Systems, compositions, and methods for producing sharp edges

Abstract

The present disclosure relates to systems, compositions, and methods for producing objects with sharp edges having high strength and hardness.SOLUTION: To form the sharp edge, the object can be subjected to a compressive force, which locally deforms the object to produce the sharp edge. In some embodiments, the deformation may occur by passing the material through a system of one or more opposing tapered rolls having one or more taper angles to deform the material. The tapered rolls can rotate the material and drive the material downstream to the next opposed pair of tapered rolls. The tapered rolls deform the material by changing the microstructure of the material and compress the particles of the material in place to create a more homogeneous microstructure. The resulting local modification of the microstructure increases the hardness and strength as well as the homogeneity of the material and prevents cracking and / or chipping of the material.SELECTED DRAWING: Figure 3

Description

Disclosure Contents

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This disclosure claims priority to and benefit of U.S. Provisional Application No. 62 / 902,018, entitled "Systems and Methods for Producing Sharp Edges," filed September 18, 2019, and incorporated herein by reference in its entirety.

[0002] [Field] The present disclosure relates to systems, compositions, and methods for manufacturing objects with sharp edges, and more particularly to the localized deformation of a material to form sharp edges at desired locations of the material without substantially changing the composition and / or mass of the material.

[0003] 〔background〕 The manufacture of materials with varying degrees of sharpness has been practiced by humans for thousands of years. From hunting spears to swords, axes, needles, and modern thumb tacks, materials have been designed for use as tools, capable of cutting, piercing, and binding everyday objects to enhance the quality of life. Over the past few centuries, innovations such as knives, scissors, and razor blades have harnessed the capabilities of materials such as metals to transform the way we cook, work, and groom. However, as the world's population continues to grow, the demand for the manufacture of such tools has correspondingly increased, as has the environmental impact and energy consumed in their production. Extending the lifespan of these materials could have a positive impact on the environment. For example, in 1990, the Environmental Protection Agency (EPA) estimated that approximately 2 billion razor blades were discarded worldwide annually. Thirty years later, little progress has been made in extending the lifespan of razor blades. While cutting-edge technology has improved the closeness of shaving, razor blade dulling continues to plague the industry and, ultimately, the environment.

[0004] Existing methods for producing sharp edges have several drawbacks. Traditional methods involve ablating material to form a wedge shape that can be used for cutting or penetrating. The most common manufacturing method for this type of sharp edge, particularly for razor blades, involves a process called "honing." In honing, the starting material begins in strip or plate form and is heat-treated until the desired microstructure and hardness are achieved. Abrasive wheels are then used to remove material from specific locations, forming the wedge profile. Due to uneven exposure times and inconsistencies in the microstructures that make up the material, honed materials often have uneven edges, which can wear down over time when exposed to frequent and regular stresses and strains. For example, repeated contact with the uneven edge of the honed material can cause cracks and chips that propagate throughout the material, dulling it and rendering it inefficient after several uses. The honing process also requires a large amount of energy to perform the heat treatment and polishing, and often results in wasted material, as the removed material is often discarded.

[0005] Therefore, there is a need for systems, compositions and methods for producing sharp edges that have high strength and hardness while being less susceptible to cracking and / or chipping.

[0006] 〔overview〕 The present application is directed to systems, compositions, and methods for manufacturing objects with sharp edges that are resistant to cracking and / or chipping. In at least some examples, the material undergoes severe plastic deformation at the tip, enabling a sharp edge with high strength and hardness. The deformation of the material can occur by passing the material through a system of one or more tapered rolls, which locally deform the material to produce the sharp edge. The tapered rolls can include cylindrical bodies that apply compressive forces to the material, deforming it at the desired location. The tapered rolls can have one or more taper angles for deforming the material. The tapered rolls can be positioned in opposing pairs, with the material received between each pair of rolls and the rolls contacting the material on their opposing surfaces. The tapered rolls can be configured to rotate and drive the material in a rotational direction. In some embodiments, the system can include multiple pairs of tapered rolls that deform the material. In such embodiments, each pair of tapered rolls can be positioned downstream of each other, with rotation of the upstream pair of rolls driving the material to the downstream pair of rolls. In some embodiments, the taper angle of the last pair or pairs of rolls may be different from the taper angle of the first pair or pairs of rolls to provide possible "separation" on the two sides and / or to provide a specific angle at the very tip of the sharp edge.

[0007] The use of tapered rolls can localize severe plastic deformation at sharp edges, inducing cementite dissolution and, if necessary, resulting in a strong, homogeneous material. For example, the microstructure of a material before deformation is composed of heterogeneous grains of various sizes and hardnesses scattered throughout the material, with spaces or voids between individual grains (grain boundaries). These spaces result in weaknesses in the material's overall structure, which, when stressed, can cause grains to displace into the spaces, forming cracks within the material and thus chipping at the sharp edges. Contact with the tapered rolls compresses the grains in a given location to a smaller size (grain refinement), allowing them to fill the spaces and create a more homogeneous microstructure. This process increases both the homogeneity of the resulting microstructure and the hardness and strength of the material, preventing cracking and / or chipping of the material.

[0008] One exemplary embodiment of a deformed material includes a length of metallic material having a substantially homogeneous microstructure in at least a deformed portion thereof, the substantially homogeneous microstructure having a plurality of substantially uniformly sized deformed grains that are smaller in size than the grains in one or more of the undeformed portions of the length of metallic material and the grains in the deformed portion prior to deformation.

[0009] The length of metallic material can include one or more of pure iron, steel, stainless steel, copper, martensite, chromium, carbide, nitride, metallic glass, polymer, pearlite, cementite, martensitic steel, aluminum, pearlitic steel, titanium, nickel, cobalt, hydroxyapatite, silver, or gold. The size of the plurality of deformed particles can be approximately within a range from about 75% of the average grain size of the deformed particles to about 125% of the average grain size of the deformed particles. In some embodiments, the size of the deformed particles can be about 25% of the size of the grains in the undeformed portion. In alternative embodiments, the size of the deformed particles can be about 25% of the size of the grains before deformation.

[0010] One exemplary embodiment of a system for producing sharp edges includes a first pair of opposed tapered rolls and at least one additional pair of opposed tapered rolls disposed laterally downstream of the first pair of opposed tapered rolls. The first pair of opposed tapered rolls is configured to rotate to drive material disposed therebetween downstream. The first pair of opposed tapered rolls also has one or more features configured to deform the material while the material is being driven downstream. The at least one additional pair of opposed tapered rolls is configured to rotate to drive material received from the first pair of opposed tapered rolls downstream. Each roll of the first pair of opposed tapered rolls includes a somewhat cylindrical configuration, including a first end, a second end, and an apex, and the opposing surfaces of each roll are tapered between the first end and the apex and between the second end and the apex. The distance between each roll of the first pair of opposed tapered rolls, measured from the top along the opposed surfaces of each roll of the first pair of opposed tapered rolls, is greater than the distance between each roll of at least one additional pair of opposed tapered rolls, measured from the top along the opposed surfaces of each roll of at least one additional pair of opposed tapered rolls.

