How to Coat Razor Blades

Abstract

A method of making a razor blade by forming a cutting edge on a substrate having an outer bonding surface, wherein a first self-assembled monolayer having a non-fluorinated organic material is deposited on the outer bonding surface of the substrate.

Description

[Technical field]

[0001] The present invention relates generally to coatings on substrates, and more specifically to improved coatings on razor components, such as razor blades. [Background technology]

[0002] A typical razor blade used for shaving is generally made by grinding a sharp bevel on a martensitic steel substrate. A hard coating is often applied to strengthen the blade edge and create a tip shape suitable for shaving, as well as to allow adhesion of a top coating of polytetrafluoroethylene (PTFE). PTFE is almost always applied to the top surface of the razor blade edge to create a low energy, non-stick surface required for low hair cutting force. The PTFE coating also allows for good hair engagement and efficient cutting as well as high quality hair cutting. Razor blade edges without a PTFE coating typically have a hair cutting force twice as high as PTFE coated edges. This increase in cutting force causes significant discomfort to the user during shaving. The discomfort during shaving increases as the number of blades used in a shaving razor increases. Razor blade edges without a PTFE coating are less efficient at engaging hair compared to PTFE coated edges, so additional strokes may be required during shaving. Similar behavior is seen with the quality of hair cutting, where non-PTFE coated edges often shave the hair rather than cutting it cleanly.

[0003] The application of PTFE coatings typically requires high sintering temperatures (e.g., near 400°C) to allow for proper bonding, which often softens and potentially damages the steel substrate. Tempering the steel substrate at such high temperatures reduces hardness and can limit the durability of existing edges as well as the ultimate sharpness of potential steel edges. Furthermore, to create a uniformly coated blade, PTFE is often applied as a very thick layer that is later thinned. This later thinning allows for a comfortable shave in early use of the razor, but also adds additional cost and complexity during production of the blade edge. Many current processes for the application of PTFE to the blade surface require removing the blade from a vacuum chamber to be sprayed with an aqueous PTFE dispersion, thus increasing the cost and time required for production. Furthermore, PTFE may be limited to the types of materials it bonds to. The production and use of fluorinated polymer coatings (e.g., PTFE) are under review by regulators as a class of materials included in the broader PFAS chemicals due to concerns about environmental persistence.

[0004] Fluorinated polymers are believed to be the only lubricious coating currently used on multi-blade wet shaving razor blades. Multi-blade wet shaving razors are the most commonly used wet shaving razors in developed countries such as the United States and European countries. The technology of fluorinated polymer coated blades has advanced significantly over the last few decades. Currently, there is no known alternative to fluorinated polymer coated blades that does not significantly reduce shaving performance. The coating of the blades has a significant impact on other factors involved in the design of the shaving razor system. For example, over the past few decades, shaving razor cartridge designs and blade edge geometries for wet shaving razors have been based on the use of fluorinated polymer (e.g., PFTE) coated blades. Without being bound by theory, it is believed that PTFE coated blades do not provide a comfortable shave (e.g., resulting in skin cuts) when high aspect ratio blade geometries, e.g., greater than 2:1, are used. PTFE coatings (fluorinated polymers) can exacerbate the problem of cuts and / or discomfort from high aspect ratio blades. Thus, shaving razor cartridge designs must compensate for skin cuts, for example, by adding additional features to protect the skin (e.g., blade guards and wire wrapping on the blades).

[0005] Prior to the discovery of fluorinated polymer coatings for blade edges, silicone coatings were used. For example, the blade is coated with a silicone gel. Without wishing to be bound by theory, it is believed that silicone coatings are generally difficult to control the coating thickness, require more severe processing conditions (e.g., over-curing vs. under-curing), and may also be more sensitive to environmental conditions such as relative humidity and dew point. Thus, silicone-coated blades tend to have either low durability and low cutting force, or high durability and high cutting force, with a limited processing window to achieve the desired low cutting force with sufficient coating adhesion / durability. High performance blades ideally have high durability and low cutting force. Summary of the Invention [Problem to be solved by the invention]

[0006] Thus, there is a need for an improved coating on cutting edges, such as blade edges, that does not utilize a PTFE coating, yet has optimal properties for applications such as hair cutting (e.g., cutting force, surface energy, minimal nicking of skin, etc.), minimizes softening and potential damage to the substrate, such as thermal effects, and utilizes a cost-effective and time-efficient manufacturing process. [Means for solving the problem]

[0007] The razor blades described herein may include a sharp cutting edge having an outermost layer formed by depositing a lubricious non-fluorinated organic coating material in one or more monolayers. The outer surface of the sharp cutting edge may be coated and / or treated to promote 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 deposited on the outer bonding surface forms 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 disclosure, a razor blade is provided, the razor blade comprising a sharp cutting edge and a non-fluorinated organic coating material comprising an organosilane deposited in one or more monolayers on the sharp cutting edge, the deposited organic coating material forming the outermost layer of the razor blade. In some aspects, the sharp cutting edge may comprise an outer bonding surface, and the non-fluorinated organic coating material may be deposited on the outer bonding surface. In some particular aspects, the outer bonding surface may comprise a boron-rich material. In other aspects, the sharp cutting edge may comprise a tip portion comprising a cutting edge defined by a sharp tip and one or more adjacent facets, and 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 alkenes.

[0010] According to another aspect of the present disclosure, a method of making a razor blade is provided, the method comprising 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 an outermost layer of the razor blade. In some aspects, the method may comprise depositing a first material on the sharp cutting edge of the razor blade to form an outer bonding surface, and treating the sharp cutting edge comprises treating the outer bonding surface to form a treated outer bonding surface, and depositing a non-fluorinated organic coating material on the treated outer bonding surface.

