Razor Cartridge

Abstract

The razor cartridge (20) comprises three or more substantially parallel cutting members (28a-d) disposed between a front longitudinal side (24) and a rear longitudinal side (25) of the razor cartridge in a shaving direction (S) of the razor cartridge. Each of the cutting members (28a-d) comprises a blade support (32) having, in use, a blade mounting portion (71) disposed on an inner surface (66) of the respective blade support facing away from the shaving plane (SH), and a blade (33) attached to the blade mounting portion (71). The cutting members (28a-d) are arranged to define a plurality of inter-blade spans (40, 41, 42) between the cutting edges (30) of the blades. The front inter-blade span (40) closer to the front longitudinal side (24) of the razor cartridge than the rear inter-blade span (42) is different from the rear inter-blade span (42) closer to the rear longitudinal side (25) of the razor cartridge than the front inter-blade span.

Description

[Technical field]

[0001] This application claims the benefit of European Patent Application Nos. EP19154897.3, filed January 31, 2019, EP19177659.0, filed May 31, 2019, and EP19177663.2, filed May 31, 2019, the contents of which are incorporated herein by reference.

[0002] DETAILED DESCRIPTION OF THE DISCLOSURE The embodiments described in the following disclosure relate to razor cartridges, methods of manufacturing razor cartridges, shaving razor assemblies, and associated kits of parts. [Background technology]

[0003] A razor cartridge (also called a safety razor cartridge) is permanently or removably attached to a razor handle that is oriented in a shaving direction during use. A razor cartridge typically has one or more cutting members, each of which supports a blade mounted perpendicular to the shaving direction. A razor cartridge is typically further provided with a guard (on the front longitudinal side of the razor cartridge in the shaving direction) and a cap (on the rear longitudinal side of the razor cartridge in the shaving direction). A skin care element is often also provided on the rear longitudinal side. In use, a user holds the razor handle in the shaving direction and contacts the razor cartridge with a portion of the skin that defines a shaving plane.

[0004] Typically, the shaving plane is defined as, for example, a tangent line intersecting the first and second skin contact points of the cutting edge of the shaving head. More simply, the shaving plane may be approximated as a line between the highest points on the skin contact surface of the razor cartridge, for example, a plane between the top of the guard and the top of the cap of the shaving head. When the razor handle is moved, the blades of the razor cartridge move across the shaving plane in the shaving direction, allowing the blades to remove unwanted hair.

[0005] The performance of the razor cartridge can be further improved. Summary of the Invention

[0006] According to a first aspect, there is provided a razor cartridge comprising three or more substantially parallel cutting members disposed between a front longitudinal side and a rear longitudinal side of the razor cartridge in a shaving direction of the razor cartridge.

[0007] Each of the cutting members comprises a blade support which, in use, comprises a blade mounting portion disposed on an inner surface of the respective blade support facing away from the shaving plane SH, and a blade attached to the blade mounting portion.

[0008] The cutting members are positioned to define a plurality of inter-blade spans between the cutting edges of the blades.

[0009] The front interblade span closer to the front longitudinal side of the razor cartridge than the rear interblade span is different from the rear interblade span closer to the rear longitudinal side of the razor cartridge than the front interblade span.

[0010] In embodiments, the front inter-blade span closer to the front longitudinal side of the razor cartridge than the rear inter-blade span is smaller than the rear inter-blade span closer to the rear longitudinal side of the razor cartridge than the front inter-blade span.

[0011] In an embodiment, the front inter-blade span closer to the front longitudinal side of the razor cartridge than the rear inter-blade span is greater than the rear inter-blade span closer to the rear longitudinal side of the razor cartridge than the front inter-blade span.

[0012] According to one example, a razor cartridge is provided that includes three or more substantially parallel cutting members disposed between a front longitudinal side and a rear longitudinal side of the razor cartridge in a shaving direction of the razor cartridge.

[0013] Each of the cutting members comprises a blade support which, in use, comprises a blade mounting portion disposed on an inner surface of the respective blade support facing away from the shaving plane SH, and a blade attached to the blade mounting portion.

[0014] The cutting members are positioned to define a plurality of inter-blade spans between the cutting edges of the blades.

[0015] In one example, a front inter-blade span proximate a front longitudinal side of the razor cartridge is different from a rear inter-blade span proximate a rear longitudinal side of the razor cartridge.

[0016] The front inter-blade span near the front longitudinal side of the razor cartridge is less than the rear inter-blade span near the rear longitudinal side of the razor cartridge.

[0017] In another example, the front inter-blade span near the front longitudinal side of the razor cartridge is greater than the rear inter-blade span near the rear longitudinal side of the razor cartridge.

[0018] According to a second aspect, a method of manufacturing a razor cartridge includes: Obtaining a razor cartridge housing and three or more cutting members, each of the cutting members comprising a blade support comprising, in use, a blade mounting portion disposed on an inner surface of the respective blade support facing away from a shaving plane SH, and a blade attached to the blade mounting portion; The method includes disposing the cutting member between the front longitudinal side and the rear longitudinal side of the razor cartridge housing in the shaving direction of the razor cartridge, such that, in use, the inner surface of each blade support faces away from the shaving plane SH.

[0019] The cutting members define a plurality of inter-blade spans between the cutting edges of the blades.

[0020] The front inter-blade span proximate the front longitudinal side of the razor cartridge is different from the rear inter-blade span proximate the rear longitudinal side of the razor cartridge.

[0021] According to a third aspect, -Razor handle, According to a first aspect there is provided a shaving razor assembly comprising: a razor cartridge, the razor cartridge being either releasably attached to the razor handle via a pivotable or non-pivotable connection, integrally formed with the razor handle via a non-pivotable connection, or integrally formed with the razor handle via a pivotable connection.

[0022] In one example, the razor handle can be reused by replacing the razor cartridge, or the razor cartridge is fixedly attached to the razor handle via a pivotable or non-pivotable connection.

[0023] According to a fourth aspect, there is provided a kit of parts comprising a razor handle and a razor cartridge holder having a plurality of razor cartridges according to the first aspect.

[0024] Further embodiments are presented in the dependent claims and the detailed description, to which the reader should now refer.

[0025] The effect of the razor cartridge according to these embodiments is that during shaving, in addition to the cutting edge of the blade, the blade support of the cutting member contacts the skin (shaving plane). Thus, the number of contact points between the razor cartridge and the skin is increased, up to doubled. The amount of pressure exerted by each cutting edge on a portion of the skin is significantly reduced, thereby reducing the occurrence of skin damage ("cuts") and providing a more comfortable shave.

[0026] The blade is attached to the inner surface of the blade support in a manner that allows the blade support to contact the skin simultaneously with the cutting edge of the blade during use, meaning that the portion of the blade support that contacts the skin reduces or minimizes "skin bulge" and reduces the risk of cuts occurring.

[0027] Another effect is improved blade durability due to less pressure on the skin resulting in a less aggressive shave and therefore less wear on the blade.

[0028] Providing a variable inter-blade span from small to large from the front longitudinal side to the rear longitudinal side of the razor cartridge means a smoother, less aggressive shave, and therefore fewer painful cuts and skin irritation for the user. A smaller inter-blade span to the front longitudinal side of the razor cartridge improves the glide of the shaver along the shaving plane and provides better skin support at the front edge of the razor cartridge with the same number of blades, as compared to conventional razors.

[0029] This makes the razor cartridge suitable for frequent (daily) shavers, who do not need to remove as much hair as those who shave infrequently. Therefore, a large gap near the leading edge of the razor cartridge is less important for frequent shavers. However, the advantage of the skin support concept using a blade mounted on the inner surface of the blade support still allows for a shave with better glide. And this advantage is provided at the same time as the increased gap near the trailing edge of the razor cartridge improves the rinsability of the cartridge.

[0030] In examples where the front inter-blade span between the cutting edges towards the front longitudinal side of the razor cartridge is greater than the rear inter-blade span between the cutting edges towards the rear longitudinal side of the razor cartridge, another effect is that the larger gap between the cutting members at the front longitudinal side of the razor cartridge allows more removed hair to pass, resulting in a greater flow of debris and lather during shaving, and improved rinsability. Users who use razors less frequently may need to remove more hair than users who shave daily, as they may wait several days between shaves. Thus, the razor cartridge according to this example is better suited to users who shave less frequently, as the increased inter-blade span (or spans) towards the front longitudinal edge of the razor cartridge can accommodate the thicker and / or longer hair clippings characteristic of less frequent shaving users.

