Razor Cartridge

Abstract

A razor cartridge is provided that includes a housing and a blade assembly attached to the housing. The blade assembly can include at least one razor blade defined by a substrate including a first portion and a second portion. The first portion can include a first outer surface and a second outer surface. The second portion can include a first section and a second section separated by a parting line. The first section can include a first facet and a final facet. The second section can include a final facet. The final facets of the first and second sections can converge at a tip to define a cutting edge. A shoulder can be positioned between the first and final facets of the first section and define a skin-contacting surface.

Description

[Technical field]

[0001] The present invention relates generally to a razor blade cartridge, and more particularly to a razor blade cartridge having a razor blade with a skin-contacting shoulder. [Background technology]

[0002] A razor cartridge typically comprises a cartridge housing including a cap and a guard structure, and one or more razor blade assemblies located between the cap and the guard structure. A plane may extend between an upper surface of the cap and an upper surface of the guard structure to define a shaving surface. The razor blade assemblies typically comprise razor blades having a symmetrical shape. It is well known that the shaving geometry of a razor cartridge is important in determining the shaving performance of the cartridge. The shaving geometry defines the position and orientation of the blade relative to other skin-contacting parts, particularly the cap and guard structures of the razor cartridge. One parameter of the shaving geometry is the blade exposure, which is the vertical distance that the cutting edge of the blade projects above or below the shaving surface. Summary of the Invention [Problem to be solved by the invention]

[0003] While current razor blades function adequately, improvements in shaving geometry, such as blade shape, may be made to enable next generation products to perform better. [Means for solving the problem]

[0004] According to a first aspect of the present disclosure, a razor cartridge is provided that includes a housing and a blade assembly attached to the housing. The blade assembly may include at least one razor blade defined by a substrate including a first portion and a second portion. The first portion may include a first outer surface and a second outer surface. The second portion may include a first section and a second section separated by a parting line. The first section may include a first facet and a final facet. The second section may include a final facet. The final facets of the first and second sections may converge at a tip to define a cutting edge. A shoulder may be positioned between the first and final facets of the first section and define a skin contacting surface.

[0005] The final facet of the second section may include the second facet, and the final facet of the first section may include the third facet.

[0006] The second section may further include a second facet extending from the second outer surface of the first portion. The final facet of the second section may include a fourth facet and the final facet of the first section may include a third facet.

[0007] The final facet of the second section may be located closer to the parting line than the first and final facets of the first section.

[0008] The first and second outer surfaces of the first portion of the substrate may be generally parallel to one another, and the parting line may pass through the tip and be generally parallel to the first and second outer surfaces of the first portion.

[0009] The first section and the second section of the second portion may define asymmetric first and second sections.

[0010] The first facet may extend directly from the first outer surface of the first portion.

[0011] The housing may include a cap structure and a guard structure. A shaving plane may be defined between the cap structure and the guard structure. The blade assembly may further include a blade support member to which the razor blade substrate is coupled. The blade support member may be configured such that a shoulder positioned between the first and final facets of the first section is positioned in or near the shaving plane. The shoulder may be positioned near the shaving plane when the shoulder is located above or below the shaving plane by a distance less than about 0.2 mm and less than about 0.5 mm, respectively, from the shaving plane.

[0012] The cartridge may further include a first clip and a second clip that are attached to the housing and engage opposite ends of a shoulder of the base plate that defines the razor blade to secure the razor blade within the housing.

[0013] According to a second aspect of the present disclosure, a razor cartridge is provided that includes a housing, a first blade assembly mounted to the housing, the first blade assembly including a first razor blade, and a second blade assembly mounted to the housing, the second blade assembly including a second razor blade. At least one of the first razor blade or the second razor blade may be defined by a substrate including a first portion including a first outer surface and a second outer surface, and a second portion including a first section and a second section separated by a parting line. The first section may include a first facet and a final facet. The second section may include a final facet. The final facets of the first section and the second section may converge at a tip to define a cutting edge. A shoulder may be positioned between the first facet and the final facet of the first section to define a skin contact surface.

[0014] The final facet of the second section may include the second facet, and the final facet of the first section may include the third facet.

[0015] The second section may further include a second facet extending from the second outer surface of the first portion. The final facet of the second section may include a fourth facet and the final facet of the first section may include a third facet.

[0016] The final facet of the second section may be located closer to the parting line than the first facet and the final facet of the first section.

[0017] The first and second outer surfaces of the first portion of the substrate may be generally parallel to one another, and the parting line may pass through the tip and be generally parallel to the first and second outer surfaces of the first portion.

[0018] The first section and the second section of the second portion may define asymmetric first and second sections.

[0019] The first facet may extend directly from the first outer surface of the first portion.

[0020] The housing may further comprise a cap structure and a guard structure. A shaving plane may be defined between the cap structure and the guard structure. The first blade assembly may further comprise a blade support member to which the first razor blade is coupled. The blade support member may be configured such that a shoulder of the substrate defining the first razor blade is positioned in or near the shaving plane. The shoulder may be positioned near the shaving plane when the shoulder is located above or below the shaving plane by a distance less than about 0.2 mm and less than about 0.5 mm, respectively, from the shaving plane.

[0021] The cartridge may further include a first clip and a second clip that are attached to the housing and engage opposite ends of a shoulder of the base plate that defines the first razor blade to secure the first razor blade within the housing.