[0011] The one or more features may include a first taper angle extending along the outer surface of the tapered roll between the top of the tapered roll and one or more of the first and second ends. Additionally, the top and outer surface of the tapered roll may be configured to apply a compressive force to deform the material. In some embodiments, the tapered roll may include a second taper angle extending between the first taper angle and one or more of the first and second ends of the tapered roll. This taper angle may have a value different from the value of the first taper angle. The value of the first taper angle may be approximately within a range of about 3° to about 60°. In some embodiments, the value of the first taper angle may be approximately within a range of about 5° to about 30°.

[0012] The at least one additional pair of opposed tapered rolls of the system can include at least five pairs of opposed tapered rolls. In at least some such embodiments, each pair can be positioned downstream from one another, and the distance between each roll of each pair of the at least five pairs of opposed tapered rolls can decrease with each subsequent downstream pair of the at least five pairs of opposed tapered rolls. Each roll of the first pair of opposed tapered rolls can rotate in the opposite direction to the opposite tapered roll of the first pair of opposed tapered rolls to drive the material downstream. In some embodiments, the distance between each roll of the end pair of opposed tapered rolls of the at least one additional pair of opposed tapered rolls can be effectively zero. In some embodiments, at least one roll of the first pair of opposed tapered rolls can include multiple tapers, each taper having multiple taper angles.

[0013] The system can prevent substantially any portion of the material from being removed during deformation. In some embodiments, the mass of the deformed material can be substantially the same as the mass of the material before deformation. The material can include one or more of pure iron, steel, stainless steel, copper, martensite, chromium, carbide, nitride, metallic glass, polymer, pearlite, cementite, martensitic steel, aluminum, pearlitic steel, titanium, nickel, cobalt, hydroxyapatite, silver, or gold.

[0014] One exemplary method for producing an edge includes feeding a length of metal material between a first pair of opposed tapered rolls and rotating the first pair of opposed tapered rolls to advance the length of metal material through the first pair of opposed tapered rolls. The pair of opposed tapered rolls induces localized deformation on both sides of the length of metal material. The length of metal material is then split to form two metal pieces, each having a sharp edge including the localized deformation region.

[0015] In some embodiments, the method may further include receiving the length of metal material between at least one additional pair of opposed tapered rolls positioned laterally downstream of the first pair of opposed tapered rolls. In such embodiments, the method may further include rotating the additional pair of opposed tapered rolls to advance the received length of metal material downstream through the rolls. The additional pair of opposed tapered rolls may produce additional localized deformation on both sides of the length of metal material. By rotating the first pair of opposed tapered rolls and the additional pair of opposed tapered rolls and advancing the length of metal material laterally through them, two specular V-shaped notches may be formed along the length of metal material. The method may further include positioning the length of metal material against the first pair of opposed tapered rolls such that edges are formed at the predetermined locations along the length of metal material.

[0016] In some embodiments, the first taper angle can extend along the outer surface of the first pair of opposed tapered rolls between the apex and one or more of the first and second ends of the first pair of opposed tapered rolls. A portion of the outer surface including the first taper angle can engage the length of metal material to deform both sides of the length of metal material. In at least some such embodiments, outside of the predetermined location, substantially no local deformation occurs along the length of metal material.

[0017] In some embodiments, substantially no portion of the length of metallic material can be removed during deformation. Alternatively or additionally, the mass of the length of metallic material after deformation can be substantially the same as the mass of the material before deformation. In some embodiments, the length of metallic material can comprise one or more of stainless steel or pearlitic steel. In some embodiments, the length of metallic material can comprise copper.

[0018] The present disclosure will be more fully understood from the following detailed description taken in conjunction with the accompanying drawings. [Brief explanation of the drawings]

[0019] [Figure 1] FIG. 1 is an enlarged schematic side view of a conventional razor blade showing variations in surface hardness. [Figure 2] FIG. 1 is a perspective view of an exemplary embodiment of a tapered roll used in the just-disclosed system to deform metal. [Figure 3] FIG. 3 is a schematic side view of a continuous taper roll system utilizing multiple taper rolls of FIG. 2. [Figure 4] FIG. 1 is a schematic perspective view of an exemplary embodiment of a set of tapered rolls for deforming material therebetween; [Figure 5A] 5 is a scanning electron microscope image of a cross section of a portion of the material of FIG. 4 before deformation. [Figure 5B] 5 is a scanning electron microscope image of a cross section of a portion of the material of FIG. 4 after deformation, showing notches formed therein. [Figure 6A] 1 is a schematic front view of an exemplary embodiment of a tapered roll, the tapered roll having a taper angle. [Figure 6B] 1 is a schematic front view of another exemplary embodiment of a tapered roll, the tapered roll having a taper angle. [Figure 6C] 1 is a schematic front view of yet another exemplary embodiment of a tapered roll, the tapered roll having two taper angles. [Figure 6D] 1 is a schematic front view of another exemplary embodiment of a tapered roll, the tapered roll having three sets of tapers. [Figure 7A] FIG. 5 is a schematic cross-sectional view of the material of FIG. 4 before deformation. [Figure 7B] FIG. 7C is an enlarged perspective view of the material of FIG. 7B after deformation. [Figure 8] 5 is a scanning electron microscope image of a cross section of a portion of the material of FIG. 4 after deformation, showing variations in hardness within the material.

[0020] Detailed Description Certain exemplary embodiments will now be described to provide a general understanding of the principles of the structure, function, manufacture, and use of the systems, devices, and methods disclosed herein. One or more examples of these embodiments are illustrated in the accompanying drawings. Those skilled in the art will understand that the systems, compositions, and methods specifically described herein and illustrated in the accompanying drawings are non-limiting exemplary embodiments, and that the scope of the present disclosure is defined only by the claims. Features illustrated or described in connection with one exemplary embodiment may be combined with features of other embodiments. Such modifications and variations are intended to be within the scope of the present disclosure.

[0021] To the extent that the present disclosure includes various terms for components and / or processes of the disclosed compositions, systems, methods, etc., those skilled in the art will understand, in light of the claims, the present disclosure, and the knowledge of those skilled in the art, that such terms are merely examples of such components and / or processes, and that other components, designs, processes, and / or actions are possible. As a non-limiting example, those skilled in the art will understand that any number of tapered roll or drum pairs can be used, and that the terms "roll" and "drum" are used interchangeably within the present disclosure. Furthermore, those skilled in the art will understand, in light of the present disclosure, that the terms "space" and "void" can be used interchangeably within the present disclosure to refer to gaps between particles within the microstructure of a material. Furthermore, although the systems, compositions, and methods in the present disclosure are discussed with respect to the production of sharp edges for razor blades, those skilled in the art will recognize that the sharp edges of the present disclosure can be used in other fields and / or for other purposes where a sharp edge is desired. For example, in addition to razor blades, the sharp edges resulting from the present disclosure can have a variety of configurations, sizes, shapes, etc., and can be utilized in connection with creating sharp edges for many different objects, including, but not limited to, scalpels, knives, combat knives, and cutting tools for sugar refining, salt refining, cutting plastic, cutting wood, cutting metal, and cutting rock, among other uses.