[0031] The inter-blade span is defined in one example with reference to a plane intersecting the cutting edges of at least two blades of the razor cartridge. A line between the cutting edges of the first and second blades and perpendicular to the first and second cutting edges is the inter-blade span (or space). In the following applications, the fact that the first inter-blade span and the second inter-blade span are "different" from each other means that the first distance defining the first inter-blade span in the lateral direction of the razor cartridge and the second distance defining the second inter-blade span in the lateral direction of the razor cartridge have different lengths. In other words, in one example, the first distance is greater than the second distance. In another example, the first distance is less than the second distance. In other words, the first distance defining the parallel spacing of the first inter-blade span is greater or less than the second distance defining the parallel spacing of the second inter-blade span.

[0032] Generally, a razor cartridge according to the present specification provides a razor cartridge, wherein each of the cutting members has a blade support including a blade mounting portion disposed on an inner surface of the respective blade support that faces away from the shaving plane in use, and the spacing between the blades may be customized to provide a variety of razor cartridges to accommodate different shaving habits. [Brief description of the drawings]

[0033] Other features will become apparent from the accompanying drawings, which form a part of this disclosure. The drawings are intended to further explain the disclosure and to enable those skilled in the art to practice the disclosure. However, the drawings are intended as non-limiting examples. Common reference numbers in different figures indicate similar or similar features.

[0034] [Figure 1] FIG. 1 is a perspective view of a shaving razor assembly. [Figure 2a] 1 shows a schematic side view of a portion of a prior art razor cartridge in use. [Figure 2b]1 shows a schematic side view of a portion of a prior art razor cartridge in use. [Diagram 3] 1 is a schematic side view of a portion of a prior art razor cartridge in use. [Figure 4] FIG. 2 is a perspective exploded view of the razor cartridge. [Figure 5a] FIG. 5 is a schematic cutaway side view of the razor cartridge taken along axis PQ from the embodiment of FIG. [Figure 5b] FIG. 5b is a reproduction of the schematic cutaway side view of the razor cartridge shown in FIG. 5a with different annotations to indicate the spacing between the blades. [Figure 6] FIG. 11 is an alternative exploded view of an alternative embodiment of a razor cartridge showing the relative positions of optional trimming blades and / or skin care element (lubricating strip) subassemblies. [Figure 7] FIG. 4 is a perspective detailed view of an end of the cutting member. [Figure 8] FIG. 2 is a perspective view of a blade support member. [Figure 9] FIG. 2 is a schematic side view of a cutting member including blade mounting portions disposed on an inner surface of each blade support that faces away from the shaving plane in use. [Figure 10] 1 illustrates a schematic side view of four razor blades of a razor cartridge according to one embodiment. [Figure 11] 13A-13C show side views of blade arrangements illustrating the reduction of skin bulging when the blade support member is brought into contact with the skin during shaving. [Figure 12] 13 shows a further side view of the blade arrangement illustrating the advantage of allowing the blade support member to contact the skin. [Figure 13] 1 illustrates a method of manufacturing a razor cartridge according to one embodiment. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0035] FIG. 1 is a perspective view of a shaving razor assembly 1 according to one embodiment. The shaving razor assembly includes a blade that is not driven by a motor. The shaving razor assembly 1 includes a handle 2 extending in a handle direction H between a proximal portion 4 and a distal portion 6 of the handle 2. A razor cartridge 20 is attached to the distal portion 6 of the handle 2. The razor cartridge 20 will be presented in more detail following a discussion of the shaving razor assembly 1.

[0036] Mounting of the razor cartridge 20 to the distal portion 6 of the handle 2 in the figures is via a pivotable bearing member 8a which allows the frame of reference of the handle 2 to change relative to the frame of reference of the razor cartridge 20, thus changing the angle of the razor cartridge relative to the user's skin to accommodate changes in use.

[0037] In particular, the razor cartridge 20 pivots relative to the handle 2 in use about a longitudinal axis L of the razor cartridge 20. For example, the pivoting allows a user to adapt to body contours. The longitudinal axis L of the razor cartridge 20 is substantially perpendicular to the shaving direction along the handle 2. Another example of a connection mechanism for connecting the razor cartridge 20 to the handle 2 is discussed in WO2006 / 027018A1. Another alternative is a razor cartridge 20 that can pivot about a second pivot axis (locking axis) that is substantially perpendicular to the axis L.

[0038] In an example, the pivotable bearing member 8a may be omitted (not shown) and the handle 2 may be provided as an integrally connected part of the support for the razor cartridge 20. In one example, the pivotable bearing member 8a may further comprise or be replaced with a release mechanism 5a, 5b that allows for rapid release of an exhausted razor cartridge from the handle 2.

[0039] In one example, the handle 2 and support of the razor cartridge 20 are integrally formed with a pivotable bearing member (not shown), such as a plastic spring member.

[0040] In one example, the handle 2 is provided with a handle grip 9 formed of rubber or a rubber-like material to improve grip friction. In one example, the handle is provided with a thumb rest to allow the user to grip the handle 2 more securely.

[0041] 2a and 2b are schematic side views of a portion of a prior art razor cartridge in use. In conventional razor cartridges with three or more blades, the inter-blade span is measured to be constant, ranging from about 1.05 mm to 1.5 mm, and the razor blades are attached to the top of a blade support.

[0042] For purposes of this specification, the expression "top of the blade support" refers to the side of the blade support of the razor cartridge that is closest to the user's shaving plane SH (skin) when the razor cartridge is in use, as shown in Figures 2a and 2b. Use of such a top-mounted cutting member-mounted razor cartridge can result in greater cuts and increased irritation during aggressive shaving, since the shaving plane SH (skin) is supported exclusively by the cutting edges 30 of the blade support blades. This provides a relatively small surface area for the skin to support during shaving, increasing the amount of "bulge" 12 of the shaving plane SH (skin) between the inter-blade gaps.

[0043] Figure 3 is a schematic side view of a portion of a prior art razor cartridge in use. To reduce the effect of skin bulge 12, the inter-blade span IBS can be reduced, as shown in Figure 3. However, this reduces the gap for rinsing, and debris such as foam and hair can easily block gaps with narrow inter-blade spans. Reducing the IBS between all blades also requires a higher blade density (number of blades in the same size cartridge).

[0044] According to a first aspect, a razor cartridge 20 is provided that includes three or more substantially parallel cutting members disposed between a front longitudinal side 24 and a rear longitudinal side 25 of the razor cartridge in a shaving direction of the razor cartridge.

[0045] Each of the cutting members has a blade support with a blade mounting portion disposed on an inner surface of the respective blade support that, in use, faces away from the shaving plane SH, and a blade attached to the blade mounting portion.

[0046] The cutting members are positioned to define a plurality of inter-blade spans between the cutting edges 30 of the blades.

[0047] The front interblade span closest to the longitudinal front side 24 of the razor cartridge is different from the rear interblade span closest to the rear longitudinal side 25 of the razor cartridge.

[0048] In other words, in different examples, the forward inter-blade span is smaller or larger than the aft inter-blade span. The following disclosure considers various examples in which the forward inter-blade span is larger or smaller than the aft inter-blade span.

[0049] 4 is a perspective, partially exploded view of a razor cartridge 20 according to an example of a first embodiment in which the front inter-blade span is greater than the rear inter-blade span. By "partially exploded" it is meant that some minor components of the razor cartridge 20 have been omitted from the exploded view for clarity of the drawing.

[0050] The shaving direction S is indicated by arrow S in Figure 4. In use, the razor cartridge 20 contacts a shaving plane SH (not shown in Figure 4) and is translated across the shaving plane SH in the direction of arrow S.

[0051] Frame 21 may be partially or completely fabricated from a synthetic material such as plastic, resin, or elastomer. Frame 21 includes a platform member 22 that is connectable to handle 2 of shaving razor assembly 1 either integrally or by a connection mechanism such as pivotable bearing member 8a or by an interconnecting member (not shown).

[0052] A guard member 23 is provided as substantially a longitudinal side edge of the razor cartridge 20. In use, the guard member 23 is the first portion of the razor cartridge 20 that contacts uncut hair and is therefore located at the front longitudinal side 24 of the razor cartridge 20. The side of the razor cartridge 20 opposite the front longitudinal side and opposite the shaving direction is the rear longitudinal side 25 of the razor cartridge 20. The rear longitudinal side 25 is therefore the last portion of the razor cartridge 20 that contacts the shaving plane SH in use.

[0053] It should be noted that the terms "front longitudinal side 24" and "rear longitudinal side 25" are used to indicate particular locations on razor cartridge 20 and do not imply or require the presence or absence of particular features. For example, guard member 23 may be located on "front longitudinal side 24" in one example and a trimming blade (not shown in FIG. 4) may be located on "rear longitudinal side 25" in another example, although it is not required that these locations include such features.

[0054] In one example, the guard member 23 includes an elastomeric layer (not shown in FIG. 4). In one example, the elastomeric layer includes one or more fins extending longitudinally parallel to the guard member 23 and substantially perpendicular to the shaving direction. One purpose of such an elastomeric layer is, for example, to provide tension to the skin prior to cutting.

