U.S. patent application number 12/874762 was filed with the patent office on 2010-12-30 for razors.
Invention is credited to Luis Burrel, Thomas Hoppenstedt, Patrick F. McNally, Evan Pennell, Stefan Rehbein, Gerrit Ronneberg, Uwe Schaaf, Fred Schnak, Keith A. Swenson.
Application Number | 20100325872 12/874762 |
Document ID | / |
Family ID | 37575207 |
Filed Date | 2010-12-30 |
View All Diagrams
United States Patent
Application |
20100325872 |
Kind Code |
A1 |
Schnak; Fred ; et
al. |
December 30, 2010 |
Razors
Abstract
Razor handles are provided for razors having a battery-powered
functionality. Methods of manufacturing such handles are also
provided. In one implementation, the handle includes a unitary grip
portion constructed to receive a razor head at one end thereof, and
a battery cover, mounted on the grip portion. The grip portion and
the battery cover, when joined, may together define a water-tight
unit prior to mounting of the razor head on the grip portion.
Inventors: |
Schnak; Fred; (Kronberg,
DE) ; Burrel; Luis; (Kettenhofweg, DE) ;
Rehbein; Stefan; (Schumannstr., DE) ; Ronneberg;
Gerrit; (Darmstadt, DE) ; Schaaf; Uwe;
(Alsbach-Hahnlein, DE) ; Pennell; Evan; (Hingham,
MA) ; McNally; Patrick F.; (Providence, RI) ;
Hoppenstedt; Thomas; (Kronberg im Taunus, DE) ;
Swenson; Keith A.; (Hanover, MA) |
Correspondence
Address: |
THE PROCTER & GAMBLE COMPANY;Global Legal Department - IP
Sycamore Building - 4th Floor, 299 East Sixth Street
CINCINNATI
OH
45202
US
|
Family ID: |
37575207 |
Appl. No.: |
12/874762 |
Filed: |
September 2, 2010 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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11998516 |
Nov 30, 2007 |
7810243 |
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12874762 |
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11220008 |
Sep 6, 2005 |
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11998516 |
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Current U.S.
Class: |
29/593 |
Current CPC
Class: |
Y10T 29/49004 20150115;
B26B 21/526 20130101 |
Class at
Publication: |
29/593 |
International
Class: |
G01R 31/28 20060101
G01R031/28 |
Claims
1. A method of manufacturing a razor handle, comprising: forming a
unitary grip tube having a closed end configured to receive a razor
head; inserting a battery and a carrier into an open opposite end
of the grip tube, the carrier having electronic components mounted
thereon; sealing the open end of the grip tube; and testing the
electronic functionality of the resulting assembly.
2. The method of claim 1 further comprising mounting a razor head
on the closed end if the testing step results in a determination
that the electronics are functional.
3. The method of claim 1 wherein the sealing step comprises
mounting a removable battery cover on the open end.
4. The method of claim 3 wherein mounting the battery cover on the
open end renders the assembly water-tight.
5. The method of claim 2 wherein the mounting step comprises
fixedly mounting the razor head.
6. The method of claim 2 wherein the razor head is configured to
receive a disposable razor cartridge.
7. The method of claim 1 wherein forming the unitary grip tube
comprises molding a grip tube preform having a window opening and
welding a window into the opening.
8. A method of forming a plurality of razor products having a
battery-powered functionality, the method comprising: forming a
plurality of substantially identical razor sub-assemblies, each
sub-assembly including (a) a unitary grip tube having a closed end
configured to receive a razor head, and (b) a battery and
battery-powered components disposed within the grip tube, the grip
tube being sealed in a water-tight manner; and mounting a first
razor head on the closed ends of a first sub-set of the razor
sub-assemblies to form a first product, and mounting a second,
different razor head on the closed ends of a second sub-set of the
razor sub-assemblies to form a second, different product.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. application Ser.
No. 11/998,516, filed on Nov. 30, 2007, currently pending, which is
a divisional of U.S. application Ser. No. 11/220,008, filed Sep. 6,
2005 now abandoned.
TECHNICAL FIELD
[0002] This invention relates to razors, and more particularly to
razors for wet shaving that include a battery-powered
functionality.