[0022] A shaving plane of the first razor blade may be defined by a plane extending from a top surface portion of the skin-contacting element forward and rearward of the cutting edge of the first razor blade. The first blade assembly may further include a blade support member to which the first razor blade is coupled. The blade support member may be configured such that a shoulder of the first razor blade is positioned in or near the shaving plane. [Brief description of the drawings]

[0023] 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. 1 is a front view of a razor system including a handle and a razor cartridge according to the present disclosure. [Figure 2A] FIG. 2 is a cross-sectional view of the razor cartridge of FIG. 1. [Figure 2B] 1A-1C are schematic diagrams illustrating the cap and guard structure and first, second, third, fourth and fifth razor blade assemblies of a razor cartridge of the present disclosure. [Figure 3A] FIG. 1 is a cross-sectional side view of an asymmetric razor blade according to a first embodiment of the present disclosure. [Figure 3B] FIG. 3B is an enlarged view of the tip of the razor blade of FIG. 3A. [Figure 3C] FIG. 3C shows the bevel shoulder of the razor blade of FIGS. 3A and 3B located in the shaving plane. [Figure 3D] FIG. 3D is a view taken along line 3D-3D of FIG. 3A. [Figure 4A]FIG. 2 is a cross-sectional side view of an asymmetric razor blade according to a second embodiment of the present disclosure. [Figure 4B] FIG. 4B is an enlarged view of the tip of the razor blade of FIG. 4A. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0024] Introduction 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 to divide 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 of the second portion may function as a hair-cutting surface.

[0025] "Bevel shoulder", "bevel shoulder structure", or "shoulder", which may be used interchangeably, are used herein to refer to a structure on the outer surface of the first section of the second portion of the substrate of a razor blade. The bevel shoulder structure is located where the facets meet in the first section, and the bevel shoulder defines a significant portion of the skin contact surface of the blade. The bevel shoulder may be smooth, rounded, or angled, but is generally a linear structure that runs parallel to the cutting edge. The bevel shoulder structure of the present invention performs most of the skin contact function of the blade, thus reducing pressure from the tip. In providing minimal to zero tip pressure, the shoulder provides the benefit of a highly defined skin guard incorporated in the first section. In an asymmetric blade having a bevel shoulder on the outer surface of the first section of the second portion of the substrate of the blade of the present invention, the cutting force can still be much lower than if the blade substrate were symmetric. This is due to the fact that there is desirably substantially no or minimal bevel shoulder on the hair-cutting side (e.g., the second section of the second portion). Having a significant bevel shoulder on the second section, the section that dominates the hair-cutting effect, would undesirably increase the hair-cutting force. The bevel shoulder of the present invention is described in more detail below.

[0026] As used herein, "partition line" means a line extending through the tip of the tip portion of the blade substrate, separating the second portion into asymmetric first and second sections, and generally parallel to the first and second generally parallel outer surfaces of the first portion that define the blade body of the blade substrate.

[0027] As used herein, a "shaving plane" refers to a plane extending between the top surface of the cap structure of the razor cartridge housing and the top surface of the guard structure of the razor cartridge housing. The "shaving plane" can be a plane tangent to each of the cap structure and the guard structure. In some embodiments, the cap structure, guard structure, and top surface portion in the razor cartridge are not all disposed in the same plane. In such embodiments, the "shaving plane" as used herein is intended to mean a plane extending between the top surface portions of two skin-contacting elements, one immediately in front of the razor blade tip of the razor blade and the other immediately behind it. In the case of a first blade in a series of blades, the shaving plane is defined by a plane extending from the top surface, i.e., the top surface portion, of the guard structure on a first side of the first razor blade tip and the top surface portion plane of the skin-contacting element directly adjacent to and on the second side of the first blade tip. In the case of a middle blade in a series of blades, the shaving plane is defined by a plane extending from the top surface portion of the adjacent skin-contacting element on either side of the middle razor blade tip. In the present invention where the top surface portion on the razor blade may be defined by a bevel shoulder, the top surface portion of the skin-contacting element immediately behind the razor blade tip of the razor blade may include the bevel shoulder of the razor blade. The top surface portion on the skin-contacting element on either side of the razor blade tip may be the top surface on the adjacent razor blade, an element on the razor blade itself (such as a bevel shoulder), or a guard structure. In the case of razor blade 18A in FIG. 2B, the shaving plane is defined by a plane extending from the top surface portion of razor blade 18B, the blade immediately forward of blade 18A, and the bevel shoulder (41, 81) of razor blade 18A. The top surface portion of the razor blade 18B as shown is likewise a bevel shoulder (e.g., 41, 81). For a first blade in a series of blades, such as razor blade 18E in FIG. 2B, the shaving plane is defined by the surface extending from the top surface portion of the preceding guard structure 28 and the top surface portion immediately aft of the razor blade tip, which in this case may be the blade bevel shoulder (e.g., 41, 81) of razor blade 18E.

[0028] With reference to FIG. 1, a shaving razor system 10 includes a handle 12 and a razor cartridge 14. In some embodiments, the razor cartridge 14 may be removably attached to the handle 12 using a connector 20 as shown, while in other embodiments, the razor cartridge 14 may be permanently attached to the handle 12. The razor cartridge 14 may pivot relative to the handle 12. The razor cartridge 14 may include a cartridge housing 16 having one or more blades 18. Although five blades are shown in FIG. 1, it will be understood that any number of blades, more or less, may be mounted within the razor cartridge 14. The blades 18 may be mounted within the cartridge housing 16 and secured with clips 24a and 24b as shown. The cartridge housing 16 may further include a cap structure 22 located near the rear of the cartridge housing 16 and one or more guard structures 28 located near the front of the cartridge housing 16. The cap structure 22 may include one or more lubricating members (not labeled).