[0055] In embodiments, razor cartridge 20 may further include a cap member at or near rear longitudinal side 25, although this is not shown in the embodiment of FIG. 4 as an aid for clarity.

[0056] The razor cartridge 20 further includes a group of cutting members 29 housed in a blade receiving portion 31 of the frame 21. The group of cutting members 29 includes a plurality of cutting members 28a-d. The group of cutting members 29 are arranged on the frame 21 longitudinally and parallel to the shaving direction SH such that, in use, the blades of the cutting members 28a-d contact the shaving plane SH and cut hair present on the shaving plane SH as the razor cartridge 20 moves across the shaving plane SH in the shaving direction S. The particular design of the group of cutting members 29 is discussed in more detail below.

[0057] In one example, a razor cartridge is provided with three cutting members. In one example, a razor cartridge is provided with four cutting members. In one example, a razor cartridge is provided with five cutting members. In one example, a razor cartridge is provided with six cutting members. In one example, a razor cartridge is provided with seven or more cutting members.

[0058] The group of cutting members 29 defines a plurality of substantially parallel inter-blade spans, the number of which is one less than the number of cutting members.

[0059] The frame 21 further comprises a first retainer 26 and a second retainer 27 configured to retain the razor blades within the housing of the razor cartridge 20. The frame 21 further comprises a first side 16 and a second side 18. The first and second sides 16, 18 are configured to fixedly confine the longitudinal ends of the guard member 23, the cap member 29 (if present, not shown in FIG. 4), and the cutting member 29 when the razor cartridge 20 is in an assembled condition. The first side retainer 26 and the second retainer 27 can comprise, for example, a plastic, elastomeric, or metallic material, and further can be shaped differently than those illustrated.

[0060] Although not shown, in one example, a pivotable bearing member 8b can be provided on a side of the razor cartridge 20 that is configured to connect to the pivotable handle 2. Such pivotable bearing member 8b, in one example, includes two or more shell bearings that are configured to connect to the pivotable bearing member 8a of the handle 2.

[0061] The cutting members included in the group of cutting members 29 have two cutting edges 30, each located on the two most forward (closest to the front of the razor cartridge) cutting members of the group of cutting members 29, that define a forward interblade span that is greater than the rear interblade span defined between the two cutting edges closest to the front longitudinal side 24 of the razor cartridge 20 and closest to the rear longitudinal side 25 of the razor cartridge in the variation shown in Figure 4. The interblade span is further shown in Figure 10 and will be discussed later. Furthermore, in the embodiment not shown, the forward interblade span closest to the front longitudinal side 24 of the razor cartridge 20 is smaller than the rear interblade span defined between the two cutting edges closest to the rear longitudinal side 25 of the razor cartridge.

[0062] Each cutting member in the group of cutting members 29 comprises a longitudinal blade support 32 to which a longitudinal blade is attached. The cutting edges 30 of the cutting members 28a-d face forward in the direction of shaving S. The blade supports 32 of the cutting members 28a-d are elongated, bent pieces of rigid material. In one example, the blade supports 32 are metal, such as austenitic stainless steel.

[0063] Each cutting member in the group of cutting members 29, in one example, is resiliently mounted in a blade receiving portion 31 of the razor cartridge 20. The blade receiving portion 31 includes a longitudinal space within the razor cartridge 20 that is sized to accommodate the group of cutting members 29. At least one cutting member in the group of cutting members 29, and up to all cutting members in the group of cutting members 29, may be resiliently mounted in the blade receiving portion 31. In the example shown in FIG. 4, the lateral inner side of the frame 21 includes a plurality of retention slots 34. Each lateral inner retention slot 34 is configured to receive and retain one side of a blade support 32 of a cutting member in the group of cutting members 29 such that the cutting members in the group of cutting members 29 are retained in the blade receiving portion 31 with substantially parallel inter-blade spans. Thus, each lateral inner side of the frame 21 is provided with the same number of retention slots 34 as there are blade support members.

[0064] Between the blade receiving portion 31 and the handle (e.g., adjacent the connection portion of the handle 2), in the example, one or more cross members 35 are provided which are formed integrally with the frame 21. The cross members 35 may include a number of blade support guides 36 provided as a number of protrusions aligned with the laterally inner retention slots 34 of the frame 21. The blade support guides 36 function to longitudinally restrict the span between the parallel blades.

[0065] As discussed above, the razor cartridge 20 according to the first embodiment has a variable interblade span IBS. Thus, in the variation shown in FIG. 4, the spacing of the blade supports 32 is progressively increased between the front longitudinal side 24 and the rear longitudinal side 25 of the razor 20 to create a variable interblade span IBS. One alternative way to achieve this arrangement is to progressively increase the spacing between the retention slots 34 located laterally inward in the lateral direction (y to -y) of the razor cartridge. The positioning and / or width of the blade support guides 36 are adjusted proportionately so that the groups of interblade spaces IBS between the cutting edges 30 of the cutting members 28a-d are parallel. In another variation (not shown), the spacing of the blade supports 32 is progressively decreased between the front longitudinal side 24 and the rear longitudinal side 25 of the razor 20 to create a variable interblade span IBS.

[0066] The razor cartridge 20 of Figure 4 includes four resilient fingers 38a, 38b, 38c, 38d below the first retainer 26. The razor cartridge 20 includes four resilient fingers below the second retainer 27 that correspond laterally to and are aligned with the four resilient fingers 38a, 38b, 38c, 38d below the first retainer 26.

[0067] In total, the eight resilient fingers each exert a biasing force against a respective cutting member of the group of cutting members 29 in the direction of the shaving plane SH such that, when assembled, the cutting members of the group of cutting members 29 are in a rest position. In the rest position, the cutting edge 30 of the blade 33 bears against, for example, corresponding stop portions at each lateral end of the blade 33 near the first retainer 26 and the second retainer 27. In one example, the stop portions may be the first retainer 26 and the second retainer 27.

[0068] Thus, the rest positions of the cutting members 28a-d are clearly defined, allowing for high shaving precision. Of course, there are many variations on the illustrated biasing arrangement. For example, one or more cross members 35 can be provided with additional resilient fingers. In simplified razor cartridge designs (such as low-cost disposable razors), the resilient fingers may be omitted. Those skilled in the art will appreciate that the number of resilient fingers 38 provided is related to the number of cutting members 28a-d in the group of cutting members 29, and that fewer or more than eight resilient fingers 38 may be provided.

[0069] Figure 5a is a schematic cutaway side view of a razor cartridge taken from the embodiment of Figure 4 along transverse axis PQ shown in dotted line in Figure 4. Where possible, like elements are given like reference numerals.

[0070] In addition to the features shown in the partially exploded view of FIG. 4, FIG. 5a further illustrates a rear longitudinal side assembly 49 that may, but need not, be included as part of the razor cartridge 20 in some instances.

[0071] In particular, the rear longitudinal side assembly 49 includes, in an example embodiment, a longitudinal skin care element 50 (lubricating strip) for applying a compound, such as a lubricating compound, to the shaving plane after the cutting edge 30 of the blade passes over the shaving plane.

[0072] The rear longitudinal side assembly 49, in an example, includes a longitudinal trimming blade 53 disposed on the rear longitudinal side 25 of the razor cartridge 20. The trimming blade 53 may be used to trim hairs that are hard to reach using the blades 33 of the group of cutting members 29, such as, for example, outgrown nose hairs. In one example, the trimming blade 53 only extends a portion of the length of the rear longitudinal side assembly 49, such as up to three-quarters, one-half, or one-quarter.

[0073] As shown, the trimming blade 53 is mounted to a trimming blade support 54. The assembly of the trimming blade 53 mounted to the trimming blade support 54 is, in one example, the same design as the blade receiver 31, blade support 32, and blade 33 in the group of cutting members 29 to reduce part variation. Alternatively, the trimming blade 53 and trimming blade support 54 are manufactured to a different design than the blade receiver 31, blade support 32, and blade 33 in the group of cutting members 29.

[0074] For purposes herein, the trimming blade 53 is not included within the group of cutting members 29 intended to contact the shaving plane. For purposes herein, an inter-blade span is defined between the cutting edges 30a-d of the blades 33a-d of the group of cutting members 29, but the span between the cutting edge 53 of the trimming blade and one of the cutting edges 30a-d of the blades 33a-d of the group of cutting members 29 is not considered an inter-blade span.

[0075] In one example, the rear longitudinal side assembly 49 includes a retractable cover 52 as a safety feature and to keep the trimming blades 53 sharp when not in use.