BACKGROUND
[0003] Recently, some wet shaving razors have been provided with a
battery-powered functionality. For example, the Gillette.RTM. M3
Power.TM. razor, sold by The Gillette Company, provides a vibrating
function that is powered by a battery disposed in a chamber within
the handle of the device. The battery is replaceable by the user,
by removing a battery cover. It is desirable for safety and
durability reasons that the handle of such a device be
water-tight.
SUMMARY
[0004] The present invention provides razors having handles that
are reliably water-tight and that can be readily sealed by the user
when the battery cover is replaced by the user after changing the
battery.
[0005] In one aspect, the invention features a razor handle for a
razor having a battery-powered functionality, the handle including
a unitary grip portion constructed to receive a razor head at one
end thereof, and a battery cover, mounted on the grip portion, the
grip portion and the battery cover, when joined, together defining
a water-tight unit prior to mounting of the razor head on the grip
portion.
[0006] Some implementations may include one or more of the
following features. The razor handle may further include a
plurality of components that provide the battery-powered
functionality, and all components of the razor that provide the
battery-powered functionality may be disposed within the grip
portion. The razor handle may further include a razor head, fixedly
mounted on the grip portion. The battery cover may be removably
mounted on the grip portion, or, alternatively, may be permanently
welded to the grip tube. The razor handle may further include a
sealing member, e.g., an elastomeric seal, disposed at an interface
between the battery cover and grip portion to provide a water-tight
seal at the interface. The razor handle may further include a
subassembly, disposed within the grip portion, including a carrier
and a switch or electronic components mounted on the carrier. The
carrier may include a portion constructed to receive a battery and
provide electrical communication between the battery and electronic
components. The carrier may also include a portion constructed to
engage a corresponding portion of the battery cover. The handle may
further include a sleeve, disposed inside the battery-receiving
portion of the carrier and surrounding the battery.
[0007] In another aspect, the invention features a razor handle for
a razor having a battery-powered functionality, the handle
including: (a) a grip portion; (b) within the grip portion,
components configured to provide the battery-powered functionality;
(c) an actuator, mounted on the grip portion and positioned to be
depressed by a user of the razor; and (d) an electronic switch, in
electrical communication with the components, positioned to be
actuated when the actuator is depressed.
[0008] Some implementations may include one or more of the
following features. The electronic switch may require an actuation
force of at least 4 N applied over about a displacement of about
0.25 mm. The grip portion may include a resilient membrane that is
interposed between the actuator and the electronic switch. The
resilient membrane may be configured to exert a restoring force on
the actuator after the actuator is depressed and released. The
actuator may include a button and an underlying cantilevered member
supporting the button. The components may include a printed circuit
board, and the electronic switch may be in communication with the
printed circuit board to activate circuitry of the printed circuit
board. The actuator may include a button, and an upper surface of
the button may be substantially flush with an outer surface of the
grip tube. The electronics may be configured to drive a vibrating
function of the razor.
[0009] In some implementations, the razor handle may further
include a closing system, including a first component within the
battery cover, and a second component secured to the interior wall
of the grip portion, the first component being configured to move
axially within the battery cover during engagement of the battery
cover with the grip portion, and being biased toward a
predetermined axial position. The first and second components may
be configured to engage each other by rotation of the battery cover
relative to the housing. The first component may include a spring
element configured to apply an axial force between the grip portion
and battery cover when the first and second components are engaged.
Engagement of the first and second components may provide an
electrical connection between the first and second components. The
handle may further include, within the grip tube, a pair of battery
clamp fingers configured to exert a clamping force against the
battery when the battery is in place in the razor.
[0010] The grip tube may include a window, and the razor handle may
further include an indicator, e.g., an LED or other light or
display, beneath the window.
[0011] In other aspects, the invention features methods of
manufacturing razor handles. In one such aspect, the invention
features a method including: (a) forming a unitary grip tube having
a closed end configured to receive a razor head; (b) inserting a
battery and a carrier into an open opposite end of the grip tube,
the carrier having electronic components mounted thereon; (c)
sealing the open end of the grip tube; and (d) testing the
electronic functionality of the resulting assembly.
[0012] Some implementations of this method may include one or more
of the following features. The method may also include mounting,
e.g., fixedly mounting, a razor head on the closed end if the
testing step results in a determination that the electronics are
functional. The sealing step may include mounting a removable
battery cover on the open end. Mounting the battery cover on the
open end may render the assembly water-tight. The razor head may in
some cases be configured to receive a disposable razor cartridge.
