contact surface may be complementary to an asymmetric coating, as discussed herein.

[0083] The treatment of the sharp cutting edge, for example by etching, can be performed to clean and activate the surface, for example by oxidizing the surface to generate hydroxyl groups (-OH) on the surface of the sharp cutting edge when preparing to deposit the coating material. These hydroxyl groups are used as bonding sites for non-fluorinated organic materials, which improve the adhesion between the surface and the coating material, such as covalent bonding. In principle, activation can be obtained in a variety of ways. The best activation method varies depending on the oxide. In some examples, the treatment of the sharp cutting edge may include plasma etching, for example, plasma etching using a gas mixture including a process gas and a carrier gas. In some aspects, the process gas may be selected from the group consisting of: molecular oxygen and water, and / or the carrier gas may include one or more rare or inert gases and may be selected from the group consisting of: nitrogen, argon, helium, neon, krypton, xenon and radon. In other aspects, the treatment may include plasma etching with molecular oxygen alone or with argon alone. In other aspects, the treatment may include plasma etching with molecular oxygen and argon. In further aspects, processing the sharp cut edge includes plasma etching with a process gas of hydrogen and one or more carrier gases including nitrogen, argon, helium, neon, krypton, xenon, or radon.

[0084] The surface on which the non-fluorinated organic material is deposited may be referred to herein as an "external bonding surface". In some examples, the external bonding surface may include a treated (uncoated) sharp cutting edge. In other examples, method 400 may also include depositing at least one material layer on the sharp cutting edge at 405 before treating to form a coated sharp cutting edge, which coated sharp cutting edge may serve as the external bonding surface. At least one material layer is disposed between the sharp cutting edge and the non-fluorinated organic coating material, and treating the sharp cutting edge includes treating the coated sharp cutting edge. The at least one material layer may include one or more of an outer layer, an interlayer, a hard coating, and a protective layer (see Figure 5 ) and may include one or more of the following: (i) diamond, amorphous diamond, or diamond-like carbon (DLC); or (ii) chromium, platinum, boron, chromium diboride, titanium, titanium diboride, vanadium, aluminum, silicon, tin, tantalum, zirconium, niobium, magnesium, manganese, iron, cobalt, copper, silver, zinc, hafnium, tungsten, molybdenum, or nickel, and their oxides, nitrides, and oxynitrides. Steps 420 and 425 may optionally be repeated as described herein to obtain one or more additional monolayers of non-fluorinated organic material.

[0085] refer to Fig.10, method 500 may include depositing a first material on a sharp cutting edge of a razor blade to form an outer bonding surface at 510; treating the outer bonding surface to form a treated outer bonding surface at 520; and depositing a non-fluorinated organic material in one or more monolayers on top of the treated outer bonding surface at 530, such that the organic coating material forms an outermost layer of the sharp cutting edge. In some examples, the non-fluorinated organic material includes an organosilane. In other examples, the non-fluorinated organic material is selected from the group consisting of: carboxylates, catechols, amines, alkynes, and olefins.

[0086] Depositing the first material to form the outer bonding surface may include depositing one or more of an outer layer, an interlayer, a hard coating, and a protective layer (see Figure 5 ), wherein the external bonding surface may include a material or layer immediately below the non-fluorinated organic material, i.e., a material or layer to which the non-fluorinated organic material is bonded. Figure 5 In the example shown, the protective layer 74 can be used as the outer bonding surface of the outermost layer 76. In other examples (not shown), the protective layer 74 can be omitted, and the hard coating 72 can serve as the outer bonding surface. The outer bonding surface can include one or more of the following: (i) diamond, amorphous diamond or diamond-like carbon (DLC); or (ii) chromium, platinum, boron, chromium diboride, titanium, titanium diboride, vanadium, aluminum, silicon, tin, tantalum, zirconium, niobium, magnesium, manganese, iron, cobalt, copper, silver, zinc, hafnium, tungsten, molybdenum or nickel and their oxides, nitrides and oxynitrides. In some specific examples, the outer bonding surface can include a metal boride, a metal boride alloy or a boron-rich metal mixture or alloy. The material forming the outer bonding layer can be deposited using any suitable method, as described herein.