[0076] In common with the razor frame 21, the rear longitudinal side assembly 49 and / or the retractable cover 52 may be provided as a plastic or resin material. In one example, the rear longitudinal side assembly 49 is integrally formed with the frame 21. In one example, the rear longitudinal side assembly 49 is, for example, glued or ultrasonically welded to the frame 21. In one example, the razor cartridge 21 is provided without the rear longitudinal side assembly 49, such that the rear edge of the frame 21 in the shaving direction is the rear longitudinal side 25 of the razor cartridge 20. In embodiments in which the razor cartridge 20 includes a rear longitudinal side assembly 49, the rear longitudinal side 25 of the rear longitudinal side assembly 49 in the shaving direction is considered to be the rear edge of the frame 21 in the shaving direction.

[0077] Figure 5a shows a side view of retention slots 34 provided in first retainer 26 and second retainer 27 for retaining groups of cutting members 29. Blade support guides 36 and resilient fingers 38 shown in Figure 4 are not shown in the projection of Figure 5a for clarity.

[0078] FIG. 5a shows a gradually increasing longitudinal span in the direction from the front longitudinal side 24 to the rear longitudinal side 25 between a series of retention slots 34 for holding groups of cutting members 29 provided on the first side 16 and the second side 18.

[0079] Of course, it is not necessary to provide a series of retention slots 34 in the first retainer 26 and second retainer 27 to support the cutting members of the group of cutting members 29. The group of cutting members 29 can also be supported using, for example, a plurality of blade support guides 36 (protrusions) disposed on one or more cross members 35, the plurality of blade support guides 36 providing a progressively increasing longitudinal inter-blade span from the front longitudinal side 24 to the rear longitudinal side 25 of the razor cartridge 20. In one example, a plurality of blade support guides 36 and a series of retention slots 34 can be used in combination to provide a progressively increasing longitudinal span between the front and rear sides of the razor cartridge.

[0080] Figure 5b is a reproduction of the schematic cutaway side view of razor cartridge 20 shown in Figure 5a, annotated to indicate the spacing between the blades. The longitudinal line on the interior front longitudinal wall of blade receiving portion 55, which in use is closest to the shaving plane SH, serves as the origin O for purposes of this definition.

[0081] The forward blade 33d to the frame 21, span 44, is a lateral span perpendicular to the longitudinal orientation of the blades of the group of cutting members 29 (substantially aligned with the shaving direction S) that spans the space between the interior forward longitudinal wall of the blade receiving portion 55 that is closest to the (origin) shaving plane SH when in use and the cutting edge 30d of the forward blade of the group of cutting members 29.

[0082] The front interblade span 40, which is the interblade span closest to the front longitudinal side 24 of the razor cartridge, is a lateral span (which in use is substantially aligned with the shaving direction S) that is substantially perpendicular to the longitudinal orientation of the blades of the group of cutting members 29. The front interblade span 40 begins at a point on the cutting edge 30d of the first intermediate blade 33c and ends at a corresponding point on the cutting edge 30c.

[0083] The first intermediate inter-blade span 41 is a lateral span (which in use is substantially aligned with the shaving direction S) that is substantially perpendicular to the longitudinal orientation of the blades of the group of cutting members 29. The first intermediate inter-blade span 41 begins at a point on the cutting edge 30c of the second intermediate blade 33b and ends at a corresponding point on the cutting edge 30b.

[0084] The rear inter-blade span 42 is a lateral span (which in use is substantially aligned with the shaving direction S) perpendicular to the longitudinal orientation of the blades of the group of cutting members 29. The rear inter-blade span 42 begins at a point on the cutting edge 30b of the blade 33a closest to the rear longitudinal side 25 of the razor cartridge 20 and ends at a corresponding point on the cutting edge 30a.

[0085] A rear blade-to-frame span 45, which is a lateral span perpendicular to the longitudinal orientation of the blades of the group of cutting members 29, the cutting edges 30a and corresponding points on the interior rear longitudinal wall of the blade receiving portion 56 (substantially aligned with the shaving direction S in use).

[0086] Thus, the total span of blade receiving portion 31 corresponds to the sum of spans 44, 40, 41, 42, and 45. In practice, the total span of the blade receiving portion may range from 7 mm to 15 mm.

[0087] As will be discussed below, each blade mounting portion 71 is disposed on an inner surface 66 of a respective blade support 32 that faces away from the shaving plane SH in use. The cutting edge 30 extends forward from the front of the blade support 32. However, the blade support 32 has a measurable thickness. For example, the blade support 32 has a thickness in the range of 0.12 mm to 0.21 mm, more specifically in the range of 0.155 mm to 0.185 mm, and most specifically 0.17 mm.

[0088] As a result, a non-negligible span, defined as the lateral span perpendicular to the longitudinal orientation (which in use is substantially aligned with the shaving direction S), exists between each cutting edge 30 and the blade mounting end of each blade support 32 of each cutting member of the group of cutting members 29. This can be referred to as the cutting edge to blade span 43 of the respective cutting member. The edge support span can be derived using trigonometry based on the thickness of the blade support 32 and the inclination angle of the blade receiving portion 31 of the blade support 32 with respect to the shaving plane.

[0089] In one example, each blade support 32 in the group of cutting members 29 is identical and has the same thickness T2 and the same tilt angle A. In this case, the cutting edges up to blade spans 43a, 43b, 43c, and 43d are identical.

[0090] In one example, one or more of the cut edges of blade spans 43a, 43b, 43c, and 43d are in the range of 0.3 mm to 0.6 mm, specifically 0.5 mm.

[0091] In one example, at least one blade support 32 of the group of cutting members 29 has a different thickness and / or inclination angle than the remaining blade supports 32. In this case, at least one cutting edge to blade span 43a will be different from the rest. The effect may be adjusted to provide finer control over the skin bulging effect for each individual cutting edge to blade span 43a-43d. For example, the cutting edge to blade span 43a-43d can be designed to increase or decrease progressively. The front blade to frame span 44 is a transverse span (substantially aligned with the shaving direction S in use) perpendicular to the longitudinal orientation of the blades of the group of cutting members 29. The front blade to frame span, in one example, begins at a point on the inner front longitudinal wall 55 closest to the shaving plane SH. The front blade to frame span, in one example, ends at a corresponding point on the cutting edge 30d of the blade 33 of the front cutting member 28d closest to the shaving plane SH.

[0092] In one example, the front frame to blade span 44 is 0.5 mm to 0.9 mm, specifically 0.7 mm.

[0093] The rear blade-to-frame span 45 is a lateral span (substantially aligned with the shaving direction S in use) perpendicular to the longitudinal orientation of the blades of the group of cutting members 29. The rear blade-to-frame span begins at a point on the cutting edge 30a of the blade 33a of the rear cutting members 28a-d. The rear blade-to-frame span 45 ends at a corresponding point on the interior rear longitudinal wall 56, in one example, closest to the shaving plane SH.

[0094] In one example, the aft frame to blade span 44 is 1.6 mm to 2.0 mm, specifically 1.8 mm. In one example, the forward blade to frame span 44 is greater than the aft blade to frame span 45. In one example, the forward blade to frame span 44 is less than the aft blade to frame span 45.

[0095] In one example, the forward blade to frame span 44 is substantially equal to the aft blade to frame span 45. In one example, the forward blade to frame span 44 is greater than the forward inter-blade span 40. In one example, the forward blade to frame span 44 is substantially equal to the forward inter-blade span 40. In one example, the forward blade to frame span 44 is less than the forward inter-blade span 40. In one example, the aft blade to frame span 45 is greater than the aft inter-blade span 42. In one example, the aft blade to frame span 45 is substantially equal to the aft inter-blade span 42. In one example, the aft blade to frame span 45 is less than the aft inter-blade span 42. In one example, the first intermediate inter-blade span 41 and the second intermediate inter-blade span 42 are each substantially equal to the forward inter-blade span 40. In one example, the first intermediate inter-blade span 41 and the second intermediate inter-blade span are each substantially equal to the aft inter-blade span 42. In one example, the first intermediate inter-blade span 41 is greater than the forward inter-blade span 41 and less than the second intermediate inter-blade span.

[0096] In one example, the second intermediate interblade span is equal to the rear interblade span 42. In some examples, the front interblade span closest to the front longitudinal side of the razor cartridge is less than the rear interblade span closest to the rear longitudinal side of the razor cartridge.

[0097] 5b also shows a first debris outflow portion 46, a second debris outflow portion 47, and a third debris outflow portion 48. The width of the debris outflow portion is determined by the relative spacing of the cutting members of the group of cutting members 29. As shown, the first debris outflow portion 46 is narrower than the second debris outflow portion 47, which is narrower than the third debris outflow portion 48. The effect of this is that, in use, more hair clippings and foam can be removed via the debris outflow portions (such as debris outflow portion 48) that are progressively closer to the rear edge of the razor cartridge 20.

[0098] The design of the size of the forward blade to frame span 44 and / or the aft blade to frame span 45 is optional. The forward blade to frame span 44 may be greater than, equal to, or less than the forward inter-blade span 40. The aft blade to frame span 45 may be greater than, equal to, or less than the aft inter-blade span 42.