In other cases, the razor head and razor cartridge may be integral,
e.g., if the razor is a disposable razor. Forming the unitary grip
tube may, for example, include molding a grip tube preform having a
window opening and welding a window into the opening.
[0013] In another aspect, the invention features a method of
forming a plurality of razor products having a battery-powered
functionality. The method includes (i) forming a plurality of
substantially identical razor sub-assemblies, each sub-assembly
including (a) a unitary grip tube having a closed end configured to
receive a razor head, and (b) a battery and battery-powered
components disposed within the grip tube, the grip tube being
sealed in a water-tight manner; and (ii) mounting a first razor
head on the closed ends of a first sub-set of the razor
sub-assemblies to form a first product, and mounting a second,
different razor head on the closed ends of a second sub-set of the
razor sub-assemblies to form a second, different product.
[0014] The details of one or more embodiments of the invention are
set forth in the accompanying drawings and the description below.
Other features, objects, and advantages of the invention will be
apparent from the description and drawings, and from the
claims.
DESCRIPTION OF DRAWINGS
[0015] FIG. 1 is a top view of a razor handle according to one
embodiment.
[0016] FIGS. 1A and 1B are cross sectional views of the razor
handle of FIG. 1.
[0017] FIG. 2 is a bottom view of the razor handle of FIG. 1.
[0018] FIG. 3 is a partially exploded view of the razor handle of
FIG. 1.
[0019] FIG. 4 is a perspective view of the head tube exploded from
the grip tube of the razor.
[0020] FIG. 5 is a side view of the grip tube.
[0021] FIG. 6 is an exploded view of the grip tube showing the
components contained therein.
[0022] FIGS. 7-7C are exploded views illustrating the assembly of
the components contained in the grip tube.
[0023] FIG. 8 is a perspective view of the grip tube with the LED
window exploded from the tube and the actuator button omitted. FIG.
8A is a perspective view of the grip tube with the LED window
welded in place and the actuator button exploded from the tube.
FIGS. 8B-8D are enlarged perspective views of a portion of the grip
tube, showing steps in assembly of the actuator button onto the
tube.
[0024] FIG. 9 is a perspective view of a bayonet assembly used in
the razor of FIG. 1. FIG. 9A is an enlarged detail view of area A
in FIG. 9. FIG. 9B is an enlarged detail view of the bayonet
assembly with the male and female components engaged and the
bayonet and battery springs compressed.
[0025] FIG. 10 is a side view of the bayonet assembly shown in FIG.
9, rotated 90 degrees with respect to the position of the assembly
in FIG. 9.
[0026] FIG. 11 is an exploded view of the lower portion of the
bayonet assembly and the battery shell that contains the lower
portion.
[0027] FIG. 12 is a cross-sectional view of the battery shell.
[0028] FIG. 13 is an exploded view of the venting components of the
battery shell.
[0029] Like reference symbols in the various drawings indicate like
elements.
[0030] FIG. 14A shows a razor having a speed control switch.
[0031] FIG. 14B shows a razor having a speed control switch and a
memory for storage of preferred speeds.
[0032] FIG. 14C shows a razor having an indirect power supply.
[0033] FIG. 14D shows a voltage converter for the indirect power
supply of FIG. 14C.
[0034] FIG. 14E shows the signals output by the control logic and
the oscillator, and their effect on the capacitor voltage.
[0035] FIG. 14F shows another voltage converter for the indirect
power supply of FIG. 14C.
[0036] FIG. 14G shows a circuit for supplying power to a load.
[0037] FIG. 15A shows a blade-life indicator that counts the number
of times a motor has started since blade replacement.
[0038] FIG. 15B shows a blade-life indicator that accumulates
motor-operating time since blade replacement.
[0039] FIG. 15C shows a blade-life indicator that counts the number
of strokes since blade replacement.
[0040] FIG. 15D shows a blade-life indicator that accumulates
stroke time since blade replacement.
[0041] FIG. 16A shows a mechanical lock.
[0042] FIG. 16B shows a locking circuit in which a lock signal
disarms the razor.
[0043] FIG. 17A shows a force-measurement circuit that senses
variations in current drawn by the motor.
[0044] FIG. 17B shows a force-measurement circuit that senses
variations in motor speed.