[0029] The substrate 30 may be coated. The coating on the substrate 30 may be in the range of 200 to 1500 angstroms, preferably 300 to 1000 angstroms.

[0030] FIG. 3A is a cross-sectional side view of an asymmetric razor blade 18 according to a first embodiment of the present disclosure. The razor blade 18 is defined by a substrate 30 with a first portion 32 including a blade body 132A and a second portion 34 including a tip portion 134A. In the embodiment of FIG. 3A, a dotted line 33 extends between the first portion 32 and the second portion 34. The razor blade 18 may be formed of stainless steel, other metals and / or alloys, plastic, or any other material or combination thereof. The first portion 32 may include first and second generally parallel outer surfaces 32A and 32B and may be defined by a portion of the substrate 30 that is free of facets. The second portion 34 is defined by a parting line SL, which is a slit 36, and a slit 37. 34The casing may comprise a generally asymmetric first section 36 and a second section 38 separated by a dividing line SL, the first section 36 and the second section 38 including third and fourth asymmetric outer surfaces 36A and 38A. 34 may pass through or emanate from tip 46 of tip portion 134A and may be generally parallel to first and second outer surfaces 32A, 32B of first portion 32 of blade substrate 30. See FIG. 3A. Parting line SL 34 may extend through the first portion 32. In the exemplary embodiment of FIGS. 3A and 3B, the dividing line SL 34 does not separate first portion 32 and second portion 34 into equal halves. In the illustrated embodiment, the asymmetric first and second sections 36, 38 of second portion 34 may extend longitudinally different distances away from tip 46.

[0031] The first section 36 includes a first bevel or facet 40 and a third bevel or facet 44, and the second section 38 includes a second bevel or facet 42. The first facet 40 may extend directly from the first outer surface 32A and may be positioned between the first outer surface 32A and the third facet 44. The third facet 44 may extend directly from the first facet 40. A bevel shoulder 41 may be defined where the first facet 40 and the third facet 44 meet. The bevel shoulder 41 is a generally linear (e.g., extending into the page and along the X direction) structure that extends parallel to the cutting edge 19 of the blade 18, as shown, for example, in FIG. 3D. The bevel shoulder 41 may be smooth, rounded, or angled. The second facet 42 may extend directly from the second outer surface 32B. The second facet 42 and the third facet 44 may define a final facet that converges at a tip 46 to define the cutting edge 19 of the blade 18 that performs the cut of the hair. As described further below, during use of the razor blade 18, a bevel shoulder 41 between the first facet 40 and the third facet 44 may contact and move along the skin of a user. The angle Θ' (see FIG. 3A) of the bevel shoulder 41 extending from the first facet 40 to the third facet 44 may be between 162 degrees and 176 degrees.

[0032] Length L of the first facet 40 40 is the length L of each of the second and third facets 42 and 44 42 and L 44 The length L of the third facet 44 may be longer than 1. See Figures 3A and 3B. 44 may be shorter than the length of the second facet 42. In the illustrated embodiment, the length L of the first facet 40 40 may be 100 micrometers to 500 micrometers, and the length L of the second facet 42 42 may be between 8 micrometers and 200 micrometers, and the length L of the third facet 44 44may be between 8 micrometers and 150 micrometers, preferably between 8 micrometers and 50 micrometers. The first facet 40 may extend inward from the first outer surface 32A toward the second outer surface 32B, and the second facet 42 may extend inward from the second outer surface 32B toward the first outer surface 32A. See FIG. 3A. A plane P1 extending through the center of the first portion 32 parallel to the first outer surface 32A and the second outer surface 32B may extend through the first facet 40. See FIG. 3A. As can be seen in FIG. 3A, the plane P1 bisects the first portion 32 into equal halves.

[0033] A first angle β between the first facet 40 and a first line extending from the first outer surface 32A of the first portion 32 1’ is a second angle α between the second facet 42 and a second line extending from the second outer surface 32B of the first portion 32. 2’ 3A and 3B. The third angle α between the third facet 44 and the third line extending from the first facet 40 may be greater than α . See FIG. 1’ is a second angle α between the second facet 42 and a second line extending from the second outer surface 32B of the first portion 32. 2’ The wedge angle φ′ may extend between the second facet 42 and the third facet 44. See FIG. 3B. The value of the wedge angle φ′ may be greater than the first angle β 1’ and the value of the second angle α 2’ and the value of the third angle, α 1’ and may be in the range of 13.5 degrees to 30 degrees. A smaller wedge angle φ′ is advantageous because it may result in a sharper cutting edge of the blade 18. 1’ may be in the range of 8 degrees to 21 degrees, and the second angle α 2’ can be in the range of 1 degree to 12 degrees, preferably 2 degrees to 8 degrees, and the third angle α 1’ The first angle β may be in the range of 4 degrees to 18 degrees, preferably in the range of 8 degrees to 18 degrees. 1’ and the third angle α 1’The sum of and is greater than or equal to the blade contact angle Ω, discussed below.

[0034] As noted above, a parting line SL separates the generally asymmetric first and second sections 36, 38 of the second portion 34 of the razor blade 18. 34 3A. A majority of the second facet 42 is closer to the parting line SL than a majority of each of the first facet 40 and the third facet 44. 34 See Figures 3A and 3B.