[0099] In one example, the forward inter-blade span 40 is less than the aft inter-blade span 42 .

[0100] In one example, the first intermediate inter-blade span is equal to or greater than the front inter-blade span. In one example, the first intermediate inter-blade span is equal to or less than the rear inter-blade span. Although a razor cartridge having four blades 33a-d is shown, the present specification also includes razor cartridges including three blades or more than four blades.

[0101] For example, five substantially parallel cutting members 28a-d can be arranged in the shaving direction of the razor cartridge 20 with a second intermediate interblade span defined adjacent to the rear interblade span 42. In one example, the first intermediate interblade span 41 and the second intermediate interblade span are each substantially equal to the front interblade span.

[0102] In one example, the first intermediate interblade span 41 and the second intermediate interblade span are each substantially equal to the rear interblade span 42. In one example, the first intermediate interblade span is greater than the front interblade span 40 and less than the second intermediate interblade span. In one example, the second intermediate interblade span is equal to the rear interblade span 42. In one example, the successive interblade spans of the razor cartridge increase continuously in the shaving direction between the front longitudinal side 24 and the rear longitudinal side 25 of the razor cartridge.

[0103] In one example, each of the blade supports 32a-d includes a shaving plane contact portion 58 configured to contact the shaving plane SH in addition to the cutting edge 30 of the blade during use, thereby reducing pressure at the contact point of each cutting edge with the shaving plane. Thus, compared to conventional razor heads, pressure at the contact point of the cutting edge may be reduced while still providing improved gliding performance.

[0104] 7 is a cutaway perspective view of the end of the cutting member 28. The cutting member 28 is a subassembly that includes a longitudinal blade 33 mounted on a longitudinal blade support 32. A lower portion of the blade support 60 is suitable for being retained in a retention slot 34 in the razor cartridge frame 21. A bend 62 in the longitudinal blade support 32 defines the approach angle of the longitudinal blade 33 to the shaving plane SH.

[0105] 9, approach angle A defines the angle of declination of the inner surface of blade support 66 from the datum of blade support 32. In one example, A is an acute angle, specifically between 60 and 75 degrees, and more specifically 68 degrees.

[0106] 7, the longitudinal blade 33 includes a cutting edge 30 capable of cutting hair. In one example, a rounded recess is cut out of the sheet metal forming the blade support 32.

[0107] Conventionally, the blades are mounted on the outer surface of the blade support such that, in use, no part of the blade support comes into contact with the shaving plane SH.

[0108] In particular, in this aspect and embodiment, as shown in FIG. 7, the blade mounting portion 71 of the blade support 32 is disposed on an inner surface of each blade support that faces away from the shaving plane SH in use, and the blade is attached to the blade mounting portion 71.

[0109] According to this approach, the blades 33 are mounted on and project from below the inner surface of their respective blade supports to define a cutting edge to blade span 43 toward the shaving plane SH between the cutting edge 30 of the blade and the end of the blade support 32. In use, when the cutting member 28 contacts the shaving plane SH, both the cutting edge of the blade 30 and the end of the blade support 32 contact the shaving plane SH simultaneously, reducing the force exerted on the shaving plane SH by, for example, a single cutting edge.

[0110] In other words, the position of the blade 33 on the blade support 32 when the cutting members 28a-d are mounted in the razor cartridge is defined by the fact that an imaginary tangent provided from a surface of the blade 33 oriented away from the shaving plane SH does not pass through any point on the blade support 32 to which the blade 33 is mounted.

[0111] A further definition of the position of the blade 33 on the blade support is that when the cutting members 28a-d are mounted in the razor cartridge, an imaginary tangent provided from the part of the blade 33 that contacts the blade mounting portion 71 that is oriented towards the shaving plane SH in use passes through the blade support 32 on which the blade 33 is mounted.

[0112] FIG. 8 is a perspective view of the blade support member 32 in the longitudinal direction of the blade. It includes a substantially elongated flat lower portion 60, a substantially elongated flat upper side 65, and a radius bend portion 62. The radius bend portion 62 may have an inner radius of curvature RO greater than 0.1 mm. The radius bend portion 62 may have an inner radius of curvature RO less than 0.9 mm. The minimum recommended inner radius of curvature RO of the sheet metal should be at least as large as its thickness T. A safety factor of the thickness of the blade support 32 may be applied. By multiplying the safety factor by the preferred thickness T (approximately 0.17 mm), the radius of curvature RO may be approximately 0.25 mm, specifically between 0.16 mm and 0.40 mm, most specifically between 0.25 mm or 0.28 mm.

[0113] FIG. 9 is a schematic side view of the cutting member 28 with a blade mounting portion 71 located on the inner surface of the blade support that faces away from the shaving plane SH in use.

[0114] As discussed above, the blade support 32 may be made from a flat sheet metal piece that is bent prior to welding the blade 33 onto the inner surface 66 of the blade support 32. Thus, the cutting member 28 includes the blade 33 (a razor blade).

[0115] The blade 33 has a thickness T1 at the flat portion of about 0.1 mm (e.g., 0.04-0.11 mm). The total length L2 of the blade 33 between the cutting edge 30 of the blade 33 and the opposite rear edge of the blade 33 is about 1 mm (e.g., 0.8 mm-1.3 mm). The part of the blade 33 that in use contacts the inner surface 66 of the blade support facing away from the shaving plane SH has a length L1 that is about 0.49 mm ± 0.1 mm long. In this way, good retention of the blade on the underside of the blade support 32 (the inner surface of the blade support 32) is ensured.

[0116] In one example, the height of the cutting member 28H is 2.53 mm to 2.63 mm, and particularly 2.58 mm.

[0117] In one example, the leading end 72 of the blade support is rounded or chamfered to improve the sliding properties of the cutting member.

[0118] In one example, the blade 33 is positioned on the inner surface 66 of the blade support 32 and the exposure E of the cutting edge 30 can be adjusted positively or negatively relative to the shaving plane SH. Exposure is a measure of whether the cutting edge 30 of the blade protrudes above or sinks below the end 72 of its blade support.

[0119] In one example, the blade 33 may be positioned to have an exposure in the range of -80 μm to +80 μm relative to the shaving plane SH, specifically an exposure of approximately -75 μm, -65 μm, -60 μm, -55 μm, -50 um, -45 um, -40 um, -35 um, -30 um, -25 um, -20 um, -15 um, -10 um, -5 um, 0 um, 5 um, 10 um, 15 um, 20 um, 25 um, 30 um, 35 um, 40 um, 45 um, 50 um, 55 um, 60 um, 65 um, 70 um, or 75 um.

[0120] The length L3 of the blade member 28 between the cutting edge 30 and the outer surface of the lower portion of the blade support 32 is about 1.0 mm (eg, 0.9 mm to 1.6 mm).

[0121] The blade 33 is secured to the inner surface 66 of the blade support by any known means, such as laser spot welding. In an example, the blade 33 is secured to the inner surface 66 of the blade support by a plurality of spot welds (e.g., 10-16 spot welds) distributed along the longitudinal dimension of the blade support 32. Each of the spot welds may be performed on the inner surface 70 of the blade 33. Alternatively, each of the spot welds may be performed on the outer surface of the blade support 68, or a mixture of the two.

[0122] 10 shows an example of a schematic side view of a group of cutting members 29 having inter-blade spans according to one exemplary implementation. Four razor blades of a razor cartridge according to one embodiment. FIG. 10 shows that the front inter-blade span 40 is smaller than the rear inter-blade span 42.

[0123] 10, the first intermediate inter-blade span 41 is greater than the forward inter-blade span 40 but less than the aft inter-blade span 42, although this is not an essential feature. For example, the first intermediate inter-blade span 41 could be equal to either the aft inter-blade span 42 or the forward inter-blade span 40.

[0124] Specific measurements of the inter-blade span separation distance range will now be considered. Those skilled in the art will understand that many choices and combinations of inter-blade spans are possible that satisfy the above-discussed characteristics of razor cartridge 20, and that the following discussion is not limited to the disclosed values.

[0125] In one example, the aft interblade span 40 is within the range of 1.6 mm to 2.2 mm, 1.70 mm to 2 mm, or 1.75 mm to 1.95 mm.

[0126] When three cutting members 28a-c are present, the rear inter-blade span defined above may still apply in combination with a front inter-blade span 42 within the range of 1.6 mm to 2.2 mm, 1.70 mm to 2.00 mm, or 1.75 mm to 1.95 mm.

[0127] When four cutting members 28a-d are present, the front inter-blade span 42 is within the range of 1.6 mm to 2.2 mm, 1.70 mm to 2.00 mm, or 1.75 mm to 1.95 mm.

[0128] In one example, the aft inter-blade span 40 is in the range of 1.7 mm to 2.2 mm, 1.8 mm to 2.0 mm, or 1.85 mm.