DETAILED DESCRIPTION
Overall Razor Structure
[0045] Referring to FIG. 1, a razor handle 10 includes a razor head
12, a grip tube 14, and a battery shell 16. The razor head 12
includes a connecting structure for mounting a replaceable razor
cartridge (not shown) on the handle 10, as is well known in the
razor art. The grip tube 14 is constructed to be held by a user
during shaving, and to contain the components of the razor that
provide the battery-powered functionality of the razor, e.g., a
printed circuit board and a motor configured to cause vibration.
The grip tube is a sealed unit to which the head 12 is fixedly
attached, allowing modular manufacturing and providing other
advantages which will be discussed below. Referring to FIG. 3, the
battery shell 16 is removably attached to the grip tube 14, so that
the user may remove the battery shell to replace the battery 18.
The interface between the battery shell and grip tube is sealed,
e.g., by an O-ring 20, providing a water-tight assembly to protect
the battery and electronics within the razor. The O-ring 20 is
generally mounted in groove 21 (FIG. 5) on the grip tube, e.g., by
an interference fit. Referring again to FIG. 1, the grip tube 14
includes an actuator button 22 that may be pressed by the user to
actuate the battery-powered functionality of the razor via an
electronic switch 29 (FIG. 7A). The grip tube also includes a
transparent window 24 to allow the user to view a light 31 or
display or other visual indicator (FIG. 7A), e.g., an LED or LCD,
that provides a visual indication to the user of battery status
and/or other information. The light 31 shines through an opening 45
(FIG. 8) provided in the grip tube beneath the transparent window.
These and other features of the razor handle will be described in
further detail below.
[0046] Modular Grip Tube Structure
[0047] As discussed above, the grip tube 14 (shown in detail in
FIGS. 4 and 5) is a modular assembly, to which the razor head 12 is
fixedly attached. The modularity of the grip tube advantageously
allows a single type of grip tube to be manufactured for use with
various different razor head styles. This in turn simplifies
manufacturing of "families" of products with different heads but
the same battery-powered functionality. The grip tube is
water-tight except for the opening 25 at the end to which the
battery shell is attached, and is preferably a single, unitary
part. Thus, the only seal that is required to ensure
water-tightness of the razor handle 10 is the seal between the grip
tube and the battery shell, provided by O-ring 20 (FIG. 3). This
single-seal configuration minimizes the risk of water or moisture
infiltrating the razor handle and damaging the electronics.
[0048] As shown in FIG. 6, the grip tube 14 contains a subassembly
26 (also shown in FIG. 7C) which includes a vibration motor 28, a
printed circuit board 30, an electronic switch 29 and the light 31
mounted on the printed circuit board, and the positive contact 32
for providing battery power to the electronics. These components
are assembled within a carrier 34 which also includes battery clamp
fingers 36 and a male bayonet portion 38, the functions of which
will be discussed in the Battery Clamp and Battery Shell Attachment
sections below. The assembly of all the functional electronic
components of the razor onto the carrier 34 allows the
battery-powered functionality to be pre-tested so that failures can
be detected early, minimizing costly scrapping of completed razors.
Subassembly 26 also includes an insulation sleeve 40 and mounting
tape 42, the function of which will be discussed in the Battery
Clamp section below.
[0049] The subassembly 26 is assembled as shown in FIGS. 7-7C.
First, the positive contact 32 is assembled onto a PCB carrier 44,
which is then mounted on carrier 34 (FIG. 7). Next, the printed
circuit board 30 is placed in the PCB carrier 44 (FIG. 7A), and the
vibration motor 28 is mounted on the carrier 34 (FIG. 7B) with lead
wires 46 being soldered onto the printed circuit board to complete
the subassembly 26 (FIG. 7C). The subassembly may then be tested
prior to assembly into the grip tube.
[0050] The subassembly 26 is assembled into the grip tube so that
it will be permanently retained therein. For example, the
subassembly 26 may include protrusions or arms that engage
corresponding recesses in the inner wall of the grip tube in an
interference fit.
[0051] The grip tube also includes an actuator button 22. The rigid
actuator button is mounted on a receiving member 48 (FIG. 8) that
includes the window 24, discussed above. The receiving member 48
includes a cantilevered beam 50 that carries an actuator member 52.
Actuator member 52 transmits force that is applied to the button 22
to an underlying resilient membrane 54 (FIG. 8). Membrane 54 may
be, for example, an elastomeric material that is molded onto the
grip tube to form not only the membrane but also an elastomeric
gripping portion. The cantilevered beam, acting in concert with the
membrane, provides a restoring force to return the button 22 to its
normal position after it is depressed by a user. When the button is
depressed, the actuator member 52 contacts the underlying
electronic switch 29, which activates the circuitry of the PCB 30.