[0035] Referring to FIG. 3B, the dividing line SL 34 The first distance D of 4 micrometers from the tip 46 along SL1 At the dividing line SL 34 perpendicular to the dividing line SL 34 A first distance D extending from the first facet 44 to the third facet 44 SL1A and the dividing line SL 34 perpendicular to the dividing line SL 34 The sum of the distance from the tip 46 to the parting line SL and a second distance (not labeled in FIG. 3B) extending from the tip 46 to the second facet 42 may be between 1.0 micrometers and 2.3 micrometers. 34 A second distance D of 8 micrometers along SL2 At the dividing line SL 34 perpendicular to the dividing line SL 34 A first distance D extending from the first facet 40 or the third facet 44 SL2A and the dividing line SL 34 perpendicular to the dividing line SL 34 A second distance D extending from the second facet 42 or the second outer surface 32B of the first portion 32 SL2B The total distance from the tip 46 to the dividing line SL may be 1.9 micrometers to 4.6 micrometers. 34 A third distance D of 16 micrometers along SL3 At the dividing line SL 34 perpendicular to the dividing line SL34 A first distance D extending from the first facet 40 or the third facet 44 SL3A and the dividing line SL 34 perpendicular to the dividing line SL 34 A second distance D extending from the second facet 42 or the second outer surface 32B of the first portion 32 SL3B The sum of may be 3.8 micrometers to 9.2 micrometers.

[0036] FIG. 2A is a cross-sectional view of the razor cartridge 14. The razor cartridge 14 further includes first, second, third, fourth and fifth razor blade assemblies 180A-180E including first, second, third, fourth and fifth razor blades 18A-18E, each configured to correspond to the razor blade 18 shown in FIG. 3A and FIG. 3B. The first blade assembly 180A may include a first blade 18A and a first blade support member or blade carrier 120A coupled to the first blade 18A. The second blade assembly 180B may include a second blade 18B and a second blade support member or blade carrier 120B coupled to the second blade 18B. The third blade assembly 180C may include a third blade 18C and a third blade support member or blade carrier 120C coupled to the third blade 18C. The fourth blade assembly 180D may include a fourth blade 18D and a fourth blade support member or blade carrier 120D coupled to the fourth blade 18D. The fifth blade assembly 180E may include a fifth blade 18E and a fifth blade support member or blade carrier 120E coupled to the fifth blade 18E. The blade support members 120A-120E may comprise, for example, stainless steel. The blade support members 120A-120E may be integral with their corresponding blades 18A-18E, or alternatively, the blades 18A-18E may be fixedly coupled to their respective blade support members 120A-120E, such as by welding, adhesive, or other suitable techniques. Each blade assembly 180A-E may be mounted within the cartridge housing 16 of the razor cartridge 14. The blade support members 120A-E may be positioned within respective blade slots 162A-E extending in the X-direction of the housing 16 (see FIG. 1) within the cartridge housing 16 and may be fixed or floating. For example, the blade support members 120A-E may be resiliently mounted within the housing and biased to their elevated rest position (i.e., not loaded by shaving forces) via polymer leaf spring arms (not shown). One example of this is disclosed in U.S. Pat. No. 10,391,652, the entire disclosure of which is incorporated herein by reference.Blade assemblies 180A-180E may be secured together by clips 24B (only one of which is illustrated in FIG. 2A) or other known assembly methods.

[0037] 2B is a schematic diagram of the cap structure 22, guard structure 28, and first, second, third, fourth, and fifth razor blade assemblies 180A-180E of the razor cartridge 14 of FIG. 2A. With reference to FIG. 2B, a plane extending between an upper surface of the cap structure 22 and an upper surface of the guard structure 28 of the cartridge housing 16 of the razor cartridge 14 is referred to as a shaving plane P. S , i.e., a plane tangent to each of the cap structure and guard structure 22 and 28. For razor cartridge embodiments in which the cap structure, guard structure and top portion of the razor blade do not all lie in the same plane, the "shaving plane" of a given razor blade in such a razor cartridge may be defined as the plane extending between the skin-contacting elements immediately in front of and immediately behind the razor blade tip of a given razor blade. For example, in a modified embodiment as shown in phantom in FIG. 2B, the top portion of blade 18E' is located slightly below the location of blade 18E shown in solid lines, as well as the location of the top surface of guard structure 28. The shaving plane P of modified blade 18E' may be defined as the plane extending between the skin-contacting elements immediately in front of and immediately behind the razor blade tip of a given razor blade. S’ extends from the top surface of guard structure 28' to the top portion of the skin-contacting element behind the tip of blade 18E, including the beveled shoulder of blade 18E'.

[0038] It is well known that the shaving geometry of a razor cartridge is important in determining the shaving performance of the cartridge. Shaving geometry defines the position and orientation of the blade relative to other skin-contacting parts, particularly the cap and guard structures of the razor cartridge. One parameter of shaving geometry is blade exposure, which is the vertical distance that the cutting edge of the blade projects above or below the shaving plane. In the embodiment shown in FIG. 2B, the first, second, third, fourth and fifth blade support members 120A-120E are aligned such that the bevel shoulder 41 of the substrate 30 defining each blade 18A-18E is aligned with the shaving plane P. S3A-3C. More specifically, each of the blade support members 120A-120E may include a lower portion 121A and an upper portion 121B, with the upper portion 121B at an angle Θ of 100 degrees to 125 degrees relative to the lower portion 121A. 121 2B. The upper portion 121B of each blade support member 120A-120E may be bonded to an outer surface 32B of the first portion 32 of the substrate 30 that defines a corresponding blade 18A-18E. Due to the asymmetric shape of the substrate 30 and the angle Θ between the lower portion 121A and the upper portion 121B of each blade support member, 121 As a result, the bevel shoulder 41 of the base plate 30 that defines each of the blades 18A to 18E is aligned with the shaving plane P S The endoscopic imaging system may be located within or near the endoscopic imaging system, see also Figures 3A-3C.