[0022] The present disclosure generally relates to systems, compositions, and methods for producing materials with sharp edges. The material can undergo severe plastic deformation at its tip, allowing a sharp edge with high strength and hardness to be formed thereon. The deformation can change the microstructure of the material by applying a compressive force to heterogeneous particulates, narrowing the grain boundaries between them, thereby creating a more homogeneous microstructure. In some embodiments, the increased homogeneity can be achieved without removing material or otherwise substantially changing the mass of the material. For example, deformation at the edge can reduce the size of gaps in the material's granular microstructure, thereby allowing the deformed material to have improved hardness and crack resistance. In an exemplary embodiment, the material can pass through one or more pairs of opposing tapered rolls to apply pressure and locally deform the material. The tapered rolls can be configured to rotate and drive the material in a rotational direction, passing the material between multiple pairs of opposing tapered rolls. The deformed material can have at least one notch formed therein, which can be used as a sharp edge for a razor, scalpel, or the like.

[0023] As mentioned above, the conventional process for creating a sharp edge involves honing a metal material, which reduces the mass of the metal by removing portions of the metal. Honing does not change the inhomogeneity of the blade, which does not improve its hardness or susceptibility to cracking. Furthermore, while the honing process alters the shape of the material into a wedge, the material that makes up the blade is the same material produced through heat treatment, typically a carbide-rich martensitic stainless steel. In some cases, honing the metal can result in excessive thinning, which can make the material more susceptible to cracking.

[0024] Those skilled in the art will recognize that the steel at the tip of a conventional razor blade can be highly heterogeneous. For example, conventional razor blades have a tip coated with several layers, including a hard diamond-like carbon coating to improve wear resistance and a Teflon coating to reduce friction. These razor blades use martensitic stainless steel honed into a wedge shape to form a sharp edge used for cutting. However, in the case of martensite, mechanical properties can vary from point to point. Furthermore, although steel has a high average hardness, strength and / or hardness vary from region to region within the material depending on the presence of certain microstructural features, such as martensite, retained austenite, and / or carbides. These variations in hardness and / or strength can lead to variations at the tip of the blade, which can lead to ridges that make these sharp edges less effective for their intended purpose.

[0025] Despite these measures to improve wear resistance, and the fact that steel is 50 times harder than human hair, razors rarely last more than a few weeks before needing to be discarded and replaced. Hair and steel have complex interactions that result in chipping. For example, during shaving or other grooming procedures, when the blade is angled at an angle to the hair, as is common when used in traditional shaving methods, the hair exerts out-of-plane stresses on the razor that lead to chipping after repeated use.

[0026] FIG. 1 illustrates the non-uniformity of the edge of a conventional razor blade 10. As shown, the conventional razor blade 10 is constructed of a material having multiple regions 12 of varying hardness. For example, the regions 12 of the blade 10 may be characterized as "soft," "semi-hard," "ultra-hard," etc. Those skilled in the art will recognize that for materials used in conventional razors, the "soft" region A may have a hardness range of approximately 4,000 Newtons / square millimeter to approximately 7,000 Newtons / square millimeter, the "semi-hard" region B may have a hardness range of approximately 7,000 Newtons / square millimeter to approximately 10,000 Newtons / square millimeter, and the "ultra-hard" region C may have a hardness range of approximately 10,000 Newtons / square millimeter to approximately 15,000 Newtons / square millimeter.

[0027] The material of a conventional razor blade 10 is typically highly heterogeneous. As shown, the surface of the material is mottled with bumps before use. The material may have regions A, B, and C randomly scattered throughout the material, with each of regions A, B, and C bordering another of regions A, B, and C inconsistently. When a hair or another material contacts one of the many boundaries between regions of varying hardness, a split or crack can occur and propagate throughout the material. For example, in the case of razor blade 10, when a hair presses against soft region A at boundary 14 between soft region A and semi-hard region B, or soft region A and ultra-hard region C, stress is applied to boundary 14. Repeated stresses at boundary 14 can cause cracks to form within blade 10. Those skilled in the art will recognize that cracks are more likely to form at boundaries between regions of different hardness, such as boundaries 14 between regions A and B, regions A and C, and regions B and C. Due to the non-uniform nature of blade 10, as shown in Figure 1, the edge remains non-uniform even as the material is honed. Furthermore, because regions A, B, and C are interspersed throughout blade 10 as shown in Figure 1, the blade is susceptible to crack formation and propagation throughout when hair and other materials contact one or more of regions A, B, C. As discussed above, reducing the non-uniformity of the material at the tip, especially on the radius length scale, can improve blade quality and reduce the likelihood of blade breakage and / or cracking.

[0028] FIG. 2 illustrates an exemplary embodiment of a tapered roll or drum 100 that may be used to deform a material 102. The tapered roll 100 may be configured to contact a surface 104 of the material 102 and apply a force that locally deforms the surface 104 through severe plastic deformation. As shown, the tapered roll 100 may include a substantially cylindrical outer body 106 along which the material 102 may travel. Those skilled in the art will recognize that the roll 100 may rotate to apply a substantially uniform force to the material 102 as the material 102 passes over the roll. The tapered roll 100 may be made of steel, stainless steel, and / or ceramic materials, including, but not limited to, nitrides or carbides such as tungsten carbide.

[0029] The rolls 100 may be used in pairs or sets, for example, so that the material passes between a pair of rolls, and / or in a system in which the tapered rolls are aligned sequentially and / or laterally, e.g., one after the other, to deform the material until desired blade parameters are achieved. FIG. 3 shows an exemplary embodiment of such a system 110 for producing sharp edges. As shown, the system 110 may use sequentially positioned pairs or sets of tapered rolls 100 to deform the material 102 driven therebetween. The system 110 may have one or more pairs of tapered rolls 100 positioned laterally, e.g., in an assembly line configuration, to deform the material 102. As shown, each roll 100 of a pair of tapered rolls is positioned on opposite sides of the material 102 so that the material 102 is positioned therebetween, with each roll 100 contacting opposite surfaces 104 a, 104 b of the material 102. The tapered rolls 100 may be configured to rotate to drive or move the material 102 downstream to a downstream pair of tapered rolls. Each roll 100 in a pair of rolls may rotate in opposite directions to drive the material 102 downstream to the next pair of opposed rolls 100.

[0030] Each pair of downstream rolls 100 applies a force to the material 102 to locally deform the material 102 as it is driven downstream. As shown, the material 102 disposed between a first pair of opposed rolls 100 of the system 110 has a thickness T that gradually decreases as the material 102 moves through the system 110. Additionally, the distance between each downstream pair of opposed rolls 100 can be decreased to accommodate the smaller thickness T of the material therebetween. For example, in the illustrated embodiment, the distance D1 between the rolls 100 in the first pair of opposed tapered rolls, measured from the top 120 along the opposed surface 106 of each roll 100 of the first pair of opposed tapered rolls, is greater than the distance D2 between each roll 100 of at least one additional pair of opposed tapered rolls, measured from the top along the opposed surface of each roll of at least one additional pair of opposed tapered rolls located downstream of the first pair of opposed tapered rolls. In the illustrated embodiment, the distance between each subsequent downstream pair of opposed tapered rolls, e.g., D3, D4, D5, D6, decreases as the material moves downstream through the system 110. Those skilled in the art will recognize that although the distance between the rolls is described as being measured from the top 120, the distance between the rolls 100 may be measured between any corresponding points, such as the centers of the rolls, the top or bottom surfaces of the rolls, etc.