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

[0012] While the specification concludes with claims which particularly point out and distinctly claim the subject matter regarded as forming the invention, it is believed the present invention will be better understood by reference to the accompanying drawings in conjunction with the following description, in which like reference numerals are used to indicate substantially similar elements and in which: [Figure 1] FIG. 2 is a side view of a razor blade having a symmetrical substrate in accordance with the present disclosure. [Diagram 2] FIG. 2 is a perspective view of a tip portion of another razor blade having a symmetrical substrate in accordance with the present disclosure. [Diagram 3] FIG. 1 is a side view of a razor blade having a symmetrical substrate and a coating material on a tip portion in accordance with the present disclosure. [Figure 4] FIG. 2 is a side view of a razor blade having a symmetrical substrate, a coating material on a tip portion, and a section of a body portion in accordance with the present disclosure. [Diagram 5] FIG. 2 is a detailed view of a tip portion of a razor blade having a multi-layer coating material according to the present disclosure. [Figure 6] FIG. 13 is a side view of a further razor blade tip portion having a symmetric substrate and an asymmetric coating material in accordance with the present disclosure. [Figure 7A] FIG. 2 is a side view of a razor blade having an asymmetric substrate and a coating material according to the present disclosure. [Figure 7B] FIG. 2 is another razor blade in side view having an asymmetric substrate and an asymmetric coating in accordance with the present disclosure. [Figure 8] 1 is a schematic diagram showing a tip region of a razor blade according to the present disclosure. [Figure 9] A method for making a razor blade according to the present disclosure. [Figure 10] A method for making a razor blade according to the present disclosure. [Figure 11A] 1 is a chemical reaction of a chloroalkylsilane coating with a chromium substrate according to the present disclosure. [Figure 11B] 1 is a chemical reaction of a chloroalkylsilane coating with a chromium substrate according to the present disclosure. [Figure 11C]1 is a chemical reaction of a chloroalkylsilane coating with a chromium substrate according to the present disclosure. [Figure 12] 1 is a chemical reaction of an ethoxyalkylsilane coating with a chromium substrate according to the present disclosure. [Figure 13A] 1 is a graph comparing the body hardness of a razor blade according to the present disclosure with an uncoated razor blade and a PTFE coated razor blade. [Figure 13B] 1 is a graph comparing the body hardness of a razor blade according to the present disclosure with an uncoated razor blade and a PTFE coated razor blade. [Figure 14] 1 is a graph comparing the cutting force of a razor blade according to the present disclosure to an uncoated razor blade and a PTFE coated razor blade. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0013] For purposes of the detailed description below, it should be understood that any numerical range recited herein is intended to include all subranges subsumed therein. For example, a range of "1 to 10" is intended to include all subranges between (and including) the recited minimum of 1 and the recited maximum of 10, i.e., having a minimum of 1 or more and a maximum of 10 or less.

[0014] As used herein, the use of the singular includes the plural and the plural encompasses the singular unless otherwise stated. Additionally, in this application, the use of "or" means "and / or" unless otherwise stated, even if "and / or" may be expressly used in specific instances.

[0015] As used herein, the term "asymmetric blade" refers to a blade defined by a substrate having a first portion including a blade body and a second portion including a tip portion where a parting line passes through the tip of the tip portion and extends through the first and second portions, dividing the second portion into generally asymmetric first and second sections. An outer surface of the first section of the second portion is asymmetric with respect to an outer surface of the second section. The outer surface of the first section of the second portion may function as a skin-contacting surface and the outer surface of the second section may function as a hair-cutting surface.

[0016] As used herein, "partition line" means a line extending through the tip of a tip portion of a substrate, which line is generally parallel to first and second generally parallel outer surfaces of a first portion defining a blade body of the substrate, and which separates or divides the substrate into first and second halves or sections.

[0017] The term "gel" as used herein means a semi-solid structure consisting of sparse cross-linked polymer chains having an insoluble, infusible, coherent three-dimensional network in which low molecular weight fluid material is contained. Gels may exhibit little or no flow when in a steady state. The fluid material in a gel may include a variety of liquids, including water and water-based solutions (i.e., hydrogels). The fluid material of a gel is typically completely contained within the polymer chain network of the gel, for example, by surface tension and hydrogen bonding.

[0018] As used herein, the term "self-assembled monolayer" and variations thereof (e.g., self-assembling monolayer, SAM) refers to an ordered molecular assembly of organic molecules that are spontaneously deposited on a surface by adsorption. Typically, a self-assembled monolayer is formed by the reaction of the head groups of the molecules in the liquid or gas phase with the substrate on the surface. Examples of molecules in the liquid or gas phase that can form self-assembled monolayers in the present disclosure include non-fluorinated organic compounds such as organosilanes, carboxylates, catechols, amines, alkynes, and alkenes. The head groups of the molecules that react with the substrate to form the self-assembled monolayer can be a variety of reactive functional groups such as silanes, amines, carboxyl groups, alcohols, and hydrolyzable groups. Examples of substrates onto which self-assembled monolayers can be deposited 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, as well as oxides, nitrides, and oxynitrides thereof.

[0019] Referring now to the figures, FIGS. 1, 3, and 4 are side views of a cutting member 8 (here, a razor blade) according to an embodiment of the present disclosure, and FIG. 2 is a detailed perspective view of elements of a cutting member 18 (here, a razor blade) according to an embodiment of the present disclosure. The razor blades 8 and 18 shown in FIGS. 1-4 may each comprise a substrate 28 and a coating 60 (not visible in FIGS. 1 and 2, see FIGS. 3 and 4) comprising a coating material. As used herein, "substrate" may refer to a substance or material acted upon by a deposition process in the present disclosure. The substrate 28 may comprise one or more metals, alloys, or ceramics. In some examples, the substrate 28 may be stainless steel. The razor blades 8 and 18 may each comprise 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 a tip portion 34 may include flanks 36 that converge at a sharpened tip 40 to define a sharpened cutting edge 42 that effects severing of hair. Flanks 36 may each include one or more bevels or facets 38. Substrate 28 of FIG. 2 is described in more detail in U.S. Patent No. 9,751,230. Razor blades 8 and 18 may be incorporated into a razor cartridge (not shown).

[0020] In the example illustrated in FIGS. 1 to 4, the substrate 28, and in particular the tip portion 34, is substantially symmetrical, and the dividing line SL 28 , which passes through tip 40 and divides or separates substrate 28 into first and second substantially equal sections or halves (not numbered). 28 may coincide with the centerline (not shown) of the coating 60, as described herein, so that the parting line SL 28 The dividing line SL may also divide or separate the coating 60 into substantially equal first and second sections or halves. 28 may be generally parallel to a generally flat outer surface (not numbered) of the blade body 30. One outer surface 48 (also referred to herein as a first outer surface) of the substrate 28 is aligned with the other outer surface 50 (also referred to herein as a second outer surface) at a parting line SL 28As used herein, the terms "first" and "second" (i.e., referring to structures such as sections) are for reference purposes only and are not intended to be limiting.

[0021] At least a portion of one exterior surface of the substrate 28, e.g., first exterior surface 48, may define a skin-contacting surface, and at least a portion of the other exterior surface, e.g., second exterior surface 50, may define a hair-cutting surface. The two sides of the razor blades 8 and 18 may generally perform different functions (e.g., a bottom surface that contacts the skin and a top surface that performs hair cutting, with both sides performing hair cutting and the top surface (e.g., away from the skin) having a greater effect).