[0039] 3B and 3C, the bevel shoulder 41 extends in the X direction (see FIGS. 1 and 3A) such that a portion of the bevel shoulder 41 is aligned with the shaving plane P S That is, when it is located within the shaving plane P S is in contact with the portion of the bevel shoulder 41 or a portion of the bevel shoulder 41 is in contact with the shaving plane P S A distance D1 of less than about 0.2 mm from the shaving plane P S or slightly above the shaving plane P S A distance D2 of less than about 0.5 mm from the shaving plane P S When the shaving plane P is located slightly below the S The bevel shoulder 41 is considered to be located within or near the shaving plane P. See FIG. S When positioned within or near the blade support member 121A, the cutting edge 19 of the blade 18 is aligned with the blade support member 121B at an angle Θ between the lower and upper portions 121A, 121B of the blade support member 121A. 121 Therefore, the vertical distance D 46 Only shaved plane P S The vertical distance D 46can be in the range of 0 micrometers to 46.4 micrometers, preferably including 20 micrometers. See FIG. 3B. The cutting edge 19 of the blade 18 is preferably aligned with the shaving plane P S Because the bevel shoulder 41 is positioned below the skin edge 19, the cutting edge 19 is spaced from the skin during shaving to improve shaving comfort and reduce skin irritation. Also, because of the large angle Θ' of the bevel shoulder 41, the bevel shoulder 41 defines a generally smooth surface for engaging the user's skin, thereby reducing friction as the blade moves across the skin during shaving. See also FIG. 2B.

[0040] As described above, the blades 18A-18E may be mounted within the cartridge housing 16 and secured with clips 24A and 24B. The bevel shoulder 41 of the substrate 30 that defines each blade 18A-18E is aligned with the shaving plane P. S Because the blades 18A-18E are positioned in or near the shaving plane (see also FIGS. 3A-3C), clips 24A and 24B engage bevel shoulder 41 of each blade 18A-18E (see FIG. 2A). Prior art razor blades were aligned with features during a welding operation to secure the blades to the corresponding blade support members. The alignment features often damage or shatter the ends of the blade tips. In prior art razor cartridges where the blade tips were positioned in or near the shaving plane, the clips engage the ends of the blade tips. However, because the ends of the blade tips were shattered during a prior welding operation, engagement of the shattered blade tips with the clips resulted in an indeterminate position of the blade cutting edge relative to the shaving plane. In the present invention, clips 24A and 24B engage bevel shoulder 41 of each blade 18A-18E (which shoulder 41 is not normally damaged during a prior welding operation) so that the position of blade cutting edge 19 along its entire extent is more consistently and predictably located relative to the shaving plane.

[0041] Another important factor in the shaving geometry is the blade contact angle Ω (see FIG. 3A), which is the angle between the parting line SL of the asymmetric blade 18 and the 34 But the shaving plane S PIn the embodiment of Figures 3A and 3B, the blade contact angle Ω can be in the range of 10 degrees to 36 degrees, and is preferably 17 degrees.

[0042] 4A is a cross-sectional side view of an asymmetric razor blade 50 according to a second embodiment of the present disclosure. The razor blade 50 is defined by a substrate 70 with a first portion 72 including a blade body and a second portion 74 including a tip portion. In the embodiment of FIG. 4A, a dotted line 73 extends between the first portion 72 and the second portion 74. The razor blade 50 may be formed from stainless steel, other metals and / or alloys, plastic, or any other material or combination thereof. The first portion 72 may include first and second generally parallel outer surfaces 72A and 72B, respectively. The second portion 74 is defined by a parting line SL. 74 The casing may comprise a generally asymmetric first section 76 and a second section 78 separated by a dividing line SL, the first section 76 and the second section 78 including a third asymmetric outer surface 76A and a fourth asymmetric outer surface 78A. 74 The parting line SL may pass through the tip 88 of the tip portion 74 and may be generally parallel to the first outer surface 72A and the second outer surface 72B of the first portion 72 of the blade substrate 70. See FIG. 3A. 74 may extend through the first portion 72. In the exemplary embodiment of FIGS. 4A and 4B, the dividing line SL 74 does not separate first portion 72 and second portion 74 into equal halves.

[0043] The first section 76 includes a first facet 80 and a third facet 84, and the second section 78 includes a second facet 82 and a fourth facet 86. The first facet 80 may extend directly from the first outer surface 72A and may be positioned between the first outer surface 72A and the third facet 84. The third facet 84 may extend directly from the first facet 80. A bevel shoulder 81 may be defined where the first facet 80 and the third facet 84 meet. The bevel shoulder 81 may be smooth, rounded, or angled. The bevel shoulder 81 is a generally linear (e.g., extending into the paper or along the X-direction) structure that extends parallel to the cutting edge 50A, as shown, for example, in FIG. 3D. The second facet 82 may extend directly from the second outer surface 72B and may be positioned between the second outer surface 72B and the fourth facet 86. The fourth facet 86 may extend directly from the second facet 82. The third facet 84 and the fourth facet 86 may define a final facet that converges at a tip 88 to define a cutting edge 50A of the blade 50 that performs the cutting of the hair. As described further below, during use of the razor blade 50, the first bevel shoulder 81 between the first facet 80 and the third facet 84 may contact and move along the skin of a user. The angle Θ (see FIG. 4A) of the bevel shoulder 81 extending from the first facet 80 to the third facet 84 may be between 162 degrees and 176 degrees.