Activation may be by a "push and release" on/off action or other
desired action, e.g., push on/push off. The electronic switch 29
makes an audible "click" when actuated, giving the user feedback
that the device has been correctly turned on. The switch is
preferably configured to require a relatively high actuation force
applied over a small distance (e.g., at least 4 N applied over
about an 0.25 mm displacement). This switch arrangement, combined
with the recessed, low profile geometry of button 22, tends to
prevent the razor from being accidentally turned on during travel,
or inadvertently turned off during shaving. Moreover, the structure
of the switch/membrane/actuator member assembly provides the user
with good tactile feedback. The actuator member 52 also holds the
button 22 in place, the aperture 55 in the center of the actuator
member 52 receiving a protrusion 56 on the underside of the button
22 (FIG. 8B).
[0052] Adjacent to the button 22 is the transparent window 24,
through which the user can observe the indications provided by the
underlying light, which are described in detail in the Electronics
section below.
[0053] Assembly of the window 24 and actuator button onto the grip
tube, is illustrated in FIGS. 8-8D. First, the receiving member 48,
carrying the window 24, is sealingly mounted on the grip tube,
e.g., by gluing or ultrasonic or heat welding (FIG. 8), to form the
unitary water-tight part discussed above. Next, the button 22 is
slid into place and gently (preferably with less than 10 N force)
pushed down into the opening in the receiving member, causing the
protrusion 56 to engage the aperture 55 (FIGS. 8A-8C).
[0054] Battery Shell Attachment
[0055] As discussed above, the battery shell 16 is removably
attached to the grip tube 14, allowing removal and replacement of
the battery. The two parts of the handle are connected, and
electrical contact is established between the negative terminal of
the battery and the electronic components, by a bayonet connection.
The grip tube carries the male portion of the bayonet connection,
while the battery shell carries the female portion. The assembled
bayonet connection, with the grip tube and battery shell omitted
for clarity, is shown in FIGS. 9, 9A and 10.
[0056] The male bayonet portion 38 of the carrier 34, discussed
above, provides the male portion of the bayonet connection. Male
bayonet portion 38 carries a pair of protrusions 60. These
protrusions are constructed to be received and retained in
corresponding slots 62 in a female bayonet component 64, carried by
the battery shell. Each slot 62 includes a lead-in having angled
walls 66, 68 (FIG. 9A), to guide each protrusion into the
corresponding slot as the battery shell is rotated relative to the
grip tube. A detent area 65 (FIG. 9A) is provided at the end of
each slot 62. The engagement of the protrusions in the detent areas
65 (FIG. 9B) provides a secure, twist-on mechanical connection of
the battery shell to the grip tube.
[0057] The carrier 34 and the female bayonet component 64 are both
made of metal, and thus engagement of the protrusions with the
slots also provides electrical contact between the carrier and the
female bayonet component. The carrier is in turn in electrical
contact with circuitry of the device, and the negative terminal of
the battery is in contact with a battery spring 70 (FIG. 9A) that
is in electrical communication with the female bayonet component,
and thus contact of the spring members and electrical part
ultimately results in contact between the battery and the circuitry
of the device.
[0058] As shown in FIG. 12, the battery spring 70 is mounted on a
spring holder 72, which is in turn mounted fixedly to the inner
wall of the battery shell 16. The female bayonet component 64 is
free to slide axially back and forth within the battery shell 16.
In its rest position, the female bayonet component is biased to the
base of the battery shell by a bayonet spring 74. The bayonet
spring 74 is also mounted on the spring holder 72 and thus its
upper end is fixedly mounted with respect to the inner wall of the
battery shell. When the battery shell is twisted onto the grip
tube, the engagement of the protrusions on the male bayonet
component with the angled slots on the female bayonet component
draws the female bayonet component forward, compressing the bayonet
spring 74. The biasing force of the bayonet spring then causes the
female bayonet component to pull the male bayonet component and
thus the grip tube toward the battery shell. As a result, any gap
between the two parts of the handle is closed by the spring force
and the O-ring is compressed to provide a water-tight sealing
engagement. When engagement is complete and the protrusions 60 are
received into the corresponding V-shaped detent areas 65 of the
female bayonet slots 62 (FIG. 9B). This is perceived by the user as
a clear and audible click, providing a clear indication that the
battery shell has been correctly engaged. This click is the result
of the action of the bayonet spring causing the protrusions to
slide quickly into the V-shaped detent areas 65.