[0022] As shown in Figures 3 and 4, the razor blades 8 and 18 can include a coating 60 disposed substantially on at least a portion of the first and second outer surfaces 48 and 50 of the substrate 28. The coating 60 can include a single layer, as shown in Figures 3 and 4, or can include two or more layers (see Figure 5). As used herein, the term "coating" refers to a coating, including a monolayer, a free film, an impregnation, etc., that is applied to an object or substrate such that the coating can be continuous or discontinuous, can have a single thickness or a range of thicknesses, or can be in a single plane or multiple planes. The coating 60 can include one or more layers, each layer including one or more materials. The term "coating" can be used to indicate a full or total coating on one or both sides of the razor blades 8, 18, e.g., the first and second outer surfaces 48 and 50.

[0023] In the embodiments shown in FIGS. 3 and 4, the coating 60 is shown as extending along the first outer surface 48 and the second outer surface 50 of the substrate 28 from the tip region 35 toward the base 32. In some embodiments, the coating 60 may terminate short of the blade body 30 and / or the base 32, and in some particular embodiments, the coating 60 may be disposed substantially only on the tip portion 34 of the substrate 28, as shown, for example, in FIG. 3. In other embodiments, the coating 60 may be disposed on at least a portion of the tip portion 34 of the substrate 28 and the blade body 30, as shown, for example, in FIG. 4. The coating on the blade body 30 may make rinsing and debris removal easier, which may allow for less water usage during rinsing and cleaning of the cartridge, resulting in a shaving cartridge that is cleaner and more aesthetically pleasing over the life of the product. In some particular embodiments (not shown), the coating 60 may extend from the tip region 35 to the base 32. In some aspects (not shown), the coating 60 may be disposed only on the first outer surface 48 or the second outer surface 50. In other embodiments (not shown), the coating 60 may be disposed on the first and second outer surfaces 48 and 50, but may extend different distances along the first and second outer surfaces 48 and 50.

[0024] 5 provides a detailed view of the tip region 35 of substrate 28 having a multi-layer coating 60', which may be any substrate according to the present disclosure. Coating 60' may include two or more layers, including outermost layer 76, one or more of intermediate layer 70, hard coating layer 72, and overcoat layer 74, and outer layer 76.

[0025] The intermediate layer 70 may be used to facilitate bonding of the hard coating layer 72 to the substrate 28. Examples of suitable materials for the intermediate layer 70 may include niobium, titanium, and chromium-containing materials. Particular intermediate layers are made of niobium with a thickness of greater than about 100 angstroms and preferably less than about 500 angstroms. In some examples, the intermediate layer 70 may have a thickness of about 150 angstroms to about 350 angstroms.

[0026] The hard coating layer 72 can provide improved strength, corrosion resistance, and shaving ability, and can also be used to obtain a desired tip shape. The hard coating layer 72 can be made of microcrystalline, microcrystalline, or nanocrystalline carbon-containing materials (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., alumina, zirconia), or ceramic materials (including nanolayers or nanocomposites). The carbon-containing materials can be doped with other elements such as tungsten, titanium, silver, or chromium, for example, by including these additives in the target material during application by sputtering. These materials can also incorporate hydrogen, for example hydrogenated DLC. Preferably, the hard coating layer 72 is made of diamond, amorphous diamond, or DLC. Specific examples include DLC having a thickness of less than about 3000 Angstroms, preferably from about 500 Angstroms to about 1500 Angstroms. DLC layers and deposition methods are described in U.S. Patent No. 5,232,568. As described 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."

[0027] The overcoat layer 74 is used to reduce rounding of the hard-coated edges and to facilitate bonding of the outer layer 76 to the hard coating 72 while still maintaining both benefits. The overcoat layer 74 is preferably made of a chromium-containing material, such as chromium or a chromium alloy or compound, such as CrPt, that is compatible with the hard coating 72 and the outer layer 76. A particular overcoat layer 74 is chromium with a thickness of about 100 to about 200 angstroms. The overcoat layer 74 can include similar materials as the intermediate layer 70 and / or the hard coating layer 72, such as niobium or boron. In some embodiments, the overcoat layer 74 can have a thickness of about 50 angstroms to about 500 angstroms, preferably about 100 angstroms to about 300 angstroms.

[0028] The outermost layer 76 may be used, for example, to reduce friction. The outermost layer 76 may be a non-fluorinated organic coating material, as described herein. The term "non-fluorinated" as used herein refers to a material that does not contain or is devoid of fluorine. The outermost layer 76 is preferably continuous, which may allow for reduced coating thickness and improved first-pass shaving results.

[0029] In the examples shown in Figures 3-5, the coatings 60 and 60' may generally conform to and / or mirror the contours of the underlying portion of the substrate 28 and may have a substantially uniform thickness. Figure 6 shows an example of a coating 160 that does not conform to and / or mirror the contours of the underlying portion of the substrate 128 (referred to herein as an asymmetric coating). The asymmetric coating 160 may have a variable thickness that varies along at least a portion of the substrate 128. The 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 one or more of layers 70, 72, and 74 of Figure 5.

[0030] The substrate 128 of FIG. 6 may include a dividing line 180 (also referred to as a centerline) that passes through the tip 140 and divides or separates the substrate 128 into substantially equal first and second sections or halves (not numbered). The centerline 180 may be generally parallel to the generally flat outer surface of the blade body (see FIGS. 1-4). 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, with the centerline 182 of the asymmetric coating 160 being determined, for example, by the angle at which the asymmetric coating 160 is deposited. In some embodiments, the centerline 182 of the asymmetric coating 160 may be offset from the centerline 180 of the substrate 128 by at least at least 3 degrees, and in other embodiments, by at least 5 degrees, at least 8 degrees, or at least 10 degrees. In all embodiments, the centerlines 180 and 182 may be offset by up to 30 degrees. The substrate 128 and asymmetric coating 160 in FIG. 6 are shown relative to the skin surface. As described herein, the first exterior surface 148 of the substrate 128 may define the skin-contacting surface, and at least a portion of the other exterior surface, e.g., the second exterior surface 150, may define the hair-cutting surface. The asymmetric coating 160, particularly when the outermost layer 176 comprises a non-fluorinated organic coating material described herein, may help improve shaving comfort and safety by reducing cutting forces and improving skin management, and may also help improve durability by reducing shear forces and wear on the critical surface (i.e., the hair-cutting surface) resulting from peak cutting forces of the hair.