[0044] The length L of the first and second facets 80 and 82 80 , L 82 is the length L of each of the third and fourth facets 84 and 86 84 and L 86 See FIG. 4A. As shown in FIG. 4A, the length of the second facet 82 may be longer than the length of the first facet 80. The length L of the third facet 84 may be longer than the length of the first facet 80. 84 is the length L of the fourth facet 86 86In the illustrated embodiment, the length L of the first facet 80 is 80 may be 100 micrometers to 500 micrometers, and the length L of the second facet 82 82 may be 100 micrometers to 1000 micrometers, and the length L of the third facet 84 84 may be 8 micrometers to 150 micrometers, preferably 8 micrometers to 50 micrometers, and the length L of the fourth facet 86 86 may be between 8 micrometers and 200 micrometers. The first facet 80 may extend inwardly from the first parallel outer surface 72A at a first angle β1, the second facet 82 may extend inwardly from the second parallel outer surface 72B at a second angle β2, the third facet 84 may extend inwardly from the first facet 80 at a third angle α1, and the fourth facet 86 may extend inwardly from the second facet 82 at a fourth angle α2. See FIG. 4A. A plane P2 extending through the center of the first portion 72 parallel to the first outer surface 72A and the second outer surface 72B may extend through the first facet 80. See FIG. 4A.

[0045] A first angle β1 between the first facet 80 and a first line extending from the first outer surface 72A of the first portion 72 may be greater than a second angle β2 between the second facet 82 and a second line extending from the second outer surface 72B of the first portion 72. A third angle α1 between the third facet 84 and a third line extending from the first facet 80 may be greater than a fourth angle α2 between the fourth facet 86 and a fourth line extending from the second facet 82. A wedge angle φ may extend between the third facet 84 and the fourth facet 86. A value of the wedge angle φ may be equal to the sum of a value of the first angle β1, a value of the second angle β2, a value of the third angle α1, and a value of the fourth angle α2. The first angle β1 may be in the range of 8 degrees to 18 degrees, the second angle β2 may be in the range of 0.5 degrees to 6.0 degrees, the third angle α1 may be in the range of 4 degrees to 18 degrees, preferably 8 degrees to 18 degrees, and the fourth angle α2 may be in the range of 1 degree to 12 degrees, preferably 2 degrees to 8 degrees. The sum of the first angle β1 and the second angle β2 may be in the range of 8.5 degrees to 24 degrees. The sum of the first angle β1 and the third angle α1 may be in the range of 12 degrees to 28.5 degrees. The sum of the second angle β2 and the fourth angle α2 may be in the range of 1.5 degrees to 18 degrees. The difference between the first angle β1 and the second angle β2 may result in an asymmetric first section 36 and second section 38 and may be in the range of 4 degrees to 17.5 degrees. Preferably, the second angle β2 is greater than or equal to the overall thickness T of the blade 50. 50 may be minimized. The first angle β1, the second angle β2, the third angle α1, and the fourth angle α2, which define the wedge angle φ, may be within a range of 13.5 degrees to 30 degrees. A smaller wedge angle φ is advantageous because it may result in a sharper cutting edge 50A of the blade 50.

[0046] As noted above, a parting line SL separates the generally asymmetric first and second sections 76 and 78 of the second portion 74 of the razor blade 50. 744A. A majority of the second facet 82 and the fourth facet 86 are closer to the parting line SL than a majority of the first facet 80 and the third facet 84, respectively. 74 4A and 4B.

[0047] Referring to FIG. 4B, the dividing line SL 74 The first distance D of 4 micrometers from the tip 88 along SL10 At the dividing line SL 74 perpendicular to the dividing line SL 74 A first distance D extending from the first facet 82 to the third facet 84 SL10A and the dividing line SL 74 perpendicular to the dividing line SL 74 The sum of the distance from the tip 88 to the parting line SL and a second distance (not labeled in FIG. 4B) extending from the tip 88 to the fourth facet 86 may be between 1.0 micrometers and 2.3 micrometers. 74 A second distance D of 8 micrometers along SL11 At the dividing line SL 74 perpendicular to the dividing line SL 74 A first distance D extending from the first or third facet 80, 84 SL11A and the dividing line SL 74 perpendicular to the dividing line SL 74 A second distance D extending from the second or fourth facet 82, 86 SL11B The total distance from the tip 46 to the dividing line SL may be 1.9 micrometers to 4.6 micrometers. 74 A third distance D of 16 micrometers along SL12 At the dividing line SL 74 perpendicular to the dividing line SL 34 A first distance D extending from the first or third facet 80, 84 SL12A and the dividing line SL 74 perpendicular to the dividing line SL 74 A second distance D extending from the second or fourth facet 82, 86 SL12BThe sum is 3.8 micrometers to 9.2 micrometers.

[0048] The razor blade 50 of Figures 4A and 4B may be used in place of one or more of the razor blades 18, 18A-18E used in the razor cartridge 14 of Figures 1 and 2A. Just as the razor blades 18A-18E are coupled to the first, second, third, fourth and fifth blade support members 120A-120E, each razor blade 50 used in the razor cartridge 14 will also be coupled to a corresponding blade support member. The blade support members will then be positioned within respective blade slots extending within the cartridge housing and may be fixed or free-floating. Each blade assembly including the blade 50 may be secured by clips or other known assembly methods.