[0031] Additionally, while the above embodiment includes six pairs of opposed taper rolls, those skilled in the art will recognize that the system 110 can include any number of opposed taper rolls 100. For example, in other examples, there may be seven, eight, nine, ten, or more (or fewer) pairs. In embodiments in which multiple pairs of opposed taper rolls are used, it will be understood that each pair of opposed taper rolls can impart a gradual deformation to the material 102 to prevent rapid cracking of the material 102 due to excessive force. Furthermore, those skilled in the art will understand, in light of the present disclosure, that the distance between two rolls in a pair, as well as the distance between successive pairs of rolls in a line of multiple pairs of rolls (i.e., a second pair of rolls downstream from the first pair of rolls), can be varied or otherwise adjusted based on a variety of factors, including, but not limited to, the distance between the pairs before and after a pair, the desired configuration of the material, and the configuration of each roll in that pair. The distance between the end pair of rolls 100t can be, for example, substantially zero, meaning that the rolls can be touching or nearly touching (e.g., within 1 mm of each other) and material passing through them can separate into two or more separate parts. The distance between the end pair of rolls can affect whether the two blades are separated by the rolls themselves (e.g., when the rolls are touching, the rolls can separate the material into two blades) or whether they separate after deformation (e.g., if the distance between the end pair of rolls is far enough apart not to separate the blades).

[0032] The tapered roll 100 can include one or more indicators 130 that indicate which direction the roll 100 rotates or the direction the material 102 is driven. For example, as shown in FIG. 3 , the roll 100 can include a label or image thereon that indicates the direction of rotation. In some embodiments, each pair of rolls can include a first image of an arrow 132 pointing in a direction. For example, the lower roll 100 of a pair of rolls can point in a clockwise direction, while the upper roll 100 of the pair can point in a counterclockwise direction to indicate that the material is moving from left to right. Those skilled in the art will recognize that for material moving from right to left, the lower roll 100 of the pair can point in a counterclockwise direction, while the upper roll 100 of the pair can point in a clockwise direction. It will be understood that other images can be used instead or in addition, such as a text label stating "rotates clockwise," other drawings, etc. It will also be understood that a label may appear on only one roll 100 of a pair of rolls, on one roll in the system 100, or not at all.

[0033] Although each roll 100 in a pair of opposed rolls is shown as having the same configuration, it will be understood that characteristics such as size, shape, material, etc. of each roll in an opposed pair of tapered rolls may differ. Similarly, the size, shape, material, etc. of each roll in additional pairs of opposed tapered rolls may differ from each other, from the rolls in the first pair of tapered rolls, and / or from the rolls in subsequent pairs of opposed tapered rolls. Various characteristics of the rolls 100 that may be used in the just-disclosed system are discussed in further detail below.

[0034] Some non-limiting examples of materials 102 that may be transformed using the presently disclosed system 110 include pure iron, steel, stainless steel, copper, martensite, chromium, carbides, nitrides, metallic glasses, polymers, pearlite, cementite, martensitic steel, aluminum, pearlitic steel, titanium, nickel, cobalt, hydroxyapatite, silver, and / or gold, and any combination thereof. The type of material used may depend, at least in part, on the intended purpose and / or sharpness of the material 102. For example, for sharp edges used on scalpels, one may want to consider other biocompatible materials suitable for acceptance by the human body during surgical procedures. Furthermore, in some embodiments, severe plastic deformation induces cementite dissolution in pearlitic steel and also dissolves M. 23 The C6 carbide can be transformed to M6C by dissolution of atoms in the matrix. In such an embodiment, complete dissolution of the carbide can be achieved as the stress level is increased.

[0035] The deformation of the material 102 resulting from contact with the tapered rolls 100 can be seen in more detail in FIG. 4 , which shows a pair of rolls 100 deforming a portion of the material 102 positioned between them. Deformation of the material 102 via the system 110 described above can cumulatively deform the initial material 102 from one having a rectangular cross-section to one with an "hourglass cross-section," as shown below. Deformation of the material 102 occurs when the material 102 is placed between a pair of opposing rolls 100 and driven downstream in the direction of the arrows. The orientation of the tapered rolls 100 relative to the material 102 can localize the deformation to a central region 134, e.g., the region in contact with the two rolls 100, while the remaining surface 104 is typically not altered in any way, thus retaining the properties of the starting material. It will be appreciated that in some embodiments, the orientation of the rolls 100 relative to the material can be varied, for example, based on the desired location of deformation along the surface of the material 102. As previously mentioned, no material is removed during deformation. Rather, the material 102 is locally deformed to form the final wedge shape by compressing the microstructure of the material 102. After deformation, the material 102 can be driven downstream to the next pair of opposed tapered rolls 100 for further deformation, as described above with respect to FIG.

[0036] 5A and 5B show cross-sectional views of material 102 before and after deformation by tapered roll 100 of FIG. 4. As shown in FIG. 5A, the microstructure of material 102 is composed of large grains 140 of various sizes and shapes. Due to the size of the grains 140, they are dispersed throughout material 102 with one or more spaces 142 between them. The irregular shapes of individual grains 140 result in uneven grain boundaries 144 between two or more grains 140, thereby forming spaces 142 at these grain boundaries 144. Furthermore, as discussed above with respect to FIG. 1, the grains 140 that make up these materials may have different hardnesses. Stresses at these grain boundaries 144, when applied at certain angles, exert uneven forces on the grain boundaries 144, causing friction and relative movement of the grains 140 at the boundaries 144.

[0037] FIG. 5B illustrates an exemplary embodiment of a material 102 that has been locally deformed by a tapered roll 100 at a distal end 102d of the material. As shown, the distal end 102 includes a refined region 146 that includes a notch 150 that forms a sharp edge. As shown, the refined region 146 includes deformed grains 140' that have been compressed to reduce their size to produce a substantially homogeneous microstructure, e.g., the deformed grains 140' in the refined region 146 are substantially uniform in size. As shown, the size of the deformed grains 140' in the refined region 146 is significantly smaller than the unrefined region at the proximal end 102p of the material 102. Furthermore, the size of the deformed grains 140' in the refined region 146 decreases over the length of the material 102, and the deformed grains 140' are located proximate to the notch 150. Those skilled in the art will recognize that a material 102 having a substantially homogeneous microstructure, and / or the substantially uniform size of the deformed grains 140' within the refined region 146, suggests that the size of each grain in the deformed grains 140' is about 75% of the average grain size of the deformed grains, or the size of each grain in the deformed grains 140' is about 90% of the average grain size of the deformed grains, or the size of each grain in the deformed grains 140' is about 95% of the average grain size of the deformed grains, or the size of each grain in the deformed grains 140' is about 100% of the average grain size of the deformed grains, or the size of each grain in the deformed grains 140' is about 110% of the average grain size of the deformed grains, or the size of each grain in the deformed grains 140' is about 115% of the average grain size of the deformed grains, or the size of each grain in the deformed grains 140' is about 125% of the average grain size of the deformed grains. Further, the size of the deformed particles 140' may be about 25% of the size of the particles 140, but in some embodiments the size of the deformed particles 140' may be about 15% of the size of the particles 140, or the size of the deformed particles 140' may be about 10% of the size of the particles 140, or the size of the deformed particles 140' may be about 5% of the size of the particles 140, or the size of the deformed particles 140' may be about 1% or less of the size of the particles 140.