[0087] Fig.10 The deposition of non-fluorinated organic materials and the treatment of the external bonding surface can be carried out using the above-mentioned Fig. 9 The method may also include curing the sharp cut edge at 535 after depositing the non-fluorinated organic material, which may be performed as described above with respect to Fig. 9 Said execution. Fig.10 The method 500 depicted in the foregoing may be performed as described above with respect to Fig. 9 The process may be performed at a temperature (i.e., processing temperature) as described herein. Steps 530 and 535 may optionally be repeated as described herein to obtain one or more additional monolayers of non-fluorinated organic material. A curing step between depositing additional monolayers may be optional (e.g., multiple layers may be deposited without curing in between).

[0088] FIG. 11A to FIG. 11C and Fig.12 Depicted are exemplary chemical reactions 901, 902, 903, 941 that may be utilized in a method or in manufacturing a cutting member such as a razor blade according to the present disclosure. FIG. 11A to FIG. 11CDepicted is the deposition of various chlorosilane coating materials 912, 922, 932 onto substrates 910, 920, 930, for example via vapor deposition, while Fig.12 Ethoxysilane 952 is depicted deposited on substrate 950, for example, by dipping, flooding, or soaking. Substrates 910, 920, 930, 950 may include, for example, a sharp cutting edge and / or a body of a razor blade. Although a chromium (Cr) substrate is depicted, substrates 910, 920, 930, 950 may include any other material or combination of materials described herein. FIG. 11A to FIG. 11C and Fig.12 Prior to depositing the coating material 912, 922, 932, or 952, the substrate 910, 920, 930, 950 may be treated, for example, by etching as described herein, to clean and oxidize the surface and produce a substrate 908 having a plurality of hydroxyl (—OH) groups, such as Fig.11A Described in.

[0089] Fig.11A A chemical reaction 901 is depicted in which dichlorodimethylsilane 912 is deposited on a substrate 908. The first step 914 of reaction 901 is hydrolysis, in which dichlorodimethylsilane 912 combines with water molecules, causing two chlorine groups from each dichlorodimethylsilane molecule 912 to be replaced by two hydroxyl (-OH) side groups, and each dichlorodimethylsilane 912 releases two hydrochloric acid molecules. The second step 916 of reaction 901 is the covalent bonding of dichlorodimethylsilane derivatives 918 from step 914 to substrate 910 and to each other. In step 916, the dehydration of dichlorodimethylsilane derivatives 918 allows dichlorodimethylsilane derivatives 918 to bond to substrate 910 via the oxygen groups of dichlorodimethylsilane derivatives 918 to form a monolayer as shown. Dichlorodimethylsilane derivatives 918 can also bond to each other via their oxygen groups. A single dichlorodimethylsilane group may be bonded to substrate 910 twice via two chromiums, or may be bonded to substrate 910 once via one chromium and once to another dichlorodimethylsilane. The (coated) substrate 910 may undergo a post-deposition cure at step 940, which may be UV and / or thermal, as described herein, after which reaction 901 may end. Reaction 901 may optionally include a second deposition step 942, in which a second monolayer of dichlorodimethylsilane 912 is deposited to form substrate 910'. Substrate 910' may undergo a final cure at step 944, after which reaction 901 may end.

[0090] Fig. 11B Depicted is a chemical reaction 902 in which trichloromethylsilane 922 is deposited on a substrate 908 (see Fig.11A). The first step 924 of reaction 902 is hydrolysis, in which trichloromethylsilane 922 combines with water molecules, causing three chlorine groups from each trichloromethylsilane molecule 922 to be replaced by three hydroxyl (-OH) side groups, and each trichloromethylsilane 922 releases three hydrochloric acid molecules. The second step 926 of reaction 902 is covalent bonding of trichloromethylsilane derivatives 928 from step 924 to substrate 920 and to each other. In step 926, dehydration of trichloromethylsilane derivatives 928 allows trichloromethylsilane derivatives 928 to bond to substrate 920 via the oxygen groups of trichloromethylsilane derivatives 928 to form a monolayer as shown. Trichloromethylsilane derivatives 928 may also bond to each other via their oxygen groups. Although not shown, the (coated) substrate 920 may undergo post-deposition curing after step 926, and may optionally undergo a second deposition step and a second curing (see Fig.11A ).