[0049] As discussed above in connection with FIG. 2B, each of the blade support members may include a lower portion 121A and an upper portion 121B, with the upper portion 121B at an angle Θ of 100 degrees to 125 degrees relative to the lower portion 121A. 121 The upper portion 121B of each blade support member may be bonded to a second facet 82 of the second portion 74 of the substrate 70 that defines a corresponding blade 50. Due to the asymmetric shape of the substrate 70 and the angle Θ between the lower portion 121A and the upper portion 121B of each blade support member, 121 Thus, the bevel shoulder 81 of the substrate 30 defining each blade 50 is aligned with the shaving plane P S The ion exchange membrane may be located within or adjacent to the ion exchange membrane, see also Figures 4A-4B.

[0050] As noted above, the second facets 82 may extend inwardly from the second parallel outer surface 72B at a second angle β2. Because the upper portion 121B of each blade support member is coupled to the second facets 82 of its corresponding blade 50 rather than to the outer surface of the first portion, similar to the blade 18 of FIGS. 3A-3C, the cutting edge 50A of the blade 50 is aligned closer to the shaving plane P than the cutting edge 19 of the blade 18 of the embodiment of FIGS. S The cutting edge 50A is located further away from the shaving plane P SThis provides the advantageous advantage of improved comfort during shaving as it is located further away from the

[0051] 4B, the bevel shoulder 81 extends in the X direction (see FIGS. 1 and 4A) such that a portion of the bevel shoulder 81 is aligned with the shaving plane P S That is, when it is located within the shaving plane P S is in contact with the portion of the bevel shoulder 81, or a portion of the bevel shoulder 81 is in contact with the shaving plane P S 3C) from the shaving plane P S or slightly above the shaving plane P S 3C) from the shaving plane P S When the shaving plane P is located slightly below the S The bevel shoulder 81 is considered to be located within or near the shaving plane P S When positioned within or near the blade support member 121A, the cutting edge 50A of the blade 50 is aligned with the blade support member 121B at an angle Θ between the lower and upper portions 121A, 121B of the blade support member 121A. 121 Therefore, the vertical distance D 76 Only shaved plane P S When the upper portion 121B of the blade support member is coupled to the second facet 82 of the blade 50, the distance D 76 can be changed by varying the second angle β2 between the second facet 82 and the second parallel outer surface 72B of the blade 50. 76 The cutting edge 50A of the blade 50 is aligned with the shaving plane P S , so that the cutting edge 50A is spaced from the skin during shaving to improve shaving comfort and reduce skin irritation.

[0052] Additionally, because of the large angle Θ of the beveled shoulder 81, the beveled shoulder 81 defines a generally smooth surface for engaging the user's skin, thereby reducing friction as the blade 50 moves across the skin during shaving.

[0053] When the razor blade 50 is used in a razor cartridge, the blade contact angle Ω may be in the range of 10 degrees to 36 degrees, preferably 17 degrees.