[0031] Referring to FIG. 8, the substrate 28 is at a distance D of 4 micrometers from the sharp tip 40. 1 The thickness T is about 1.3 to 2.0 micrometers, measured 1 , 40 to 8 micrometers distance D from the sharp tip 2 The thickness T is about 2.3 to 3.5 micrometers, measured at 2, 40 to 16 micrometers distance D from the sharp tip 3 The thickness T is approximately 3.8 to 6.4 micrometers, measured at 3 , and / or a distance D of 40 micrometers from the sharp tip 4 The thickness T is approximately 9.3 to 16.2 micrometers, measured at 4 Alternatively, or in addition, the substrate 28 may have a thickness T, measured in 4 micrometers, that is at least 0.55. 1 and the thickness T measured in 8 micrometers 2 and / or a thickness T measured at 4 micrometers that is at least 0.28 1 and the thickness T measured in 16 micrometers 3 The ratio may include:

[0032] 7A and 7B show examples of cutting members 218 and 318 (here razor blades) that include asymmetric substrates 228 and 328. With reference to FIG. 7A, razor blade 218 may include a first portion having a blade body 230 and a second portion having a tip portion 234, which may include a base (not shown) and tip portion 234 may include flanks (not numbered) that converge at a sharpened tip 240. The flanks may each include one or more bevels or facets (not numbered) that are unequal in length such that tip portion 234 is asymmetric. Although tip portion 234 is shown as including two facets on each of first outer surface 248 and second outer surface 250, it may be understood that first and second outer surfaces 248 and 250 may include different numbers of facets and in some examples, one of the outer surfaces, e.g., second outer surface 250, may not include facets.

[0033] The razor blade 218 may include a coating 260 extending from the tip region 235 toward the base (not shown) along the first and second outer surfaces 248 and 250. As described herein, the first outer surface 248 may define a skin-contacting surface and the second outer surface 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, as shown in FIG. 7A, or may be disposed only on the tip portion 234 (not shown; see FIG. 3). Although a single layer is shown for convenience, the coating 260 may include an outermost layer and at least one additional layer, as described herein (see FIGS. 5 and 6).

[0034] 7A, the coating 260 may generally conform to and / or mirror the contour of the underlying portion of the substrate 228 and may have a substantially uniform thickness. 228 2 may pass through the tip 240 and may be generally parallel to the outer surface (not numbered) of the blade body 230. The coating 260 generally conforms to the contour of the substrate 228 so that the parting line SL of the substrate 228 228 may coincide with a centerline (not shown) of the coating 260, as described herein.

[0035] 7B, the substrate 328 may be substantially similar to the substrate 228 of FIG. 7A, except that the coating 360 is asymmetric, i.e., the coating 360 does not conform to and / or reflect the contours of the underlying portion of the substrate 328. The asymmetric coating 360 may include a variable thickness that varies along at least a portion of the substrate 328. The substrate 328 may be aligned along the parting line SL shown in FIG. 7A. 228The asymmetric coating 360 may include a parting line 380 (also referred to as a centerline) that may be substantially similar to the centerline 380 of the substrate 328, as shown by 384. The asymmetric coating 360 may include a centerline 382 that may be offset from the centerline 380 of the substrate 328, as described above. As ... parting line 380 (also referred to as a centerline) that may be substantially similar to the centerline 380 of the substrate 328, as shown 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 embodiments, 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 embodiments, by at least 8 degrees. In further embodiments, the centerlines 380 and 382 may be offset by up to 30 degrees. As described above, the asymmetric coating 360 may help improve shaving comfort and safety, as well as durability, especially when the outermost layer (not shown) includes a non-fluorinated organic coating material as described herein.

[0036] According to the present disclosure, a cutting member is provided that may include razor blades 8, 18, 118, and 218 of Figures 1-6, 7A, and 7B. The razor 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, the non-fluorinated organic coating material forming the outermost layer of the razor blade. The non-fluorinated organic coating material may be directly or indirectly attached 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 layer of material that binds to a surface in an ordered manner as a result of physical or chemical forces during the deposition process. Silanes can form SAMs by liquid or vapor deposition processes. In certain embodiments, the first self-assembled monolayer (SAM) may be directly or indirectly attached to the substrate, and the second self-assembled monolayer (SAM) may be directly attached to the first self-assembled monolayer (SAM) and / or the substrate (e.g., the outer binding surface). Additional self-assembled monolayers (SAMs) may be added to fill any gaps on the substrate and / or to build layers on top of an existing self-assembled monolayer (SAM), such as the first self-assembled monolayer (SAM). For example, a third self-assembled monolayer (SAM) may be directly attached to the first self-assembled monolayer (SAM), the second self-assembled monolayer (SAM) and / or the substrate. In some examples, the razor blade may include a tip portion having a sharp tip and a cutting edge defined by one or more adjacent facets, as described herein, and the non-fluorinated organic coating material may be deposited on the tip portion to form a non-fluorinated organic coating. Without wishing to be bound by theory, it is believed that coating thickness and uniformity are important for lubricating blade coatings, especially silicone-based coatings, and thus, in typical coatings, thicker coatings may be required to ensure complete surface coverage to compensate for inconsistencies.Self-assembled monolayers can offer the advantage of coating the entire surface of the blade (in the desired area) without applying too much beyond the desired thickness and target surface (e.g., beyond the tip). For example, self-assembled monolayers can be applied to the blade in very thin layers at a time, providing better control and consistency of thickness and uniformity of coverage.

[0037] The substrate including the sharp cutting edge may include a metal, an alloy, or a ceramic, such as stainless steel. In some embodiments, the substrate, particularly the sharp cutting edge, may include one or more of the following materials (see FIG. 5 and FIG. 6), for example, as at least one additional material layer disposed between the sharp cutting edge and the non-fluorinated organic coating material: (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 oxides, nitrides, and oxynitrides thereof. In one embodiment, the one or more additional material layers may include chromium. In one particular example, the additional layer may include a layer of niobium, a layer of DLC, a layer of chromium, and an outermost layer comprising a non-fluorinated organic coating material, as described herein. In another example, the one or more additional material layers may include 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 that contains at least 50 atomic % boron. In one particular example, the additional layer may include a layer of niobium, a layer of DLC, a layer of boron or a boron-rich material, and an outermost layer comprising a non-fluorinated organic coating material, as described herein.