[0038] Reducing the size of the deformed grains 140′ allows the grains to pack closely together, filling the previous spaces 142, thereby substantially eliminating these spaces between the deformed grains 140′. The absence of spaces between the deformed grains 140′ allows the material 102 to exhibit excellent alignment between them, creating grain boundaries 144′ in the central region 134 that are less susceptible to fracture than their macroscopic counterparts. The packing of the deformed grains 140′ can also strengthen the material 102 within the refined region 146, at least in part due to a higher density of load-bearing microstructure within the refined region 146. For example, in embodiments in which the material 102 is pearlitic steel, strengthening in the refined region 146 can occur through the Hall-Petch effect (dislocation accumulation at phase boundaries during plastic deformation), composite effect (plastic co-deformation of nano-sized cementite and ferrite platelets), interfacial strengthening (gradual change in carbon content between the two phases), and / or solid solution strengthening (supersaturated ferrite). In the illustrated embodiment, the strength and hardness of the material 102 is greatest near the notch 150 at the distal end 102d and gradually decreases away from the distal end 102d.

[0039] Those skilled in the art will recognize that the size of the refined region 146 can vary based, at least in part, on the location of the tapered roll 100 relative to the material 102, as well as the material 102 itself. As shown, the refined region 146 is limited to the portion of the material 102 compressed by the tapered roll 100. For example, in some embodiments, the refined region 146 may be approximately 350 μm in size, although this size may be increased or decreased based, at least in part, on the size of the tapered roll 100, the number of rolls in the system 110, the placement of the roll 100 relative to the material 102, etc.

[0040] While the notches 150 as shown have a specular V-shape, in some other embodiments, the notches may be U-shaped, wedge-shaped, or the like. The size and angle of the notches 150 may be modified, at least in part, based on the desired sharpness of the leading edge of the material 102. For example, the angle of the taper in the tapered roll 100 may be varied to vary the sharpness of the leading edge of the material 102. FIG. 6A shows the tapered roll 100 in further detail. The substantially cylindrical body 106 of the tapered roll 100 may include an outer surface 154 extending between a first end 156 and a second end 158. In some embodiments, the tapered roll 100 may resemble two sections of a cylinder oriented to abut against each other to form the body 106. As described above, the body 106 can taper to an apex 120 located approximately in the center of the tapered roll 100, such that the taper of the body 106 between the first end 156 and the second end 158 is symmetrical, as shown. Alternatively, in some embodiments, the apex 120 can be closer to the first end 156 than to the second end 158, or vice versa. The outer surface 154 of the tapered roll 100 can be angled to form a taper along the body 106. As shown, the outer surface 154 can have a taper angle α from the apex 120 toward the first end 156 and the second end 158. The taper angle α can deform the material 102 to form a tip with high resistance at the edge during cutting. For example, the taper angle α can be approximately in the range of about 5° to about 30°, although in some instances the taper angle can be less, e.g., about 3°, or greater, e.g., at least about 60°. A smaller angle can generally provide a sharper edge, while a larger angle can generally result in a greater load being imparted to the blade and, therefore, to the object of which the blade is a part (e.g., a knife that includes the blade).For example, a small angle can be used to produce a very sharp edge, which may be desirable when making razor blades and scalpels, a medium angle can be used to produce a sharp but resistant edge, which may be desirable for knives that need to support high loads during cutting, and a large angle can be used to produce a very damage-resistant and durable cutting tool, which may be desirable for manufacturing commercial products such as salt refining tools and / or cutting tools for plastics and wood. In some embodiments, any and all pairs of rolls can include a flat roll and a tapered roll having a taper angle as provided herein, and the final sharp object exhibits a "chisel edge" rather than a "V-edge," where the "chisel edge" in cross-section is configured to look like half of a "V," with one side forming a substantially straight vertical portion (e.g., like this: | / ).

[0041] Those skilled in the art will recognize that some non-limiting examples of factors that may influence the selected taper angle, number of tapered roll pairs, distance between rolls in a single pair, and distance between successive pairs of rolls may include, but are not limited to, the desired hardness and sharpness of the edge, the type of material from which the edge is formed (e.g., aluminum, steel), and / or the end use of the edge (i.e., is the formed edge intended to be used to cut particularly hard materials, traditionally difficult-to-cut materials, etc.).

[0042] FIG. 6B shows a roll 100' including a tapered intermediate portion 170. As shown, the taper can extend from the apex 120' over a distance of the body 106' that is less than the distance between the apex 120' and either the first end 156' or the second end 158'. That is, the taper angle α can terminate before the first end 156' and / or the second end 158', with the outer body 154' extending substantially perpendicularly from the taper to each of the first end 156' and the second end 158'. Such a configuration can impart localized deformation only in specific regions (e.g., where the sharp edge of the blade will be), thereby enabling the production of large knife bodies, for example, with a substantially constant thickness and a final sharp edge located at a specific location. The taper angle α can be the same as that described above with respect to FIG. 6A, although in some embodiments, this angle can be smaller or larger. As discussed above in connection with Figure 3, those skilled in the art will recognize that the taper angle α of the end pair of rolls can be different from the taper angle of the pair upstream from them. For example, the taper angle of the last pair or pairs of rolls can be different from the taper angle of the first pair or pairs of rolls. Such a configuration can provide possible "separation" on the two sides and / or impart a particular angle to the distal-most tip of the sharp edge.

[0043] The tapered rolls of the present disclosure can have multiple taper angles. For example, FIG. 6C shows a tapered roll 100″ having a taper angle α and a second taper angle β. As shown, the second taper angle β can begin when the taper angle α ends, and the outer surface 154″ continues to taper at the second taper angle β to the first end 156″ and the second end 158″. The overall taper of the outer surface 154″ of the body 106″ in embodiments having both taper angles α and β can result in a large overall angle, making such embodiments useful in industrial applications such as the manufacture of kitchen knives, cutting tools for plastic sheets, and other industrial applications. Those skilled in the art will recognize that in some embodiments, the second taper angle β can end before the first end 156″ and the second end 158″. In some embodiments, the tapered roll can include a third and / or fourth taper angle, and / or other configurations of angles are possible.

[0044] In some embodiments, the tapered roll can include multiple tapers 170''' in each roll. FIG. 6D shows an embodiment of the tapered roll 100''' with three tapers 170''' formed therein. Multiple tapers 170''' can be used to produce multiple sharp edges while using a single roll, as described below. For example, the tapered roll 100''' can be used to simultaneously produce cutting tools with more than two sharp edges. Three tapers 170''' can be used to produce six sharp edges, e.g., two edges per taper, although it will be understood that in some embodiments, the number of tapers and the number of edges per taper can be varied. In some embodiments, a third taper angle (not shown) can be used in the tapers 170''' of the roll 100''', resulting in the material forming three edges per taper 170'''. Additionally, the tapered roll 100''' can include two or more tapers, and one skilled in the art will recognize that this can result in materials with four edges or eight or more edges, respectively. Thus, the tapered roll 100''' can be used as one of a series of laterally arranged rolls in the system 110 or as one roll of a set of opposing pairs of rolls used to deform the material 102.