[0059] This resilient engagement of the battery shell with the grip
tube compensates for non-linear seam lines between the battery
shell and grip tube and other geometry issues such as tolerances.
The force applied by the bayonet spring also provides solid and
reliable electrical contact between the male and female bayonet
components.
[0060] The spring-loaded female bayonet component also limits the
force acting on the male and female bayonet components when the
battery shell is attached and removed. If, after the grip tube and
battery shell contact each other, the user continues to rotate the
battery shell, the female bayonet component can move forward
slightly within the battery shell, reducing the force applied by
the protrusions of the male bayonet component. Thus, the force is
kept relatively constant, and within a predetermined range. This
feature can prevent damage to parts due to rough handling by the
user or large part or assembly tolerances.
[0061] To accomplish the resilient engagement described above, it
is generally important that the spring force of the bayonet spring
be greater than that of the battery spring. Generally, the
preferred relative forces of the two springs may be calculated as
follows:
[0062] 1. Design the battery spring such that the contact force
Fbatmin applied by the spring is sufficient for a minimum battery
length.
[0063] 2. Calculate the battery spring force Fbatmax that would be
required for a maximum battery length.
[0064] 3. Calculate the maximum force Fpmax that would be required
to push the battery shell against the grip tube to overcome the
friction of the o-ring.
[0065] 4. Determine the minimum closing force Fclmin with which the
battery shell should be pressed against the grip tube in the closed
condition.
[0066] 5. Calculate the force applied by the bayonet spring
according to Fbayonet=Fbatmax+Fpmax+Fclmin.
[0067] As an example, in some implementations Fbatmax=4 N, Fpmax=2
N, and Fclmin=2 N, and thus Fbayonet=8 N.
[0068] Battery Clamp
[0069] As discussed above, carrier 34 includes a pair of battery
clamp fingers 36 (FIGS. 6, 10). These fingers act as two springs
which exert a small clamping force against the battery 18 (FIG. 3).
This clamping force is sufficiently strong so as to prevent the
battery from rattling against the inner wall of the grip tube or
against other parts, reducing the noise generated by the razor
during use. Preferably, the clamping force is also sufficiently
strong so as to keep the battery from falling out when the battery
shell is removed and the grip tube is inverted. On the other hand,
the clamping force should be weak enough so that the user can
easily remove and replace the battery. The male bayonet component
38 includes open areas 80 (FIG. 4) through which the battery can be
grasped by the user for removal.
[0070] The dimensions of the spring fingers and their spring force
are generally adjusted to allow the spring fingers to hold the
weight of the minimum size battery discussed above, to prevent it
from falling out when the razor is held vertical, while also
allowing the maximum size battery to be easily removed from the
grip tube. To satisfy these constraints, it some implementations it
is preferred that, with a coefficient of friction between the
battery and foil of about 0.15-0.30, the spring force for one
finger be about 0.5 N when a minimum size battery (e.g., having a
diameter of 9.5 mm) is inserted and less than about 2.5 N when a
maximum size battery (e.g., having a diameter of 10.5 mm) is
inserted. In general, the spring fingers will perform the above
functions if, when the razor is held with the battery opening
pointing downwards, the minimum size battery will not fall out and
the maximum size battery can be taken out easily.
[0071] Referring to FIGS. 6 and 7C, a thin insulation sleeve 40,
e.g., of plastic foil, further damps vibration noise and provides
safety against a short circuit if the battery surface is damaged.
As shown in FIG. 7C, the sleeve 40 is secured with tape 42 to the
battery clamp fingers to hold the sleeve in place when the battery
is removed and replaced. A suitable material for the insulation
sleeve is polyethylene terephthalate (PET) film having a thickness
of about 0.06 mm.
[0072] Venting Battery Compartment
[0073] Under certain conditions, hydrogen can accumulate in the
interior of battery-powered appliances. The hydrogen may be
released from the battery, or may be created by electrolysis
outside the battery. Mixing of this hydrogen with ambient oxygen
can form an explosive gas, which could potentially be ignited by a
spark from the motor or switch of the device. Thus, any hydrogen
should be vented from the razor handle, while still maintaining
water tightness.
