Elastomeric Lubrication Box Ultrasonic Compression
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Solution Overview
Problem
Current lubrication systems in wet shaving implements suffer from excessive leaching of shaving aids during initial uses, inadequate lubrication towards the end of the cartridge's life, and inefficiencies due to rigid manufacturing processes that degrade active ingredients and cause swelling issues.
Innovation Solution
A lubrication box with a first portion made of elastomeric material and ultrasonically compressed shaving aid layers, allowing expansion and distribution of the aid during use, and a second portion that creates a gap for expansion, supported by features to maintain the aid's position and prevent wastage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If lubrication strips use water soluble components dispersed in water insoluble matrix, then lubrication is provided during shaving, but the shaving aid leaches superfluously during first few shaves and dissipates by the end of cartridge life
Solution Approach 1:
The patent changes the physical state and delivery mechanism of the shaving aid from a pre-mixed water-soluble/water-insoluble matrix to separate components: a water-soluble shaving aid core and a water-insoluble porous matrix. The matrix parameters (porosity, capillary structure) are optimized to control water absorption and shaving aid dissolution rate, preventing both excessive initial leaching and premature depletion.
Solution Approach 2:
The lubrication system is segmented into distinct functional components: a porous water-insoluble matrix structure and water-soluble shaving aid material contained within capillaries. This segmentation allows independent optimization of each component - the matrix provides structural integrity and controlled release, while the shaving aid provides lubrication - resolving the contradiction between sustained delivery and wastage.
2Quantity of substance
If co-extruded core and sheath setup is used with holes through sheath, then lubrication is provided, but high temperatures and pressures degrade active shaving aid ingredients
Solution Approach 1:
The patent replaces the thermal-mechanical co-extrusion process with a mechanical assembly process involving a porous matrix and separately contained shaving aid. This substitution eliminates exposure to high temperatures and pressures during manufacturing, preventing thermal degradation of active ingredients while still achieving controlled delivery through capillary action and dissolution.
Solution Approach 2:
The porous water-insoluble matrix acts as an intermediary structure that holds the water-soluble shaving aid without requiring direct thermal processing of the active ingredients. The matrix provides a protective environment during manufacturing and a controlled release mechanism during use, resolving the thermal degradation issue.
3Stability of the object's composition
If co-molded/co-extruded set-up is used, then lubrication structure is formed, but the core swells during normal use causing substantially problems
Solution Approach 1:
The patent segments the lubrication system into a separate porous matrix and shaving aid components, allowing the matrix to be pre-formed with controlled porosity and capillary structure. This prevents the swelling issues that occur in co-molded systems where the core and sheath are integrated, as the shaving aid is contained within defined capillaries rather than being part of a continuously swelling matrix.
Solution Approach 2:
The use of a porous water-insoluble matrix with controlled pore size and capillary structure provides structural integrity while enabling controlled water absorption and shaving aid release. The porosity is optimized to allow function without excessive swelling, resolving the contradiction between structure integrity and swelling control.
4Quantity of substance
If lubrication strip is adhered to or mechanically fastened to wet-shave razor cartridge, then lubrication is provided, but the strip does not permit complete leaching of all shaving aid
Solution Approach 1:
The patent employs a porous water-insoluble matrix with capillary structures that allow complete penetration of water throughout the shaving aid material. The porosity and capillary design ensure that water can access and dissolve all shaving aid components, permitting complete leaching without waste, unlike traditional adhered strips with limited water penetration.
Solution Approach 2:
The patent changes the physical parameters of the matrix (porosity, capillary dimensions, surface area) to optimize water penetration and shaving aid dissolution. These parameter changes ensure complete leaching of the shaving aid while maintaining structural integrity, resolving the contradiction between complete delivery and waste prevention.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enhances the effectiveness and longevity of lubrication by ensuring consistent delivery of shaving aids throughout the cartridge's life, reducing wastage and maintaining the integrity of active ingredients.
Implementation Method 1
The skin-engaging member includes an elastomeric material
Implementation Method 2
The shaving aid material is ultrasonically compressed into the cavity
Data Source
Figure 1~1A
Figure 2
Figure 3
AI summary
According to one aspect of the present invention, a lubrication box includes a first portion, a shaving aid material, and a second portion. The first portion of the lubrication box has a skin-engaging surface and at least one sidewall that, together, form a cavity. The skin-engaging surface includes at least two holes therethrough. The shaving aid material, which is optionally distributed in the cavity in a series of layers, is ultrasonically compressed into the cavity such that it at least partially fills at least one of the holes in the skin-engaging surface and at least a portion of the cavity. The second portion of the lubrication box is attached to the first portion such that the cavity is substantially closed. A gap exists between in the cavity between the shaving aid and the second portion of the lubrication box to permit the shaving aid material to expand during normal use