[0091] Fig. 11C Depicted is a chemical reaction 903 in which a trichloroalkylsilane 932 is deposited on a substrate 908 (see Fig.11A ) on. The R group of the trichloroalkylsilane 932 can be any alkyl group as described herein (e.g., the alkyl group can be substituted or unsubstituted, linear or branched, saturated or unsaturated, etc.). The first step 934 of reaction 903 is hydrolysis, in which the trichloroalkylsilane 932 combines with a water molecule, thereby causing the three chlorine groups from each trichloroalkylsilane molecule 932 to be replaced by three hydroxyl (-OH) side groups, and each trichloroalkylsilane 932 releases three hydrochloric acid molecules. The second step 936 of reaction 903 is the covalent bonding of the trichloroalkylsilane derivative 938 from step 934 to the substrate 930 and to each other. In step 936, the dehydration of the trichloroalkylsilane derivative 938 allows the trichloroalkylsilane derivative 938 to bond to the substrate 930 via the oxygen groups of the trichloroalkylsilane derivative 938 to form a monolayer as shown. The trichloroalkylsilane derivatives 938 can also bond to each other via their oxygen groups. Although not shown, the (coated) substrate 930 may undergo a post-deposition cure after step 936, and may optionally undergo a second deposition step and a second cure (see Fig.11A ).

[0092] Fig.12 Depicted is a chemical reaction 941 in which triethoxyalkylsilane 952 is deposited on substrate 908 (see Fig.11A). The R group of the triethoxyalkylsilane 952 can be any alkyl group as described herein (e.g., the alkyl group can be substituted or unsubstituted, linear or branched, saturated or unsaturated, etc.). The first step 954 of the reaction 941 is hydrolysis, in which the triethoxyalkylsilane 952 combines with a water molecule, thereby causing the three ethoxy groups from each triethoxyalkylsilane molecule 952 to be replaced by three hydroxyl (-OH) side groups, and each triethoxyalkylsilane 952 releases three ethanol molecules. The second step 956 of the reaction 941 is the covalent bonding of the triethoxyalkylsilane derivative 958 from step 954 to the substrate 950 and to each other. In step 956, the dehydration of the triethoxyalkylsilane derivative 958 allows the triethoxyalkylsilane derivative 958 to bond to the substrate 930 via the oxygen groups of the triethoxyalkylsilane derivative 958 to form a monolayer as shown. The triethoxyalkylsilane derivatives 958 can also bond to each other via their oxygen groups. Although not shown, the (coated) substrate 950 may undergo a post-deposition cure after step 956, and may optionally undergo a second deposition step and a second cure (see Fig.11A ).

[0093] Deposition of non-fluorinated organic coating materials according to the present disclosure creates covalent bonds with underlying layers and / or substrates, for example via silane structures, with properties comparable to PTFE coatings and using conventional application processes. Non-fluorinated organic materials are generally inert or exhibit very low reactivity to materials often encountered in wet shaving environments, while also producing coatings that are highly durable and capable of withstanding repeated use under wet shaving conditions. Non-fluorinated organic materials allow for lower processing temperatures than PTFE, which helps maintain the properties of the substrate, including strength and hardness. In addition, non-fluorinated organic materials, particularly silanes, can form coatings as self-assembled monolayers that are uniform and do not require additional processing steps to thin the layer. The non-fluorinated organic coating materials described herein are compatible with many different substrates without causing corrosion, delamination, or adversely affecting the final tip shape.

[0094] Ideally, the coating or film comprising non-fluorinated organic coating materials according to the present disclosure is conformal, relatively thin and continuous, and includes high-density bonding sites to the substrate surface and to adjacent molecules. The coating can be realized on a suitably designed blade edge profile and tip shape (e.g., on an asymmetric coating). By selecting and pre-treating a suitable substrate surface and one or more curing steps, these types of coatings can lead to highly durable and highly bonded razor blades, thereby providing good cutting quality and low hair cutting force. In some examples, the coating can be a multilayer coating, including a first uniform and well-bonded non-fluorinated organic material layer and a second non-fluorinated organic material layer that at least partially encapsulates the first layer. This multilayer coating can have significant advantages in durability and hair cutting force, but much thicker coatings and gel-like cross-linked polymers should be avoided.