[0074] Referring to FIG. 13, a vent hole 90 is provided in the
battery shell 16. A microporous membrane 92 that is gas-permeable
but impermeable to liquids is welded to the battery shell 16 to
cover the vent hole 90. A suitable membrane material is
polytetrafluoroethylene (PTFE), commercially available from GORE. A
preferred membrane has a thickness of about 0.2 mm It is generally
preferred that the membrane have a water-proofness of at least 70
kPa, and an air permeability of at least 12 1/hr/cm.sup.2 at 100
mbar overpressure.
[0075] An advantage of the microporous membrane is that it will
vent hydrogen by diffusion due to the difference in partial
pressures of hydrogen on the two sides of the membrane. No increase
in total pressure within the razor handle is required for venting
to occur.
[0076] It is undesirable from an aesthetic standpoint for the user
to see the vent hole and membrane. Moreover, if the membrane is
exposed there is a risk that the pores of the membrane will become
clogged, and/or that the membrane will be damaged or removed. To
protect the membrane, a cover 94 is attached to the battery shell
over the membrane/vent area, e.g., by gluing. So that gas can
escape from under the cover 94, an open area is provided between
the inner surface of the cover and the outer surface 98 of the
battery shell 16. In the implementation shown in the Figures, a
plurality of ribs 96 are provided on the battery shell adjacent the
vent hole 90, creating air channels between the cover and the
battery shell. However, if desired other structures can be used to
create the venting space, for example the cover and/or the grip
tube may include a depressed groove that defines a single channel
and the ribs may be omitted.
[0077] The height and width of the air channels are selected to
provide a safe degree of venting. In one example (not shown), there
may be one channel on each side of the vent hole, each channel
having a height of 0.15 mm and width of 1.1 mm.
[0078] Cover 94 may be decorative. For example, the cover may carry
a logo or other decoration. The cover 94 may also provide a tactile
gripping surface or other ergonomic features.
[0079] Electronics
[0080] Variable Speed Control
[0081] A powered razor is often used to shave different types of
hair at different locations on the body. These hairs have markedly
different characteristics. For example, whiskers tend to be thicker
than hair on the legs. These hairs also protrude from the skin at
different angles. For example, stubble is predominantly orthogonal
to the skin, whereas leg hairs tend to lay flatter.
[0082] The ease with which one can shave these hairs depends, in
part, on the frequency at which the cartridge vibrates. Since these
hairs have different characteristics, it follows that different
vibration frequencies may be optimal for different types of hair.
It is therefore useful to provide a way for the user to control
this vibration frequency.
[0083] As shown in FIG. 14A, the vibration frequency of the shaving
cartridge is controlled by a pulse width modulator 301 having a
duty cycle under the control of control logic 105. As used herein,
"duty cycle" means the ratio between the temporal extent of a pulse
and that of the pause between pulses. A low duty cycle is thus
characterized by short pulses with long waits between pulses,
whereas a high duty cycle is characterized by long pulses with
short waits between pulses. Varying the duty cycle varies the speed
of the motor 306, which in turn governs the vibration frequency of
the shaving cartridge.
[0084] The control logic 105 can be implemented in a
microcontroller or other microprocessor based system. Control logic
can also be implemented in an application-specific integrated
circuit ("ASIC") or as a field-programmable gate array
("FPGA").
[0085] The motor 306 can be any energy-consuming device that causes
movement of the shaving cartridge. One implementation of a motor
306 includes a miniature stator and rotor coupled to the shaving
cartridge. Another implementation of a motor 306 includes a
piezoelectric device coupled to the shaving cartridge. Or, the
motor 306 can be implemented as a device that is magnetically
coupled to the shaving cartridge with an oscillating magnetic
field.
[0086] In razors having variable speed control, the control logic
105 receives an input speed control signal 302 from a speed-control
switch 304. In response to the speed control signal 302, the
control logic 105 causes the pulse-width modulator 301 to vary its
duty cycle. This, in turn, causes the motor speed to vary. The
pulse-width modulator 301 can thus be viewed as a speed
controller.
[0087] The speed-control switch 304 can be implemented in a variety
of ways. For example, the speed-control switch can move
continuously. In this case, the user can select from a continuum of
speeds. Or, the speed-control switch 304 can have discrete stops,
so that the user can select from a set of pre-defined motor
speeds.