[0129] In one example, the first intermediate blade span 41 is in the range of 1.55 mm to 1.95 mm, 1.60 mm to 1.80 mm, or 1.70 mm.

[0130] In one example, the forward inter-blade span 42 is in the range of 1.4 mm to 1.8 mm, specifically 1.50 mm to 1.65 mm, or 1.55 mm.

[0131] In one example, the distance from the front blade to the frame span 44 is within the range of 0.4 to 1.0 mm, 0.5 mm to 0.8 mm, or 0.7 mm.

[0132] In one example, the rear blade to frame span 45 is within the range of 1.7 mm to 2.2 mm, 1.8 mm to 2.0 mm, or 1.85 mm.

[0133] The ranges discussed above are typically increased as compared to conventional razor cartridges. Rinsability of the cartridges discussed herein is generally improved because more space is available between the rear cutting members 28a-d for debris to flow down near the rear edge of the razor cartridge 20. Skin bulging is also reduced, improving shaving.

[0134] According to an embodiment where the front inter-blade span 40 is larger compared to the first intermediate inter-blade span 41 or the rear inter-blade span 42, the first two blades, which cut the most hair, are far enough apart to allow easy removal of debris, thus providing a safer shaving experience. Providing blade support on the "top" of the blade provides an additional skin-contacting element (and the cutting edge 30 of the blade) to support the skin during shaving.

[0135] In embodiments in which the rear inter-blade span 42 is greater than the front inter-blade span 40, the successive inter-blade spans of the razor cartridge decrease continuously between the front longitudinal side 24 and the rear longitudinal side 25 of the razor cartridge in the shaving direction.

[0136] In one example, any possible combination of inter-blade spans is possible, provided that the front inter-blade span closest (or closer) to the front longitudinal side 24 of the razor cartridge is smaller than the rear inter-blade span closest (or closer) to the rear longitudinal side 25 of the razor cartridge.

[0137] In other examples, the forward inter-blade span 40 is within the range of 1.6 mm to 2.2 mm, 1.70 mm to 2 mm, or 1.75 mm to 1.95 mm.

[0138] When three cutting members 28a-c are present, the forward inter-blade span defined above may still apply in combination with a rearward inter-blade span 42 within the range of 1.6 mm to 2.2 mm, 1.70 mm to 2.00 mm, or 1.75 mm to 1.95 mm.

[0139] When four cutting members 28a-d are present, the rear inter-blade span 42 is within the range of 1.6 mm to 2.2 mm, 1.70 mm to 2.00 mm, or 1.75 mm to 1.95 mm.

[0140] In one example, the forward inter-blade span 40 is within the range of 1.7 mm to 2.2 mm, 1.8 mm to 2.0 mm, or 1.85 mm. In one example, the first intermediate blade span 41 is within the range of 1.55 mm to 1.95 mm, 1.60 mm to 1.80 mm, or 1.70 mm. In one example, the rear inter-blade span 42 is within the range of 1.4 mm to 1.8 mm, specifically 1.50 mm to 1.65 mm, or 1.55 mm. In one example, the forward blade to frame span 44 is within the range of 0.4 mm to 1.0 mm, 0.5 mm to 0.8 mm, or 0.7 mm. In one example, the rear blade to frame span 45 is within the range of 1.7 mm to 2.2 mm, 1.8 mm to 2.0 mm, or 1.85 mm.

[0141] However, in this example, any possible combination of inter-blade spans is possible, provided that the front inter-blade span closest (or closer) to the front longitudinal side 24 of the razor cartridge is smaller than the rear inter-blade span closest (or closer) to the rear longitudinal side 25 of the razor cartridge.

[0142] According to embodiments in which the front inter-blade span 40 is smaller compared to the first intermediate inter-blade span 41 or the rear inter-blade span 42, the blades toward the front of the razor cartridge 20 have a correspondingly narrower IBS, which further reduces the risk of cuts. Thus, a safer shaving experience is provided. By providing blade support at the "top" of the blade, an additional skin-contacting element (and the cutting edge 30 of the blade) is provided to support the skin during shaving. Since a frequently used shaver does not generate as much debris when shaving, it is less critical that a large amount of debris be removed from the inter-blade gap near the front edge of the razor cartridge.

[0143] FIG. 11 is a side view of a blade arrangement showing reduced skin bulging when allowing the blade support member to contact the skin during shaving when the inter-blade span is greater on the front longitudinal side compared to the rear longitudinal side.

[0144] FIG. 12 is a further side view of a blade arrangement showing the advantage of allowing the blade support members to contact the skin when the inter-blade span is greater at the front longitudinal side compared to the rear longitudinal side.

[0145] FIG. 13 illustrates a method of manufacturing a razor cartridge according to a further embodiment.

[0146] The method is as follows. Obtaining 74 a razor cartridge housing and three or more cutting members 28a-c, each cutting member 28a-c comprising a blade support including a blade attachment portion 71 disposed on an inner surface 66 of the respective blade support that faces away from a shaving plane (SH) in use, and a blade attached to the blade attachment portion 71; disposing three or more cutting members 28a-d between a front longitudinal side 24 and a rear longitudinal side 25 of the razor cartridge housing in a shaving direction of the razor cartridge, where in use an inner surface of each blade support faces away from the shaving plane (SH); The cutting members 28a-d define a plurality of inter-blade spans between the cutting edges 30 of the blades; The front interblade span closest to the front longitudinal side 24 of the razor cartridge is different from the rear interblade span closest to the rear longitudinal side 25 of the razor cartridge.

[0147] 1 shows a shaving razor assembly 1 according to a further aspect. The shaving razor assembly 1 comprises a razor handle 2 and a razor cartridge 20 according to the first aspect or one of its embodiments, the razor cartridge being either releasably attached to the razor handle via a pivotable 8 or non-pivotable connection, integrally formed with the razor handle via a non-pivotable connection, or integrally formed with the razor handle via a pivotable connection.

[0148] According to a further aspect there is provided a kit of parts having a razor handle 2 and a razor cartridge holder containing a plurality of razor cartridges 20 according to the first aspect or an embodiment thereof.

[0149] In the foregoing specification, a razor blade including at least three cutting members 28a-c according to an embodiment may have a fourth and a fifth blade according to certain embodiments. A front interblade span, a rear interblade span, a first intermediate blade span, and a second interblade span, if applicable, are defined between the cutting edges 30 of each of the three, four, or five blades. For example, in the case of three cutting members 28a-c, the first intermediate blade span and the second interblade span are not present. In an embodiment having four cutting members 28a-d, the second intermediate interblade span is not present. In an embodiment having five blades, there are a front interblade span, a first and second intermediate interblade span, and a rear interblade span.

[0150] In the foregoing specification, numerous specific details are described to provide a thorough understanding. However, it will be apparent to one skilled in the art that the specific details need not be employed to practice the present disclosure. In other instances, well-known materials or methods have not been described in detail to avoid obscuring the present disclosure.

[0151] References throughout the foregoing specification to "one embodiment," "one embodiment," "one example," "one aspect," or "one aspect" mean that a particular feature, structure, or characteristic described in connection with an embodiment or example is included in at least one embodiment of the disclosure. Thus, the appearances of "one embodiment," "one embodiment," "one example," "one example," "one aspect," or "one aspect" in various places throughout this specification are not necessarily all referring to the same embodiment or example.

[0152] Furthermore, the particular features, structures or characteristics may be combined in any suitable combinations and / or subcombinations in one or more embodiments or examples.

[0153] This disclosure extends to the following statements which define embodiments of the disclosed technology: A1. A razor cartridge (20), comprising: - comprising three or more substantially parallel cutting members (28a-d) arranged between a front longitudinal side (24) and a rear longitudinal side (25) of the razor cartridge in a shaving direction (S) of the razor cartridge, each of the cutting members (28a-d) has a blade support (32) including, in use, a blade mounting portion (71) disposed on an inner surface (66) of the respective blade support facing away from the shaving plane (SH) and a blade (33) attached to the blade mounting portion (71); the cutting members (28a-d) are arranged to define a plurality of inter-blade spans (40, 41, 42) between the cutting edges (30) of the blades; A razor cartridge (20) in which a front inter-blade span (40) closer to a front longitudinal side (24) of the razor cartridge than the rear inter-blade span (42) is greater than a rear inter-blade span (42) closer to a rear longitudinal side (25) of the razor cartridge than the front inter-blade span.

[0154] A2. The razor cartridge (20) of claim A1, further comprising first and second debris outflow portions (46, 47) disposed corresponding to at least the front inter-blade span (40) and the rear inter-blade span (42), respectively, wherein the first debris outflow portion (46) is dimensioned to remove relatively more debris from the respective front or rear longitudinal inter-blade span (40, 42) during shaving and / or rinsing than the second debris outflow portion (47).