[0038] Non-fluorinated organic coatings containing organosilanes In some embodiments, the non-fluorinated organic coating material may comprise an organosilane. Exemplary organosilanes include those having the general formula: SiR n X m where R is an alkyl group, X is a leaving group such as chloride, alkoxy, or hydride, n=1-3, m=1-3, and n+m=4. The alkyl groups R may be the same as each other or different alkyl groups. The alkyl groups R may be substituted or unsubstituted, linear or branched, saturated or unsaturated, etc.

[0039] In some examples, the organosilane may be derived from a compound having a hydrolyzable group, hi other examples, the organosilane may be derived from a compound selected from the group consisting of chlorosilanes, alkoxysilanes, hydroxysilanes, and hydrosilanes.

[0040] In certain examples, the organosilane may be derived from an alkoxysilane, which may be selected from the group consisting of trimethoxysilane, dimethoxysilane, and ethoxysilane. The alkoxysilane may include one or more alkyl side chains, the one or more alkyl side chains having saturated carbon-carbon bonds. In certain embodiments, the one or more alkyl side chains having saturated carbon-carbon bonds have the following general formula: CH 3 (CH 2 ) n (wherein n=0-18). In some embodiments, n=0-17 or n=0-10. In other embodiments, n=0-8.

[0041] In further examples, the non-fluorinated organic coating material may include organosilanes derived from bis(trimethylsilyl)amine or derived from hexamethyldisiloxane.

[0042] The non-fluorinated organic coating material may include organosilanes derived from chlorosilanes. Examples of chlorosilanes include those having the general formula: SiR n Cl m where R is an alkyl group, n=1-3, m=1-3, and n+m=4. The alkyl groups R may be the same or different alkyl groups.

[0043] The alkyl group R may be saturated or unsaturated, substituted or unsubstituted, linear or branched, etc. The organosilane may be derived from a chlorosilane consisting of one chlorine atom, two chlorine atoms, or three chlorine atoms. In some examples, the organosilane may be derived from a chlorosilane selected from the group consisting of methyltrichlorosilane, dimethyldichlorosilane, t-butyltrichlorosilane, 3,3-dimethylbutyltrichlorosilane, dodecyltrichlorosilane, and mixtures thereof. In certain embodiments, the one or more alkyl side chains having saturated carbon-carbon bonds are of the general formula: CH 3 (CH 2 ) n (wherein n=0-18). In some embodiments, n=0-10). In other embodiments, n=0-8.

[0044] The use of bis-siloxanes such as 1,2-bis(trimethoxysilyl)decane or 1,2-bis(trichlorosilyl)decane as well as other trialkoxysilanes and / or trichlorosilanes can have the advantage of much stronger bonding to the substrate and to each other.

[0045] Non-fluorinated organic coatings including other materials In other examples, the non-fluorinated organic coating material may be selected from the group consisting of carboxylates, catechols, amines, alkynes, and alkenes. In some embodiments, the non-fluorinated organic coating material is not an organophosphorus compound. In other embodiments, the non-fluorinated organic coating material is not an organophosphate or derivative thereof.

[0046] Non-fluorinated organic coating materials and properties of substrates coated therewith 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 that has a relatively low surface energy while still maintaining a level of durability required to withstand shaving applications. A non-fluorinated organic coating material according to the present disclosure may have a surface energy of less than 40 dynes / cm. In some embodiments, the non-fluorinated organic coating material has a surface energy of less than 37 dynes / cm, less than 35 dynes / cm, less than 33 dynes / cm, or less than 31 dynes / cm. Surface energy is a measure of the excess energy present at the surface of a material compared to its bulk, and is typically given in units of dynes per centimeter (i.e., dynes / cm). 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 the liquid that either spreads or beads on the surface is measured, for example, by measuring the contact angle between a drop of liquid and the surface of the material. For materials with high surface energy, the applied drop of liquid typically spreads and forms a film on the surface of the material. Conversely, for materials with low surface energy, the applied droplet typically forms a bead.

[0047] The non-fluorinated organic coating material may be deposited in one or more monolayers on the substrate, including the sharp cutting edge and / or body. In some embodiments, each of the one or more monolayers may be a self-assembled monolayer. In other embodiments, the non-fluorinated organic coating is not a gel. The non-fluorinated organic coating material may form a layer less than 500 angstroms thick. In some embodiments, the non-fluorinated organic coating material forms a layer less than 100 angstroms thick, or less than 30 angstroms thick. The thickness of the layer of non-fluorinated organic material may be as low as 7-10 angstroms. These relatively thin coatings are expected to be uniform in thickness and continuous in coverage, which may affect the quality and consistency of the coating, and may result in reduced cutting forces and more comfortable shaving, as well as a smaller tip radius due to the coating being more conformal to the substrate surface at the blade edge. Thicker outermost coatings, such as those derived from polymeric precursors, including cross-linked or gel coatings, can result in larger edge cross sections and tip radii, which can increase cutting forces and / or reduce bristle engagement and cutting efficiency. Increasing coating thickness also increases surface shear forces, promoting unacceptable wear of the outermost coating.

[0048] The coating, including the non-fluorinated organic coating, may have an aspect ratio of (a) to (b), as shown in the inset of Figure 3, where (a) is a first thickness 80 from the tip 41 defined by the non-fluorinated organic coating 60 (defining the outermost layer) to the sharp tip 40 of 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 underlying surface (not labeled) of the substrate 28. The thickness 82 may be measured at a distance of 4 micrometers from the sharp tip 40 (e.g., distance D in Figure 8). 1(See, for example, US Pat. No. 6,393,996, and US Pat. No. 6,393,996). In some embodiments, the aspect ratio (a) to (b) may be at least about 1.5:1, at least 2:1, or at least 2.5:1 ±0.5 for (a). In some specific embodiments, the aspect ratio (a) to (b) may be up to 3.5:1, and in other specific embodiments, the aspect ratio (a) to (b) may be up to 4:1. Generally, the higher the aspect ratio, the sharper the cutting edge and the lower the cutting force.

[0049] As described herein, coatings including non-fluorinated organic materials require lower processing temperatures (less than 300°C, preferably less than 150°C) compared to the processing temperatures required for PTFE (typically about 400°C). Figures 13A and 13B are graphs 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 PTFE coated razor blade (standard PTFE coated). Figure 13A provides the average Vickers hardness of the razor blades and Figure 13B provides the percent hardness measured relative to the uncoated razor blade. The uncoated "control" razor blade (standard uncoated) comprises a stainless steel razor blade having layers of niobium, DLC, and chromium and no additional lubricious coating. Standard PTFE coated razor blades include razor blades from the same lot with an additional PTFE coating on the chrome, which undergoes sintering at a temperature above the melting point of PTFE.Standard DMS coated razor blades include razor blades from the same lot with an additional organosilane coating, i.e., dimethylsiloxane (DMS), on the chrome in accordance with the present disclosure (e.g., as shown in FIG. 11A).

