Razor Blade Gradient Thickness and Facet Structure
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Solution Overview
Problem
Conventional razor blades face challenges in achieving a balance between cutting force and bending durability, leading to variations in shaving performance and feel due to differences in blade shape and material.
Innovation Solution
A razor blade design with a substrate having a specific thickness profile, featuring a thinner cutting edge (T4) and a thicker section further from the tip (T200), along with a facet structure formed by abrading wheels, to reduce cutting force while enhancing bending durability and adhesion between the substrate and coating layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Force
If the cutting edge thickness is reduced to lower cutting force, then the bending durability deteriorates
Solution Approach 1:
The blade employs different thickness specifications at different locations: the cutting edge portion has a thickness of 1.40 μm to 1.70 μm for reduced cutting force, while the rear portion has a thickness of 56.50 μm to 64.12 μm for enhanced bending durability. This local differentiation of physical properties resolves the contradiction between sharp cutting performance and structural strength.
Solution Approach 2:
The invention transitions from a uniform thickness design to a gradient thickness design along the longitudinal dimension of the blade. By controlling the thickness ratio (T4/T200) between 0.022 and 0.030, the blade achieves both low cutting force at the tip and high bending durability at the rear, effectively resolving the force-strength contradiction through dimensional variation.
2Ease of operation
If the blade shape is modified to improve shaving performance, then the adhesion between substrate and coating layer deteriorates
Solution Approach 1:
The invention optimizes specific geometric parameters including the thickness ratio (T4/T200) between 0.022 and 0.030, the facet angle between 150° and 170°, and the rounding radius at the cutting edge between 2 μm and 5 μm. These parameter optimizations simultaneously improve shaving performance and maintain substrate-coating adhesion by balancing the mechanical stresses involved.
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
The design results in a razor blade with lower cutting force, improved bending durability, and enhanced shaving performance and feel, along with better adhesion between the substrate and coating layers, compared to conventional blades.
Implementation Method 1
the substrate includes a first facet region including a plurality of first facets formed by first abraded scratches, a plurality of second facets formed by second abraded scratches
Data Source
AI summary
A razor blade is proposed. The razor blade may include a substrate having a cutting edge formed at a tip. The substrate may include a plurality of first facets, and a plurality of second facets formed between the tip and the plurality of first facets. The substrate may also include a facet brake region having facet brake spots where the plurality of first facets and the plurality of second facets intersect. The substrate may further include a first facet region including the plurality of first facets but not including the plurality of second facets.