[0045] The tapers 170''' can be spaced apart from one another by one or more distances c1, c2. While the distances c1, c2 can be measured between the apexes 120''' of each taper 170''', as shown, in some embodiments, the distances c1, c2 can be measured between the respective beginnings of the tapers, the ends of the tapers, and / or any corresponding points on the tapers. Additionally, while the distances c1, c2 are shown as being substantially equal, in some embodiments, the distance c1 can be greater than the distance c2, or vice versa. Some non-limiting example values ​​for the distances c1, c2 can be approximately in the range of about 1 millimeter to about 500 millimeters, or approximately in the range of about 10 millimeters to about 200 millimeters, with the values ​​of the distances c1, c2 being varied based on the purpose of the edge being produced.

[0046] As shown, the tapered roll 100''' can be similar to the tapered roll 100'' in that each taper 170''' of the tapered roll 100''' includes a first taper angle α1, α2, α3 and a second taper angle β1, β2, β3. In some embodiments, similar to the embodiment of FIG. 6C, the second taper angle β1, β2, β3 can begin when the first taper angle α1, α2, α3 ends, and the outer surface 154''' continues to tape at the second taper angle β1, β2, β3.

[0047] In some embodiments, the tapered roll 100''' can include one or more junctions 180''' on the outer surface 154''' of the tapered roll 100''' where the taper angles α1, α2, α3, β1, β2, and β3 terminate. For example, as shown in FIG. 6D , the first taper angle α1 can extend a first distance a1 from the apex 120''' of the first taper 170a''', where a1 is measured between the apex 120''' and the first junction 180a'''. Some non-limiting example values ​​for the distance a1 can be approximately in the range of about 0.001 millimeters to about 100 millimeters. As discussed above, the second taper angle β1 of the first taper 170a''' can begin when the first taper angle α1 terminates, e.g., at the first junction 180a''', and terminate at the second junction 180b'''. The second taper angle β1 can extend over a second distance b1, where b1 is measured between the first junction 180a''' and the second junction 180b'''. Some non-limiting example values ​​for the distance b1 can be approximately in the range of about 0.001 millimeters to about 100 millimeters. The taper angles α2, α3, β2, and β3 of the second taper 170b''' and the third taper 170c''' are measured over distances a2, b2, a3, and b3, respectively. Those skilled in the art will recognize that the above configurations are equally applicable to the second taper 170b''' and the third taper 170c'''. Additionally, the values ​​of one or more of the taper angles α1, α2, α3, β1, β2, β3 and the distances a1, b1, a2, b2, a3, b3 may be the same as and / or different from any other value of the taper angles α1, α2, α3, β1, β2, β3 and the distances a1, b1, a2, b2, a3, b3, at least within the ranges specified for this embodiment.

[0048] 7A and 7B show cross sections of material 102 undergoing deformation by first tapered roll 100. Fig. 7A shows material 102 before deformation, e.g., upstream of first tapered roll 100, while Fig. 7B shows material 102 after deformation by first tapered roll 100, e.g., downstream of the first tapered roll, with a central region 134 that has been transformed into a refined region 146. As shown, once deformed, material 102 can have an hourglass shape with deformation localized to its central region 134, which corresponds to the area compressed by tapered roll 100.

[0049] The refinement region 146 has substantially the same amount of material and / or mass as before deformation. That is, substantially no material was removed as a result of contact with the tapered roll 100. Those skilled in the art will recognize that having substantially the same mass of material and no material removed suggests that the deformed material has at least about 90% of the mass of the deformed material; however, in some embodiments, the mass of the deformed material may be at least about 95% of the mass of the deformed material, or at least about 97% of the mass of the deformed material, or at least about 99% of the mass of the deformed material, or at least about 100% of the mass of the deformed material. The refinement region 146 may then be driven downstream for further deformation by additional opposing pairs of tapered rolls. Once the material 102 is sufficiently deformed, it may be separated, producing two sharp edges, one on each side of the hourglass shape shown in FIG. 7B. Each of these sharp edges may be used as a razor blade, a knife blade, or for other similar purposes.

[0050] The localized deformation of the material 102, as indicated by the refined region 146 located in the central region 134 of the material, results in a microstructure of the material 102 at the tip of the newly formed sharp edge that differs from the microstructure located away from the notch 150. Thus, the localized deformation by the tapered roll makes it possible to target specific properties of the material if desired. For example, the material 102 can be customized to have high hardness and resistance at the notch 150, while the material away from the notch 150 is softer and more flexible. Those skilled in the art will recognize that current honing processes do not achieve such differences in mechanical properties because the heat treatment applied during honing is uniform throughout the entire blade and therefore applies throughout the entire length of the material.

[0051] 8 shows a heat map of hardness variation across the deformed material 102. As shown, the softer, more flexible material located away from the notch 150 maintains larger grain size particles 140, and the hardness of the material 102 gradually increases as the spread of deformed particles 140' increases along the material 102 in the refined region 146 near the notch 150. The refined region 146 near the notch 150 exhibits the greatest amount of deformation and, correspondingly, the greatest hardness. The homogeneity of the deformed particles 140' in this refined region 146 is substantially uniform.

[0052] Examples of the above-described embodiments may include the following. 1. A deformable material, 1. A deformed material comprising a length of metallic material, said length of metallic material having a substantially homogeneous microstructure in at least a deformed portion thereof, said substantially homogeneous microstructure having a plurality of deformed grains of substantially uniform size that are smaller in size than grains in one or more of the non-deformed portions of said length of metallic material and the grains in said deformed portion prior to deformation. 2. The deformable material of claim 1, wherein the length of metallic material comprises one or more of pure iron, steel, stainless steel, copper, martensite, chromium, carbide, nitride, metallic glass, polymer, pearlite, cementite, martensitic steel, aluminum, pearlitic steel, titanium, nickel, cobalt, hydroxyapatite, silver, or gold. 3. The deformed material of claim 1 or 2, wherein the size of the plurality of deformed particles is approximately within a range from about 75% of the average particle size of the deformed particles to about 125% of the average particle size of the deformed particles. 4. The deformable material according to any one of claims 1 to 3, wherein the size of the deformed particles is about 25% of the size of the particles of the non-deformed portion. 5. A deformable material according to any one of claims 1 to 3, wherein the size of the deformed particles is about 25% of the size of the particles before deformation. 6. A system for producing a sharp edge, comprising: a first pair of opposed tapered rolls configured to rotate to drive a material disposed therebetween downstream, the first pair of opposed tapered rolls having one or more features configured to deform the material while it is being driven downstream; at least one additional pair of opposed tapered rolls disposed laterally downstream of the first pair of opposed tapered rolls and configured to rotate to drive material received from the first pair of opposed tapered rolls downstream; Including, each roll of the first pair of opposed tapered rolls includes a somewhat cylindrical configuration, the somewhat cylindrical configuration including a first end, a second end, and an apex, the opposed surfaces of each roll being tapered between the first end and the apex and between the second end and the apex; a distance between each roll of the first pair of opposed tapered rolls, measured from the top along the opposed surfaces of each roll of the first pair of opposed tapered rolls, that is greater than a distance between each roll of the at least one additional pair of opposed tapered rolls, measured from the top along the opposed surfaces of each roll of the at least one additional pair of opposed tapered rolls. 7. The system of claim 6, wherein the one or more features further include a first taper angle extending along an outer surface of the tapered roll between the apex of the tapered roll and one or more of the first end and the second end, and wherein the apex and the outer surface of the tapered roll are configured to apply a compressive force to deform the material. 8. The system of claim 7, wherein the value of the first taper angle is approximately within the range of about 3° to about 60°. 9. The system of claim 8, wherein the value of the first taper angle is approximately within the range of about 5° to about 30°. 10. The system of claim 7, wherein the tapered roll includes a second taper angle extending between the first taper angle and one or more of the first end and the second end of the tapered roll, the second taper angle having a value different from the value of the first taper angle.