[0050] From Figures 13A and 13B, it can be seen that the standard PTFE coated razor blade has a significantly reduced body hardness compared to the standard uncoated razor blade, with the hardness of the standard PTFE coated razor blade being approximately 18% lower than the hardness of the standard uncoated razor blade. The reduced hardness of the standard PTFE coated razor blade is due, at least in part, to the higher processing temperatures, i.e., sintering temperatures exceeding 300°C, which can significantly reduce the hardness of the razor blade through heat tempering. In contrast, the standard DMS coated razor blade exhibits a body hardness comparable to the standard uncoated razor blade, with little hardness reduction. This retention of hardness of standard DMS coated razor blades is due, at least in part, to the lower processing temperatures permitted by the non-fluorinated organic coating materials described herein, which reduces the softening of the stainless steel substrate and therefore reduces the potential for damage to the stainless steel substrate as well as reducing the potential for damage to the blade edge during shaving.

[0051] Flow Diagram 9 and 10 are flow diagrams illustrating exemplary methods 400 and 500 of making a razor blade according to the present disclosure, respectively. As shown in FIG. 9, method 400 may include treating a (coated or uncoated) sharp cutting edge of a razor blade to form a treated sharp cutting edge (410) and depositing a non-fluorinated organic material in one or more monolayers on the treated sharp cutting edge such that the organic coating material forms an outermost layer of the sharp cutting edge (420). In some examples, the non-fluorinated organic material comprises an organosilane. In other examples, the non-fluorinated organic material is selected from the group consisting of carboxylates, catechols, amines, alkynes, and alkenes. In both examples, the monolayer may be a self-assembled monolayer.

[0052] The non-fluorinated organic material may be deposited using any suitable technique or combination of techniques, including vapor deposition, immersion, flooding, spraying, or soaking, such as PVD and atomic layer deposition. Brushing may also be used for soft coating. In some embodiments, depositing the non-fluorinated organic material may include vapor deposition in vacuum. Examples of razor blades and manufacturing processes are described in U.S. Patent Nos. 5,295,305, 5,232,568, 4,933,058, 5,032,243, 5,497,550, 5,940,975, and 5,669,144, European Patent No. 0591339, and International Application No. 92 / 03330, which are incorporated herein by reference.

[0053] In embodiments, the temperature, e.g., the processing temperature during method 400, does not exceed 300° C. In certain embodiments, 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.

[0054] The method 400 may further include curing the sharp cutting edge (425) after depositing the non-fluorinated organic material, for example, to improve the bonding and adhesion of the non-fluorinated organic material to the sharp cutting edge. The curing may include one or more of ultraviolet (UV) light curing, thermal curing, or non-oxidizing plasma treatment. If the curing includes UV curing, the curing may be performed using UV light having a wavelength between 100 nm and 400 nm. The exterior or outer surfaces of the razor blade, i.e., the skin-contacting surface and the hair-cutting surface, may be independently cured using different wavelengths of light and / or curing times. For example, the skin-contacting surface may be made durable and less hydrophobic, which improves the slippage of the edge over the skin in a moist shaving environment. This UV modification of the skin-contacting surface may be complementary to an asymmetric coating, as discussed herein.

[0055] For example, treating the sharp cutting edge by etching may be performed to clean and activate the surface in preparation for deposition of a coating material, for example by oxidizing the surface to generate hydroxyl groups (-OH) on the surface of the sharp cutting edge. These hydroxyl groups act as binding sites for non-fluorinated organic materials and improve adhesion, e.g., covalent bonding, between the surface and the coating material. In principle, activation can be obtained in a variety of ways. The optimal activation method differs for each oxide. In some examples, treating the sharp cutting edge may include plasma etching, for example, plasma etching with a gas mixture including a process gas and a carrier gas. In some embodiments, 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 noble or inert gases, and may be selected from the group consisting of nitrogen, argon, helium, neon, krypton, xenon, and radon. In other embodiments, the treatment may include plasma etching with molecular oxygen alone or argon alone. In further embodiments, the treatment may include plasma etching with molecular oxygen and argon. In yet another aspect, treating the sharp cutting 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.

[0056] The surface on which the non-fluorinated organic material is deposited may be referred to herein as the "outer bonding surface." In some embodiments, the outer bonding surface may include a treated (uncoated) sharp cutting edge. In other embodiments, the method 400 may further include depositing (405) at least one layer of material on the sharp cutting edge prior to the treatment to form the coated sharp cutting edge, which may function as the outer bonding surface. The at least one layer of material is disposed between the sharp cutting edge and the non-fluorinated organic coating material, and treating the sharp cutting edge includes treating a coated sharp cutting edge. The at least one material layer may include one or more of an outer layer, an intermediate layer, a hard coating layer, and an overcoat layer (see FIG. 5), and may be: (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 oxides, nitrides, and oxynitrides thereof. Steps 420 and 425 may be optionally repeated as described herein to obtain one or more additional monolayers of non-fluorinated organic materials.

[0057] 10, a method 500 may include depositing a first material on a sharp cutting edge of a razor blade to form an outer bonding surface (510), treating the outer bonding surface to form a treated outer bonding surface (520), and depositing a non-fluorinated organic material in one or more monolayers on the treated outer bonding surface such that the organic coating material forms an outermost layer of the sharp cutting edge (530). In some embodiments, the non-fluorinated organic material comprises an organosilane. In other embodiments, the non-fluorinated organic material is selected from the group consisting of carboxylates, catechols, amines, alkynes, and alkenes.

[0058] Depositing the first material to form the outer bonding surface may include depositing one or more of an outer layer, an intermediate layer, a hard coating layer, and an overcoat layer (see FIG. 5), where the outer bonding surface may include the material or layer immediately beneath the non-fluorinated organic material, i.e., the material or layer to which the non-fluorinated organic material bonds. With reference to the example shown in FIG. 5, the overcoat layer 74 may serve as the outer bonding surface for the outermost layer 76. In other examples (not shown), the overcoat layer 74 may be omitted and the hard coating layer 72 may serve as the outer bonding surface. The outer bonding surface may be made of (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 oxides, nitrides, and oxynitrides thereof. In some specific examples, the outer bonding surface may include a metal boride, a metal boride alloy, or a boron-rich metal mixture or alloy. The material forming the outer bonding layer may be deposited using any suitable method, as described herein.