[0155] A3. The razor cartridge (20) of any one of statements A1 or A2, comprising a fourth substantially parallel cutting member disposed between the front longitudinal side (24) and the rear longitudinal side (25) of the razor cartridge in the shaving direction (S) of the razor cartridge, and a first intermediate inter-blade span (41) is further defined between the front inter-blade span (40) and the rear inter-blade span (42).

[0156] A4. The razor cartridge (20) of claim A3, wherein the first intermediate inter-blade span (41) is equal to or less than the front inter-blade span (40).

[0157] A5. The razor cartridge (20) of any one of statements A1-A4, wherein the first intermediate inter-blade span (41) is equal to or greater than the rear inter-blade span (42).

[0158] A6. The razor cartridge (20) of any one of statements A1-A5, wherein the front inter-blade span (40) is in the range of 1.70 mm to 2.20 mm, more specifically 1.80 mm to 2.00 mm, and most specifically 1.85 mm.

[0159] A7. The razor cartridge (20) of any one of statements A1-A6, wherein the first intermediate inter-blade span (41) is in the range of 1.55 mm to 1.95 mm, more specifically 1.60 mm to 1.80 mm, and most specifically 1.70 mm.

[0160] A8. The razor cartridge (20) of any one of statements A1-A7, wherein the rear inter-blade span (42) is in the range of 1.4mm to 1.8mm, more specifically 1.50mm to 1.65mm, and most specifically 1.55mm.

[0161] A9. The razor cartridge (20) of any one of statements A3-A5, wherein one or more of the front inter-blade span (40), the first intermediate inter-blade span (41), and / or the rear inter-blade span (42) are in the range of 1.6 mm to 2.2 mm, more specifically 1.70 mm to 2.00 mm, or 1.75 mm to 1.95 mm.

[0162] A10. - The razor cartridge (20) of any one of statements A3-A9, further comprising a fifth substantially parallel cutting member disposed in a shaving direction (S) of the razor cartridge, wherein a second intermediate inter-blade span is defined adjacent to the rear inter-blade span (42).

[0163] A11. A razor cartridge (20) as described in any one of statements A1-A10, wherein each of the blade supports (32) includes a shaving plane contact portion configured to contact the shaving plane (SH) in addition to the cutting edges (30a, 30b, 30c, 30d) of the blades in use, thereby reducing pressure at the contact points of the cutting edges with the shaving plane.

[0164] A12. A razor cartridge (20) according to one of statements A1-A11, wherein successive inter-blade spans (40, 41, 42) of the razor cartridge decrease continuously in the shaving direction (S) between the front longitudinal side (24) and the rear longitudinal side (25) of the razor cartridge.

[0165] A13. A method of manufacturing a razor cartridge, comprising: Obtaining (74) a razor cartridge housing and three or more cutting members (28a-d), each of the cutting members (28a-d) comprises a blade support (32) which, in use, comprises a blade mounting portion (71) disposed on an inner surface (66) of the respective blade support facing away from the shaving plane (SH), and a blade attached to the blade mounting portion; disposing (76) the cutting members (28a-d) between a front longitudinal side and a rear longitudinal side of the razor cartridge housing in a shaving direction of the razor cartridge, such that, in use, an inner surface of each blade support faces away from the shaving plane (SH); the cutting members (28a-d) define a plurality of inter-blade spans between the cutting edges of the blades; The method, wherein the front inter-blade span closer to the front longitudinal side of the razor cartridge than the rear inter-blade span is greater than the rear inter-blade span closer to the rear longitudinal side of the razor cartridge than the front inter-blade span.

[0166] A14. A shaving razor assembly (1), comprising: - razor handles (2), - A shaving razor assembly (1) comprising: a razor cartridge (20) according to one of statements A1 to A12, the razor cartridge (20) being either releasably attached to the razor handle via a pivotable (8) or non-pivotable connection, integrally formed with the razor handle via a non-pivotable connection, or integrally formed with the razor handle via a pivotable connection.

[0167] A15. It is a kit of parts. -Razor handle, - a razor cartridge holder containing a plurality of razor cartridges (20) according to one of statements A1 to A12.

[0168] B1. A razor cartridge (20), comprising: - comprising three or more substantially parallel cutting members (28a-d) arranged between a front longitudinal side (24) and a rear longitudinal side (25) of the razor cartridge in a shaving direction (S) of the razor cartridge, each of the cutting members (28a-d) has a blade support (32) including, in use, a blade mounting portion (71) disposed on an inner surface (66) of the respective blade support facing away from the shaving plane (SH) and a blade (33) attached to the blade mounting portion (71); the cutting members (28a-d) are arranged to define a plurality of inter-blade spans (40, 41, 42) between the cutting edges (30) of the blades; A razor cartridge (20) in which a front inter-blade span (40) closer to a front longitudinal side (24) of the razor cartridge than the rear inter-blade span (42) is smaller than a rear inter-blade span (42) closer to a rear longitudinal side (25) of the razor cartridge than the front inter-blade span.

[0169] B2. The razor cartridge (20) of statement B1, further comprising first and second debris outflow portions (46, 47) disposed corresponding to at least the front inter-blade span (40) and the rear inter-blade span (42), respectively, wherein the first debris outflow portion (46) is dimensioned to remove relatively more debris from the respective front or rear longitudinal inter-blade span (40, 42) during shaving and / or rinsing than the second debris outflow portion (47).

[0170] B3. The razor cartridge (20) of claim 1 or 2, further comprising a fourth substantially parallel cutting member disposed between the front longitudinal side (24) and the rear longitudinal side (25) of the razor cartridge in the shaving direction (S) of the razor cartridge, wherein a first intermediate inter-blade span (41) is further defined between the front inter-blade span (40) and the rear inter-blade span (42).

[0171] B4. The razor cartridge (20) of claim B3, wherein the first intermediate inter-blade span (41) is equal to or greater than the front inter-blade span (40).

[0172] B5. The razor cartridge (20) of any one of statements B1-B4, wherein the first intermediate inter-blade span (41) is equal to or less than the rear inter-blade span (42).

[0173] B6. The razor cartridge (20) of any one of statements B1-B5, wherein the rear inter-blade span (40) is in the range of 1.70 mm to 2.20 mm, more specifically 1.80 mm to 2.00 mm, and most specifically 1.85 mm.

[0174] B7. The razor cartridge (20) of any one of statements B1-B6, wherein the first intermediate inter-blade span (41) is in the range of 1.55 mm to 1.95 mm, more specifically 1.60 mm to 1.80 mm, and most specifically 1.70 mm.

[0175] B8. The razor cartridge (20) of any one of statements B1-B7, wherein the front inter-blade span (42) is in the range of 1.4mm to 1.8mm, more specifically 1.50mm to 1.65mm, and most specifically 1.55mm.

[0176] B9. The razor cartridge (20) of any one of statements B3-B5, wherein one or more of the front inter-blade span (40), the first intermediate inter-blade span (41), and / or the rear inter-blade span (42) are in the range of 1.6 mm to 2.2 mm, more specifically 1.70 mm to 2.00 mm, or 1.75 mm to 1.95 mm.

[0177] B10. - The razor cartridge (20) of any one of statements B3-B9, further comprising a fifth substantially parallel cutting member disposed in a shaving direction (S) of the razor cartridge, wherein a second intermediate inter-blade span is defined adjacent to the rear inter-blade span (42).

[0178] B11. The razor cartridge (20) of any one of statements B1-B10, wherein each of the blade supports (32) includes a shaving plane contact portion configured to contact the shaving plane (SH) in addition to the cutting edges (30a, 30b, 30c, 30d) of the blades in use, thereby relieving pressure at the contact points of the cutting edges with the shaving plane.

[0179] B12. A razor cartridge (20) according to one of statements B1-B11, wherein successive inter-blade spans (40, 41, 42) of the razor cartridge increase continuously in the shaving direction (S) between the front longitudinal side (24) and the rear longitudinal side (25) of the razor cartridge.

[0180] B13. A method of manufacturing a razor cartridge, comprising: Obtaining (74) a razor cartridge housing and three or more cutting members (28a-d), each of the cutting members (28a-d) comprising a blade support (32) including a blade mounting portion (71) disposed, in use, on an inner surface (66) of the respective blade support facing away from a shaving plane (SH), and a blade attached to the blade mounting portion; disposing (76) the cutting members (28a-d) between a front longitudinal side and a rear longitudinal side of the razor cartridge housing in a shaving direction of the razor cartridge, such that, in use, an inner surface of each blade support faces away from the shaving plane (SH); the cutting members (28a-d) define a plurality of inter-blade spans between the cutting edges of the blades; The method, wherein the front inter-blade span closer to the front longitudinal side of the razor cartridge than the rear inter-blade span is smaller than the rear inter-blade span closer to the rear longitudinal side of the razor cartridge than the front inter-blade span.