[0053] 11. The system of any one of claims 6-10, wherein the at least one additional pair of opposed tapered rolls includes at least five pairs of opposed tapered rolls, each pair disposed downstream from one another, and wherein the distance between each roll of each pair of the at least five pairs of opposed tapered rolls decreases with each subsequent downstream pair of the at least five pairs of opposed tapered rolls. 12. The system of any one of claims 6 to 11, wherein the distance between each roll of the end pair of opposed tapered rolls of the at least one additional pair of opposed tapered rolls is substantially zero. 13. The system of any one of claims 6-12, wherein the material comprises one or more of pure iron, steel, stainless steel, copper, martensite, chromium, carbide, nitride, metallic glass, polymer, pearlite, cementite, martensitic steel, aluminum, pearlitic steel, titanium, nickel, cobalt, hydroxyapatite, silver, or gold. 14. The system of any one of claims 6 to 13, wherein each roll of the first pair of opposed tapered rolls rotates in the opposite direction to the opposite tapered roll of the first pair of opposed tapered rolls to drive the material downstream. 15. The system of any one of claims 6 to 14, wherein substantially no portion of the material is removed during deformation. 16. The system of any one of claims 6 to 15, wherein the mass of the deformed material is substantially the same as the mass of the material before deformation. 17. The system of any one of claims 6-16, wherein at least one roll of the first pair of opposed tapered rolls includes multiple tapers, each taper having multiple taper angles. 18. A method for manufacturing an edge, comprising: feeding a length of metal stock between a first pair of opposed tapered rolls; rotating the first pair of opposed tapered rolls to advance the length of metal material through the first pair of opposed tapered rolls; Including, The pair of opposed tapered rolls induces localized deformation on opposite sides of the length of metal material, causing the length of metal material to split and form two metal pieces, each metal piece having a sharp edge containing the localized deformation area. 19. Receiving the length of metal material between at least one additional pair of opposed tapered rolls positioned laterally downstream of the first pair of opposed tapered rolls; rotating the at least one additional pair of opposed tapered rolls to advance the length of metal material received therethrough downstream; further comprising 20. The method of claim 18, wherein the additional pair of opposed tapered rolls creates additional localized deformation on both sides of the length of metal material. 20. The method of claim 19, wherein the first pair of opposed tapered rolls and the at least one additional pair of opposed tapered rolls are rotated and the length of metal material is advanced laterally therethrough to form two specularly reflective V-shaped notches along the length of metal material.

[0054] 21. The method of claim 19 or 20, wherein a portion of the outer surface of the first pair of opposed tapered rolls between the apex and one or more of the first end and second end of the first pair of opposed tapered rolls, including a first taper angle, engages the length of metal material to deform both sides of the length of metal material. 22. The method of any one of claims 18-21, further comprising positioning the length of metal material against the first pair of opposed tapered rolls such that an edge is formed at the predetermined location along the length of metal material. 23. The method of claim 22, wherein substantially no localized deformation occurs along said length of metallic material outside said predetermined location. 24. A method according to any one of claims 18 to 23, wherein substantially no portion of said length of metallic material is removed during deformation. 25. The method of any one of claims 18 to 24, wherein the mass of the length of metallic material after deformation is substantially the same as the mass of the material before deformation. 26. The method of any one of claims 18 to 25, wherein the length of metallic material comprises copper. 27. The method of any one of claims 18 to 26, wherein the length of metallic material comprises one or more of stainless steel or pearlitic steel.

[0055] Those skilled in the art will appreciate further features and advantages of the present disclosure based on the above-described embodiments. Accordingly, the present disclosure is not to be limited by what has been particularly shown and described, except as indicated by the appended claims. All publications and references cited herein are expressly incorporated herein by reference in their entirety.

[0056] [Embodiment] (1) A deformable material, 1. A deformed material comprising a length of metallic material, said length of metallic material having a substantially homogeneous microstructure in at least a deformed portion thereof, said substantially homogeneous microstructure having a plurality of deformed grains of substantially uniform size that are smaller in size than grains in one or more of the non-deformed portions of said length of metallic material and the grains in said deformed portion prior to deformation. (2) The deformation material of claim 1, wherein the length of metallic material comprises one or more of pure iron, steel, stainless steel, copper, martensite, chromium, carbide, nitride, metallic glass, polymer, pearlite, cementite, martensitic steel, aluminum, pearlitic steel, titanium, nickel, cobalt, hydroxyapatite, silver, or gold. (3) The deformed material of embodiment 1, wherein the size of the deformed particles is approximately within a range of about 75% of the average particle size of the deformed particles to about 125% of the average particle size of the deformed particles. (4) The deformed material of claim 1, wherein the size of the deformed particles is about 25% of the size of the particles in the non-deformed portion. (5) The deformed material of embodiment 1, wherein the size of the deformed particles is about 25% of the size of the particles before deformation.

[0057] (6) A system for producing a sharp edge, comprising: a first pair of opposed tapered rolls configured to rotate to drive a material disposed therebetween downstream, the first pair of opposed tapered rolls having one or more features configured to deform the material while it is being driven downstream; at least one additional pair of opposed tapered rolls disposed laterally downstream of the first pair of opposed tapered rolls and configured to rotate to drive material received from the first pair of opposed tapered rolls downstream; Including, each roll of the first pair of opposed tapered rolls includes a somewhat cylindrical configuration, the somewhat cylindrical configuration including a first end, a second end, and an apex, the opposed surfaces of each roll being tapered between the first end and the apex and between the second end and the apex; a distance between each roll of the first pair of opposed tapered rolls, measured from the top along the opposed surfaces of each roll of the first pair of opposed tapered rolls, that is greater than a distance between each roll of the at least one additional pair of opposed tapered rolls, measured from the top along the opposed surfaces of each roll of the at least one additional pair of opposed tapered rolls. (7) The system of claim 6, wherein the one or more features further include a first taper angle extending along an outer surface of the tapered roll between the apex and one or more of the first end and the second end of the tapered roll, and the apex and the outer surface of the tapered roll are configured to apply a compressive force to deform the material. (8) The system described in embodiment 7, wherein the value of the first taper angle is approximately within the range of about 3° to about 60°. (9) The system described in embodiment 8, wherein the value of the first taper angle is approximately within the range of about 5° to about 30°. (10) The system of claim 7, wherein the tapered roll includes a second taper angle extending between the first taper angle and one or more of the first end and the second end of the tapered roll, the second taper angle having a value different from the value of the first taper angle.