[0054] The representative embodiments of the present disclosure described above can be described as follows. A. A razor cartridge comprising: Housing and A blade assembly mounted in a housing, a first portion including a first outer surface and a second outer surface; a blade assembly including at least one razor blade defined by a substrate comprising: a second portion including a first section and a second section separated by a parting line, the first section including a first facet and a final facet, the second section including a final facet, the final facets of the first and second sections converging at a tip to define a cutting edge, and a shoulder positioned between the first and final facets of the first section and defining a skin contacting surface. B. The razor cartridge of paragraph A, wherein the final facet of the second section includes the second facet and the final facet of the first section includes the third facet. C. The razor cartridge of paragraph A, wherein the second section further includes a second facet extending from the second outer surface of the first portion, a final facet of the second section includes a fourth facet, and a final facet of the first section includes a third facet. D. The razor cartridge of any one of paragraphs A-C, wherein the final facet of the second section is located closer to the parting line than the first and final facets of the first section. E. The razor cartridge of any one of paragraphs A-D, wherein the first outer surface and the second outer surface of the first portion of the substrate are generally parallel to one another, and the parting line passes through the tip and is generally parallel to the first outer surface and the second outer surface of the first portion. F. The razor cartridge of any one of paragraphs A-E, wherein the first section and the second section of the second portion define asymmetric first and second sections. G. The razor cartridge of any one of paragraphs A-F, wherein the first facet extends directly from the first exterior surface of the first portion. H. The razor cartridge of any one of paragraphs A-G, wherein the housing comprises a cap structure and a guard structure, a shaving plane defined between the cap structure and the guard structure, and the blade assembly further comprises a blade support member to which the razor blade substrate is coupled, the blade support member configured such that a shoulder positioned between the first facet and the final facet of the first section is positioned within or near the shaving plane. I. The cartridge of paragraph H, wherein the shoulder is positioned near the shaving plane when the shoulder is located above or below the shaving plane by a distance less than about 0.2 mm and less than about 0.5 mm, respectively, from the shaving plane. J. The cartridge of any one of paragraphs A-I, further comprising a first clip and a second clip attached to the housing and engaging opposite ends of the shoulder of the base plate defining the razor blade to secure the razor blade within the housing. K. A razor cartridge comprising: Housing and a first blade assembly mounted to the housing, the first razor blade assembly including a first razor blade; a second blade assembly mounted to the housing, the second blade assembly including a second razor blade; At least one of the first razor blade or the second razor blade is defined by a substrate, the substrate comprising: a first portion including a first outer surface and a second outer surface; a second portion including a first section and a second section separated by a parting line, the first section including a first facet and a final facet, the second section including a final facet, the final facets of the first and second sections converging at a tip to define a cutting edge, and a shoulder positioned between the first and final facets of the first section and defining a skin contacting surface. L. The razor cartridge of paragraph K, wherein the final facet of the second section includes the second facet and the final facet of the first section includes the third facet. M. The razor cartridge of paragraph K, wherein the second section further includes a second facet extending from the second outer surface of the first portion, a final facet of the second section includes a fourth facet, and a final facet of the first section includes a third facet. N. The razor cartridge of any one of paragraphs K-M, wherein the final facet of the second section is located closer to the parting line than the first and final facets of the first section. O. The razor cartridge of any one of paragraphs K-N, wherein the first outer surface and the second outer surface of the first portion of the substrate are generally parallel to one another, and the parting line passes through the tip and is generally parallel to the first outer surface and the second outer surface of the first portion. P. The razor cartridge of any one of paragraphs K-O, wherein the first section and the second section of the second portion define asymmetric first and second sections. Q. The razor cartridge of any one of paragraphs K-P, wherein the first facet extends directly from the first outer surface of the first portion. R. The razor cartridge of any one of paragraphs K-Q, wherein the first razor blade is defined by a substrate, the substrate having a first portion and a second portion, including a shoulder positioned between the first and final facets of the first section, the housing further includes a cap structure and a guard structure, a shaving plane is defined between the cap structure and the guard structure, and the first blade assembly further includes a blade support member to which the first razor blade is coupled, the blade support member configured such that the shoulder of the substrate defining the first razor blade is positioned within or near the shaving plane. S. The cartridge of paragraph R, wherein the shoulder is positioned near the shaving plane when the shoulder is located above or below the shaving plane by a distance less than about 0.2 mm and less than about 0.5 mm, respectively, from the shaving plane. T. The cartridge of any one of paragraphs K-S, further comprising a first clip and a second clip attached to the housing and engaging opposite ends of the shoulder of the base defining the first razor blade to secure the first razor blade within the housing. U. The razor cartridge of any one of paragraphs K-Q or T, wherein the first razor blade is defined by a substrate having a first portion and a second portion and including a shoulder positioned between the first and final facets of the first section, a shaving plane for the first razor blade is defined by a plane extending from the top surface portion of the skin-contacting element forward and rearward of the cutting edge of the first razor blade, and the first blade assembly further comprises a blade support member to which the first razor blade is coupled, the blade support member configured such that the shoulder of the first razor blade is positioned in or near the shaving plane.

[0055] The illustrations presented herein are not intended to be actual representations of any particular substrate, apparatus (e.g., device, system, etc.), or method, but rather are merely idealized and / or schematic diagrams used to describe and illustrate various embodiments of the present disclosure.

[0056] Dimensions and values ​​disclosed herein should not be understood as being strictly limited to the exact numerical values ​​recited. Instead, unless otherwise indicated, 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."

[0057] 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 stated to the contrary. 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 such invention, either alone or in combination with any other reference(s). Furthermore, to the extent that 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 assigned to that term in this document shall govern.

[0058] 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 razor cartridge comprising: Housing and A blade assembly mounted to the housing, a first portion including a first outer surface and a second outer surface; a second portion including a first section and a second section separated by a parting line, the first section including a first facet and a final facet, the second section including a final facet, the final facets of the first and second sections converging at a tip to define a cutting edge, a shoulder positioned between the first and final facets of the first section and defining a skin contacting surface; a blade assembly including at least one razor blade defined by a substrate comprising: the first and second outer surfaces of the first portion of the substrate are generally parallel to one another, the parting line passes through the tip and is generally parallel to the first and second outer surfaces of the first portion; 11. A razor cartridge comprising: a housing having a cap structure and a guard structure, a shaving plane optionally defined between the cap structure and the guard structure; and a blade assembly further comprising a blade support member to which the razor blade substrate is coupled, the blade support member configured such that the shoulder positioned between the first facet and the final facet of the first section is positioned in or near the shaving plane, the blade support member comprising a lower portion and an upper portion, the upper portion extending at an angle between 100 degrees and 125 degrees relative to the lower portion.

2. 10. The razor cartridge of claim 1, wherein said final facet of said second section includes a second facet and said final facet of said first section includes a third facet.

3. 2. The razor cartridge of claim 1, wherein said second section further includes a second facet extending from said second outer surface of said first portion, said final facet of said second section including a fourth facet and said final facet of said first section including a third facet.

4. 10. The razor cartridge of claim 1, wherein said final facet of said second section is located closer to said parting line than said first facet and said final facet of said first section.

5. 10. The razor cartridge of claim 1, wherein said first section and said second section of said second portion define asymmetric first and second sections.

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

7. 2. The cartridge of claim 1, wherein the shoulder is positioned near the shaving plane when the shoulder is located above or below the shaving plane by a distance less than about 0.2 mm and less than about 0.5 mm, respectively, from the shaving plane.

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

9. 10. The razor cartridge of claim 1, wherein a shaving plane of said at least one razor blade is defined by a plane extending from a top surface portion of a skin-contacting element forward and rearward of said cutting edge of said at least one razor blade, said blade assembly further comprising a blade support member to which said at least one blade is coupled, said blade support member configured such that said shoulder of said at least one razor blade is positioned within or near said shaving plane.

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