[0181] B14. A shaving razor assembly (1), comprising: - razor handles (2), - A shaving razor assembly (1) comprising: a razor cartridge (20) according to one of statements B1 to B12, the razor cartridge (20) being either releasably attached to the razor handle via a pivotable (8) or non-pivotable connection, integrally formed with the razor handle via a non-pivotable connection, or integrally formed with the razor handle via a pivotable connection.

[0182] B15. A kit of parts -Razor handle, - a razor cartridge holder containing a plurality of razor cartridges (20) according to one of statements B1 to B12.

[0183] C1. A razor cartridge comprising: a first blade support and a second blade support, each of the first blade support and the second blade support including a flat portion having an inner surface that faces away from the shaving plane S in use; a first blade attached to an inner surface of the flat portion of the first blade support, the first blade including a first cutting edge; a second blade attached to an inner surface of the flat portion of the second blade support, the second blade having a second cutting edge; A razor cartridge, wherein the distance between the first cutting edge and the second cutting edge is within a range of 1.6 mm to 2.2 mm.

[0184] C2. The razor cartridge of statement C1, wherein the distance between the first cutting edge and the second cutting edge is within the range of 1.70 mm to 2 mm.

[0185] C3. The razor cartridge of claim C1 or C2, wherein the distance between the first cutting edge and the second cutting edge is within the range of 1.75 mm to 1.95 mm.

[0186] C4. The razor cartridge of any one of statements C1-C3, wherein the first and second blade supports each include a front end configured to contact the skin.

[0187] C5. The razor cartridge of any one of statements C1-C4, wherein at least one leading end is rounded.

[0188] C6. The razor cartridge of any one of statements C1-C5, wherein each of the first and second blade supports includes a base extending from the flat portion at an angle β, and the angle β formed between the flat portion and the base of each of the first and second blade supports is in the range of 104° to 120°.

[0189] C7. A third blade support including a flat portion having an inner surface facing away from the shaving plane S; a third blade attached to an inner surface of the planar portion of the third blade support, the third blade including a third cutting edge; The razor cartridge of any of statements C1-C6, wherein the distance from the second to third cutting edges is within the range of 1.6 mm to 2.2 mm.

[0190] C8. The razor cartridge of claim C7, wherein the distance from the second to third cutting edges is within the range of 1.70 mm to 2 mm.

[0191] C9. The razor cartridge of any one of statements C7 or C8, wherein the distance from the second to third cutting edges is within the range of 1.75 mm to 1.95 mm.

[0192] C10. A fourth blade support including a flat portion having an inner surface facing away from the shaving plane; a fourth blade attached to an inner surface of the flat portion of the fourth blade support, the fourth blade including a fourth cutting edge; The razor cartridge of any of statements C7 to C9, wherein the distance from the third to fourth cutting edges is within the range of 1.6 mm to 2.2 mm.

[0193] C11. The razor cartridge of statement C10, wherein the distance from the third to the fourth cutting edge is within the range of 1.70 mm to 2 mm.

[0194] C12. The razor cartridge of either statement C10 or C11, wherein the distance from the third to the fourth cutting edge is within the range of 1.75 to 1.95.

[0195] C13. The razor cartridge of any one of statements C7-C12, wherein the third and / or fourth blade support includes a front end configured to contact the skin.

[0196] C14. The razor cartridge of statement C13, wherein at least one leading end is rounded.

[0197] C15. A shaver including a handle and a razor cartridge according to any of statements C1-C14, wherein the razor cartridge is connectable to the handle, the razor cartridge including four blade assemblies, and the distance between successive cutting edges is 1.85 mm ± 0.1 mm. [Table 1]

Claims

1. A razor cartridge (20) having a blade that is not driven by a motor and for use with a razor handle, comprising: - comprising four substantially parallel cutting members (28a-d) arranged between a front longitudinal side (24) and a rear longitudinal side (25) of said razor cartridge in the shaving direction (S) of said razor cartridge, each of said cutting members (28a-d) comprises a blade support (32) bent to have a lower portion (60) and an upper side (65) of the blade support (32), said lower portion (60) being held in said razor cartridge, said upper side (65) facing towards a shaving plane (SH) in use, a first surface being an outer surface (68) of the upper side (65) of each blade support (32), a second surface being an inner surface (66) of said first surface, said second surface facing away from said shaving plane (SH) in use, a blade mounting portion (71) disposed on said second surface, and a blade (33) attached to said blade mounting portion (71); A portion of said top side may come into contact with said shaving plane (SH) in use; the cutting members (28a-d) are arranged to define a plurality of inter-blade spans (40, 41, 42) between the cutting edges (30a-d) of the blades each attached to the blade supports (32a-d); a distance range of a front inter-blade span (40) closer to said front longitudinal side (24) of said razor cartridge than a rear inter-blade span (42) differs from a distance range of said rear inter-blade span (42) closer to said rear longitudinal side (25) of said razor cartridge than said front inter-blade span; a first intermediate inter-blade span (41) is further defined between said forward inter-blade span (40) and said aft inter-blade span (42), said first intermediate inter-blade span (41) being in the range of 1.55 mm to 1.95 mm; A razor cartridge (20) wherein said front inter-blade span (40) or said rear inter-blade span (42) is in the range of 1.4 mm to 1.8 mm.

2. 2. The razor cartridge (20) of claim 1, further comprising a first debris outflow portion (46, 47) positioned at least correspondingly with said rear inter-blade span (40) and said front inter-blade span (42), respectively, said first debris outflow portion (46) being dimensioned such that during shaving and / or rinsing, debris exiting the respective front or rear inter-blade span (40, 42) flows for removal relatively more than said second debris outflow portion (47).

3. 3. The razor cartridge (20) of claim 1 or 2, wherein the front inter-blade span (40) closer to the front longitudinal side (24) of the razor cartridge than the rear inter-blade span (42) is smaller than the rear inter-blade span (42) closer to the rear longitudinal side (25) of the razor cartridge than the front inter-blade span.

4. 3. The razor cartridge (20) of claim 1 or 2, wherein a front inter-blade span (40) closer to the front longitudinal side (24) of the razor cartridge than the rear inter-blade span (42) is greater than a rear inter-blade span (42) closer to the rear longitudinal side (25) of the razor cartridge than the front inter-blade span.

5. 5. The razor cartridge (20) of any one of claims 1 to 4, wherein said first intermediate inter-blade span (41) is equal to, greater than, or less than said front inter-blade span (40).

6. 6. The razor cartridge (20) of any one of claims 1 to 5, wherein said first intermediate inter-blade span (41) is equal to, less than, or greater than said rear inter-blade span (42).

7. 7. The razor cartridge (20) of any one of claims 1 to 6, wherein said rear inter-blade span (40) or said front inter-blade span (42) is in the range of 1.70 mm to 2.20 mm, more specifically 1.80 mm to 2.00 mm, and most specifically 1.85 mm.

8. The razor cartridge (20) of any one of claims 1 to 7, wherein said front inter-blade span (42) or said rear inter-blade span (40) is in the range of 1.50 mm to 1.65 mm, specifically in the range of 1.55 mm.

9. 8. The razor cartridge (20) of any one of claims 1 to 7, wherein one or more of said front inter-blade span (40), said first intermediate inter-blade span (41), and / or said rear inter-blade span (42) range from 1.6 mm to 2.2 mm, more specifically, from 1.70 mm to 2.00 mm, or from 1.75 mm to 1.95 mm.

10. A razor cartridge (20) according to any one of claims 1 to 9, comprising a fifth substantially parallel cutting member disposed in a shaving direction (S) of the razor cartridge, a second intermediate inter-blade span being defined adjacent to the rear inter-blade span (42).

11. 11. The razor cartridge (20) of claim 1, wherein each of the blade supports (32) comprises a shaving plane contact portion on the top side (65) configured to contact the shaving plane (SH) in addition to the cutting edges (30a, 30b, 30c, 30d) of the blades in use, thereby reducing pressure at the contact points of the cutting edges with the shaving plane.

12. A razor cartridge (20) according to any one of claims 1 to 11, wherein successive inter-blade spans (40, 41, 42) of the razor cartridge increase and decrease continuously in the shaving direction (S) between the front longitudinal side (24) and the rear longitudinal side (25) of the razor cartridge.

13. A shaving razor assembly (1), comprising: - a razor handle (2), A shaving razor assembly (1) comprising: a razor cartridge (20) according to one of claims 1 to 12, the razor cartridge (20) being either releasably attached to the razor handle via a pivotable (8) or non-pivotable connection, or integrally formed with the razor handle via a non-pivotable connection, or integrally formed with the razor handle via a pivotable connection.

14. 1. A kit of parts comprising: - a razor handle; A kit of parts comprising: a razor cartridge holder comprising a plurality of razor cartridges (20) according to one of claims 1 to 12.

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