[0095] Very sharp tip geometries (e.g., via high aspect ratio coatings) can also result in significantly reduced cutting forces, but can also result in skin cutting. It has been demonstrated that a cutting edge with a slightly higher surface energy, e.g., from a non-fluorinated organic coating material, and a very sharp tip geometry can provide adequate or equivalent hair and skin engagement compared to a safer edge with a lower aspect ratio coating. Even with a slightly higher surface energy, a cutting edge according to the present disclosure can have a still significantly reduced hair cutting force and can result in an improved overall closeness of the shave.

[0096] Fig.14 is a graph comparing the cutting force of a razor blade according to the present disclosure with an uncoated razor blade and a PTFE coated razor blade. Standard uncoated, standard PTFE coated, and standard DMS coated razor blades can be compared with the Fig.13A and Fig. 13B The HAR DMS coated razor blades include a high aspect ratio boron-based coating (e.g., aspect ratio of about 2:1; see Figure 3 ) and DMS coatings according to the present disclosure (see Fig.11A ) stainless steel razor blades. It can be seen that the standard DMS coated razor blades exhibit comparable cutting forces to the standard PTFE coated blades. It can also be seen that the HAR DMS coated razor blades exhibit significantly lower cutting forces than the standard PTFE coated blades.

[0097] The dimensions and values ​​disclosed herein should not 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".

[0098] 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.

[0099] 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 (8), comprising: a base (228) having a tip portion (234); a hard coating (72) deposited on said substrate, a non-fluorinated organic material deposited in one or more monolayers (76, 176, 260, 360) on the outer bonding surface (42, 72, 74) of the hard coating; wherein the hard coating has an aspect ratio (a) to (b) of at least 1.5:1, wherein (a) is a first distance from a tip defined by the hard coating to a tip portion of the substrate, and (b) is a second distance from an outer surface of the hard coating to an underlying surface of the substrate.

2. The razor blade (8) according to claim 1, wherein the non-fluorinated organic material comprises an organosilane 3. The razor blade (8) according to claim 2, wherein the organosilane is derived from bis(trimethylsilyl)amine.

4. The razor blade (8) according to claim 2, wherein the organosilane is derived from hexamethyldisiloxane.

5. The razor blade (8) according to claim 1, wherein the aspect ratio is at least 3.5:

1.

6. The razor blade (8) according to claim 1, wherein the aspect ratio is between 1.5:1 and 2.5:

1.

7. The razor blade (8) according to any one of the preceding claims, wherein the outer shape of the non-fluorinated organic coating is the same as the outer shape of the tip portion (234).

8. A razor blade (8) according to any one of the preceding claims, comprising at least one of the following items: a thickness between 1.3 microns and 2.0 microns measured at a distance of four microns from the sharp tip of the substrate (228), a thickness between 2.3 microns and 3.5 microns measured at a distance of eight microns from the sharp tip (40), a thickness between 3.8 microns and 6.4 microns measured at a distance of sixteen microns from the sharp tip (40), a thickness between 9.3 microns and 16.2 microns measured at a distance of forty microns back from the sharp tip (40), a ratio of the thickness measured at four microns to the thickness measured at eight microns of at least 0.55, and a ratio of the thickness measured at four microns to the thickness measured at sixteen microns of at least 0.

28.

9. The razor blade (8) according to any one of the preceding claims, wherein the razor blade (8) further comprises a body portion (230).

10. The razor blade (8) of claim 9, wherein the non-fluorinated organic coating material is deposited on the tip portion and at least a section of the body portion (230).

11. The razor blade (8) according to any one of the preceding claims, wherein the non-fluorinated organic coating has a thickness of less than 500 angstroms.

12. The razor blade (8) of claim 1, wherein the non-fluorinated organic coating has a thickness of less than 100 angstroms.

13. The razor blade (8) according to any one of the preceding claims, wherein the non-fluorinated organic coating has a surface energy of less than 33 dyne / cm.

14. The razor blade (8) according to any one of the preceding claims, wherein each of the one or more monolayers is a self-assembled monolayer.

15. The razor blade (8) according to any one of the preceding claims, wherein the non-fluorinated organic coating is not a gel.

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