[0059] The deposition of the non-fluorinated organic material and the treatment of the outer bonding surface in Figure 10 may be performed using one or more of the techniques described above with respect to Figure 9. The method may further include hardening the sharp cutting edges after depositing the non-fluorinated organic material (535), which may be performed as described above with respect to Figure 9. The method 500 shown in Figure 10 may be performed at a temperature, i.e., a processing temperature, as described above with respect to Figure 9. Steps 530 and 535 may be optionally repeated as described herein to obtain one or more additional monolayers of non-fluorinated organic material. A hardening step between depositing additional monolayers may be optional (e.g., multiple layers are deposited without curing in between).

[0060] 11A-11C and 12 show exemplary chemical reactions 901, 902, 903, 941 that may be utilized in methods according to the present disclosure or in the manufacture of cutting members such as razor blades. 11A-11C show deposition of various chlorosilane coating materials 912, 922, 932 onto substrates 950, 920, 930, e.g., by vapor deposition, and FIG. 12 shows deposition of ethoxysilane 952 onto substrate 950, e.g., by immersion, flooding, or soaking. Substrates 910, 920, 930, 950 may include, for example, a sharp cutting edge and / or the body of a razor blade. Although a chromium (Cr) substrate is shown, substrates 910, 920, 930, 950 may include any other material or combination of materials described herein. Prior to deposition of coating material 912, 922, 932 or 952 in Figures 11A-11C and 12, substrate 910, 920, 930, 950 may be treated, for example, by etching as described herein, to clean and oxidize the surface and produce substrate 908 having a plurality of hydroxyl (-OH) groups, as shown in Figure 11A.

[0061] 11A shows a chemical reaction 901 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, replacing two chlorine groups from each dichlorodimethylsilane molecule 912 with two hydroxyl (-OH) side groups, and releasing two hydrochloric acid molecules per dichlorodimethylsilane 912. The second step 916 of reaction 901 is covalent bonding of dichlorodimethylsilane derivatives 918 from step 914 to the substrate 910 and each other. In step 916, dehydration of the dichlorodimethylsilane derivatives 918 allows for bonding of the dichlorodimethylsilane derivatives 918 to the substrate 910 through the oxygen groups of the dichlorodimethylsilane derivatives 918, forming a monolayer as shown. The dichlorodimethylsilane derivatives 918 may bond to each other through their oxygen groups. A single dichlorodimethylsilane group may be bonded twice to the substrate 910 through two chromiums, or once to the substrate 910 through one chromium and once to another dichlorodimethylsilane. The (coated) substrate 910 may undergo a post-deposition cure, which may be UV and / or thermal, in step 940 as described herein, after which reaction 901 may terminate. 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 in step 944, after which reaction 901 may terminate.

[0062] FIG. 11B illustrates 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, replacing three chlorine groups from each trichloromethylsilane molecule 922 with three hydroxyl (-OH) side groups, and releasing three hydrochloric acid molecules per trichloromethylsilane 922. The second step 926 of reaction 902 is covalent bonding of trichloromethylsilane derivatives 928 from step 924 to the substrate 920 and each other. In step 926, dehydration of trichloromethylsilane derivatives 928 allows bonding of trichloromethylsilane derivatives 928 to substrate 920 through oxygen groups of trichloromethylsilane derivatives 928, forming a monolayer as shown. Trichloromethylsilane derivatives 928 may bond to each other through their oxygen groups. Although not shown, the (coated) substrate 920 may undergo a post-deposition cure following step 926, and may optionally undergo a second deposition step and a second cure (see FIG. 11A).

[0063] Figure 11C illustrates a chemical reaction 903 in which trichloroalkylsilanes 932 are deposited onto a substrate 908 (see Figure 11A). The R group of trichloroalkylsilanes 932 can be any alkyl group as described herein (e.g., alkyl can be substituted or unsubstituted, linear or branched, saturated or unsaturated, etc.). The first step 934 of reaction 903 is hydrolysis, in which trichloroalkylsilanes 932 combine with water molecules, replacing three chlorine groups from each trichloroalkylsilane molecule 932 with three hydroxyl (-OH) side groups, and releasing three hydrochloric acid molecules per trichloroalkylsilane 932. The second step 936 of reaction 903 is the covalent bonding of trichloroalkylsilane derivatives 938 from step 934 to the substrate 930 and to each other. In step 936, dehydration of the trichloroalkylsilane derivative 938 allows bonding of the trichloroalkylsilane derivative 938 to the substrate 930 via the oxygen groups of the trichloroalkylsilane derivative 938 to form a monolayer as shown. The trichloroalkylsilane derivatives 938 may bond to each other via their oxygen groups. Although not shown, the (coated) substrate 930 may undergo a post-deposition cure following step 936, and may optionally undergo a second deposition step and a second cure (see FIG. 11A).

[0064] FIG. 12 illustrates chemical reaction 941 in which triethoxyalkylsilane 952 is deposited on substrate 908 (see FIG. 11A). The R group of triethoxyalkylsilane 952 can be any alkyl group as described herein (e.g., alkyl can be substituted or unsubstituted, linear or branched, saturated or unsaturated, etc.). The first step 954 of reaction 941 is hydrolysis, in which triethoxyalkylsilane 952 is combined with water molecules, replacing three ethoxy groups from each triethoxyalkylsilane molecule 952 with three hydroxyl (-OH) side groups, and releasing three ethanol molecules per triethoxyalkylsilane 952. The second step 956 of reaction 941 is covalent bonding of triethoxyalkylsilane derivatives 958 from step 954 to substrate 950 and to each other. In step 956, dehydration of the triethoxyalkylsilane derivative 958 allows bonding of the triethoxyalkylsilane derivative 958 to the substrate 930 through the oxygen groups of the triethoxyalkylsilane derivative 958 to form a monolayer as shown. The triethoxyalkylsilane derivatives 958 may bond to each other through their oxygen groups. Although not shown, the (coated) substrate 950 may undergo a post-deposition cure following step 956, and may optionally undergo a second deposition step and a second cure (see FIG. 11A).