[0058] (11) The system of embodiment 6, wherein the at least one additional pair of opposed tapered rolls comprises at least five pairs of opposed tapered rolls, each pair disposed downstream from one another, and wherein the distance between each roll of each pair of the at least five pairs of opposed tapered rolls decreases with each subsequent downstream pair of the at least five pairs of opposed tapered rolls. (12) The system of embodiment 6, wherein the distance between the end pair of opposed tapered rolls of the at least one additional pair of opposed tapered rolls is substantially zero. 13. The system of claim 6, wherein the material comprises one or more of pure iron, steel, stainless steel, copper, martensite, chromium, carbide, nitride, metallic glass, polymer, pearlite, cementite, martensitic steel, aluminum, pearlitic steel, titanium, nickel, cobalt, hydroxyapatite, silver, or gold. (14) The system of embodiment 6, wherein each roll of the first pair of opposed tapered rolls rotates in a direction opposite to the opposite tapered roll of the first pair of opposed tapered rolls to drive the material downstream. (15) The system of claim 6, wherein substantially no portion of the material is removed during deformation.

[0059] (16) The system of embodiment 6, wherein the mass of the deformed material is substantially the same as the mass of the material before deformation. (17) The system of embodiment 6, wherein at least one roll of the first pair of opposed tapered rolls includes multiple tapers, each taper having multiple taper angles. (18) A method for manufacturing an edge, comprising: feeding a length of metal stock between a first pair of opposed tapered rolls; rotating the first pair of opposed tapered rolls to advance the length of metal material through the first pair of opposed tapered rolls; Including, The pair of opposed tapered rolls induces localized deformation on opposite sides of the length of metal material, causing the length of metal material to split and form two metal pieces, each metal piece having a sharp edge containing the localized deformation area. (19) receiving the length of metal material between at least one additional pair of opposed tapered rolls disposed laterally downstream of the first pair of opposed tapered rolls; rotating the at least one additional pair of opposed tapered rolls to advance the length of metal material received therethrough downstream; further comprising 19. The method of claim 18, wherein the additional pairs of opposed tapered rolls cause further localized deformation on opposite sides of the length of metal material. 20. The method of claim 19, wherein the length of metal material is advanced laterally through rotating the first pair of opposed tapered rolls and the at least one additional pair of opposed tapered rolls, thereby forming two specularly reflective V-shaped notches along the length of metal material.

[0060] 21. The method of claim 19, wherein a portion of an outer surface of the first pair of opposed tapered rolls between the apex and one or more of the first end and second end of the first pair of opposed tapered rolls, which includes a first taper angle, engages the length of metal material to deform both sides of the length of metal material. 22. The method of claim 18, further comprising positioning the length of metal material against the first pair of opposed tapered rolls such that an edge is formed at the predetermined location along the length of metal material. 23. The method of claim 22, wherein substantially no localized deformation occurs along the length of metal material outside the predetermined location. 24. The method of claim 18, wherein substantially no portion of the length of metallic material is removed during deformation. 25. The method of claim 18, wherein the mass of the length of metallic material after deformation is substantially the same as the mass of the material before deformation.

[0061] 26. The method of claim 18, wherein the length of metallic material comprises copper. 27. The method of claim 18, wherein the length of metallic material comprises one or more of stainless steel or pearlitic steel.

Claims

1. 1. A system for producing a sharp edge, comprising: a first pair of opposed tapered rolls configured to rotate to drive a material disposed therebetween downstream, the first pair of opposed tapered rolls having one or more features configured to deform the material while it is being driven downstream; at least one additional pair of opposed tapered rolls disposed laterally downstream of the first pair of opposed tapered rolls and configured to rotate to drive material received from the first pair of opposed tapered rolls downstream; Including, each roll of the first pair of opposed tapered rolls includes a cylindrical configuration, the cylindrical configuration including a first end, a second end, and an apex, the opposed surfaces of each roll being tapered between the first end and the apex and between the second end and the apex; a distance between each roll of the first pair of opposed tapered rolls, measured from the top along the opposed surfaces of each roll of the first pair of opposed tapered rolls, that is greater than a distance between each roll of the at least one additional pair of opposed tapered rolls, measured from the top along the opposed surfaces of each roll of the at least one additional pair of opposed tapered rolls.

2. 10. The system of claim 1, wherein the one or more features further include a first taper angle extending along an outer surface of the tapered roll between the apex and one or more of the first end and the second end of the tapered roll, the apex and the outer surface of the tapered roll configured to apply a compressive force to deform the material.

3. The system of claim 2 , wherein the value of the first taper angle is approximately within a range of about 3° to about 60°.

4. 3. The system of claim 2, wherein the tapered roll includes a second taper angle extending between the first taper angle and one or more of the first end and the second end of the tapered roll, the second taper angle having a value different from a value of the first taper angle.

5. 2. The system of claim 1, wherein the at least one additional pair of opposed tapered rolls includes at least five pairs of opposed tapered rolls, each pair disposed downstream from one another, and wherein the distance between each roll of each pair of the at least five pairs of opposed tapered rolls decreases with each subsequent downstream pair of the at least five pairs of opposed tapered rolls.

6. The system of claim 1 , wherein the distance between each roll of an end pair of opposed tapered rolls of the at least one additional pair of opposed tapered rolls is substantially zero.

7. The system of claim 1 , wherein substantially no portion of the material is removed during deformation.

8. The system of claim 1 , wherein the mass of the material after deformation is substantially the same as the mass of the material before deformation.

9. The system of claim 1 , wherein at least one roll of the first pair of opposed tapered rolls includes multiple tapers, each taper having multiple taper angles.

10. 1. A method of manufacturing an edge, comprising: feeding a length of metal stock between a first pair of opposed tapered rolls; rotating the first pair of opposed tapered rolls to advance the length of metal material through the first pair of opposed tapered rolls; Including, wherein the pair of opposed tapered rolls induces localized deformation on opposite sides of the length of metal material, causing the length of metal material to split and form two metal pieces, each metal piece having a sharp edge containing the localized deformation area.

11. receiving the length of metal stock between at least one additional pair of opposed tapered rolls positioned laterally downstream of the first pair of opposed tapered rolls; rotating the at least one additional pair of opposed tapered rolls to advance the length of metal material received therethrough downstream; further comprising The method of claim 10 , wherein the additional pair of opposed tapered rolls creates additional localized deformation on both sides of the length of metal material.

12. 12. The method of claim 11, further comprising rotating the first pair of opposed tapered rolls and the at least one additional pair of opposed tapered rolls and advancing the length of metal material laterally therethrough to form two specularly reflective V-shaped notches along the length of metal material.

13. 12. The method of claim 11, wherein a portion of an outer surface of the first pair of opposed tapered rolls between a top and one or more of a first end and a second end of the first pair of opposed tapered rolls, which includes a first taper angle, engages the length of metal material to deform both sides of the length of metal material.

14. The method of claim 10 , wherein substantially no portion of the length of metallic material is removed during deformation.

15. The method of claim 10 , wherein the mass of the length of metallic material after deformation is substantially the same as the mass of the metallic material before deformation.

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