[0065] The deposition of non-fluorinated organic coating materials according to the present disclosure, for example, via silane structures, produces covalent bonds with underlying layers and / or substrates that have properties comparable to PTFE coatings and use conventional application processes. Non-fluorinated organic materials are generally inert or exhibit very low reactivity with materials commonly encountered in wet shaving environments, while also producing coatings that are highly durable and can withstand repeated use in wet shaving conditions. Compared to PTFE, non-fluorinated organic materials allow for lower processing temperatures, which helps to maintain substrate properties, including strength and hardness. Furthermore, 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 can be compatible with many different substrates without causing corrosion, delamination, or adversely affecting the final tip shape.

[0066] Ideally, coatings or films comprising non-fluorinated organic coating materials according to the present disclosure are conformal, relatively thin, continuous, and contain a high density of binding sites to the substrate surface and with adjacent molecules. Coatings can be achieved over properly designed blade edge profiles and tip shapes (e.g., over asymmetric coatings). With appropriate substrate surface selection and pretreatment, along with one or more curing steps, these types of coatings can result in razor blades that are both durable and highly engaging, providing good cutting quality and low hair-cutting force. In some examples, the coating may be a multi-layer coating that includes a first uniform and well-bonded layer of non-fluorinated organic material and a second layer of non-fluorinated organic material that at least partially encapsulates the first layer. This multi-layer coating can have significant advantages in both durability and hair-cutting force, but much thicker coatings and gel-like cross-linked polymers should be avoided.

[0067] For example, a very sharp tip shape from a high aspect ratio coating can also result in a significant reduction in cutting force, but can also result in skin cutting. It has been demonstrated that a cutting edge with a slightly higher surface energy, for example from a non-fluorinated organic coating material, and a very sharp tip shape can provide adequate or equivalent hair and skin engagement compared to a safer cutting edge with a lower aspect ratio coating. Even with a slightly higher surface energy, the cutting edge according to the present disclosure can still have a significantly reduced hair cutting force and can result in an improvement in overall shaving adhesion.

[0068] 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. A standard uncoated razor blade, a standard PTFE-coated razor blade, and a standard DMS-coated razor blade may follow the similarly named razor blades described with respect to FIG. 13A and FIG. 13B. The HAR DMS-coated razor blade includes a stainless steel razor blade with a high aspect ratio boron-based coating (e.g., aspect ratio of about 2:1; see FIG. 3) and a DMS coating according to the present disclosure (see FIG. 11A). The standard DMS-coated razor blade exhibits a cutting force comparable to that of a standard PTFE-coated blade. It can also be seen that the HAR DMS-coated razor blade exhibited a significantly lower cutting force than the standard PTFE-coated razor blade.

[0069] Dimensions and values ​​disclosed herein should not be understood as being strictly limited to the exact numerical values ​​recited. Instead, unless otherwise specified, each such dimension is intended to mean both the recited value and a functionally equivalent range surrounding that value. For example, a dimension disclosed as "40 mm" is intended to mean "about 40 mm."

[0070] All documents cited herein, including any cross-referenced or related patents or patent applications, and any patent applications or patents to which this application claims priority or the benefit of, are incorporated herein by reference in their entirety, unless expressly excluded or otherwise limited. The citation of any document shall not be deemed to be prior art to any invention disclosed or claimed herein, or to teach, suggest, or disclose any such invention, either alone or in combination with any other reference or references. Furthermore, if any meaning or definition of a term in this document conflicts with any meaning or definition of the same term in a document incorporated by reference, the meaning or definition given to that term in this document shall control.

[0071] While particular embodiments of the present invention have been illustrated and described, it would be obvious to those skilled in the art that various other changes and modifications can be made without departing from the spirit and scope of the invention. It is therefore intended to cover in the appended claims all such changes and modifications that are within the scope of this invention.

Claims

1. 1. A method (500) for making a razor blade, comprising: forming a cutting edge (42) on a substrate (28, 128, 228, 328, 908, 910, 920, 930) having an outer bonding surface (42, 72, 74); depositing (530) a first self-assembled monolayer comprising a non-fluorinated organic material on the outer bonding surface (42, 72, 74) of the substrate (28, 128, 228, 328, 908, 910, 920, 930).

2. 10. The method of claim 1, further comprising curing (535) the first self-assembled monolayer after depositing the self-assembled monolayer on the outer bonding surface (42, 72, 74) of the substrate (28, 128, 228, 328, 908, 910, 920, 930).

3. The method of claim 2 , wherein the curing (535) is by at least one of UV curing or thermal curing.

4. The method of claim 3, wherein the curing (535) is by UV curing using UV light having a wavelength between 100 nm and 400 nm.

5. The method of any one of claims 1 to 4, comprising treating (520) the sharp cutting edge (42) with a plasma before the first monolayer is deposited, the plasma further comprising a gas mixture including a process gas and a carrier gas.

6. 6. The method of claim 5, wherein the process gas is selected from the group consisting of molecular oxygen, water, and alcohol, and the carrier gas comprises one or more gases selected from the group consisting of nitrogen, argon, helium, neon, krypton, xenon, and radon.

7. The method of any one of claims 1 to 6, wherein depositing (530) the first self-assembled monolayer comprises one or more of evaporating, dipping, flooding, spraying, or soaking.

8. The method of any one of claims 1 to 7, wherein depositing (530) the first self-assembly comprises evaporation.

9. The method according to any one of claims 1 to 8, wherein the temperature does not exceed 300°C.

10. The method of any one of claims 1 to 9, further comprising depositing a second self-assembled monolayer on the first self-assembled monolayer, the second self-assembled monolayer comprising a non-fluorinated organic material.

11. The method of any one of claims 1 to 10, further comprising depositing a second self-assembled monolayer comprising a non-fluorinated organic material on the outer bonding surface (42, 72, 74) of the substrate (28, 128, 228, 328, 908, 910, 920, 930).

12. 12. The method of any one of claims 1 to 11, further comprising forming the outer bonding surface (72, 74) by depositing (510) on the substrate at least one layer of material comprising one or more of: (i) diamond, amorphous diamond, or diamond-like carbon (DLC); or (ii) chromium, platinum, boron, chromium diboride, titanium, titanium diboride, vanadium, aluminum, silicon, magnesium, manganese, iron, cobalt, nickel, copper, silver, zinc, tin, hafnium, tantalum, tungsten, zirconium, molybdenum, or niobium, and oxides, nitrides, and oxynitrides thereof, wherein the at least one layer of material is disposed between the substrate and the first self-assembled monolayer.

13. 13. The method of any one of claims 1 to 12, further comprising depositing (510) at least one layer of material on the substrate prior to depositing the first self-assembled monolayer comprising a non-fluorinated organic material on the outer bonding surface of the substrate.

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