[0088] The speed-control switch 304 can take a variety of forms.
For example, the switch 304 can be a knob or a slider that moves
continuously or between discrete steps. The switch 304 can also be
a set of buttons, with each one assigned to a different speed.
[0089] Or, the switch 304 can be a pair of buttons, with one button
being assigned to increase and the other to decrease the speed. Or,
the switch 304 can be a single button that one presses to cycle
through speeds, either continuously or discretely.
[0090] Another type of switch 304 is a spring-loaded trigger. This
type of switch enables the user to vary the vibration frequency
continuously while shaving in the same way that one can
continuously vary the speed of a chain saw by squeezing a
trigger.
[0091] The actuator button 22 can also be pressed into service as a
speed control switch 304 by suitably programming the control logic
105. For example, one can program the control logic 105 to consider
a double-click or a long press of the actuator button 22 as a
command to vary the motor speed.
[0092] Among the available speeds is one that is optimized for
cleaning the razor. An example of such a speed is the highest
possible vibration frequency, which is achieved by causing the
control logic 105 to drive the duty cycle as high as possible.
Alternatively, the control logic 105 can operate in a cleaning mode
in which it causes the motor 306 to sweep through a range of
vibration frequencies. This enables the motor 306 to stimulate
different mechanical resonance frequencies associated with the
blades, the cartridge, and any contaminating particles, such as
shaven whisker fragments. The cleaning mode can be implemented as a
continuous sweep across a frequency range, or as a stepped sweep,
in which the control logic 105 causes the motor 306 to step through
several discrete frequencies, pausing momentarily at each such
frequency.
[0093] In some cases, it is useful to enable the razor to remember
one or more preferred vibration frequencies. This is achieved, as
shown in FIG. 14B, by providing a memory in communication with the
control logic 105. To use this feature, the user selects a speed
and causes transmission of a memory signal, either with a separate
control, or by pressing the actuator button 22 according to a
pre-defined sequence. The user can then recall this memorized speed
when necessary, again by either using a separate control or by
pressing the actuator button 22 according to a pre-defined
sequence.
[0094] As shown in FIGS. 3A-3B, the razor features an indirect
switching system in which the actuator button 22 controls the motor
306 indirectly through control logic 105 that operates the
pulse-width modulator 301. Thus, unlike a purely mechanical
switching system, in which the state of the switch directly stores
the state of the motor 306, the indirect switching system stores
the state of the motor 306 in the control logic 105.
[0095] Since the actuator button 22 no longer needs to mechanically
store the state of the motor 306, the indirect switching system
provides greater flexibility in the choice and placement of the
actuator button 22. For example, a razor with an indirect switching
system, as disclosed herein, can use ergonomic buttons that combine
the advantages of clear tactile feedback and shorter travel. Such
buttons, with their shorter travel, are also easier to seal against
moisture intrusion.
[0096] Another advantage to the indirect switching system is that
the control logic 105 can be programmed to interpret the pattern of
actuation and to infer, on the basis of that pattern, the user's
intent. This has already been discussed above in connection with
controlling the speed of the motor 306. However, the control logic
105 can also be programmed to detect and ignore abnormal operation
of the actuator button 22. Thus, an unusually long press of the
actuator button 22, such as that which may occur unintentionally
while shaving, will be ignored. This feature prevents the annoyance
associated with accidentally turning off the motor 306.
[0097] Voltage Controller
[0098] The effectiveness of the razor depends in part on the
voltage provided by a battery 316. In a conventional motorized wet
razor, there exists an optimum voltage or voltage range. Once the
battery voltage is outside the optimum voltage range, the
effectiveness of the razor is compromised.
[0099] To overcome this difficulty, the razor features an indirect
power supply, shown in FIG. 14C, that separates the voltage of the
battery 316 from the voltage actually seen by the motor 306. The
voltage actually seen by the motor 306 is controlled by the control
logic 105, which monitors the battery voltage and, in response to a
measurement of battery voltage, controls various devices that
ultimately compensate for variations in battery voltage. This
results in an essentially constant voltage as seen by the motor
306.
[0100] The method and system described herein for controlling the
voltage seen by a motor 306 is applicable to any energy-consuming
load. For this reason, FIG. 14C refers to a generalized load
306.
[0101] In one embodiment, the motor 306 is designed to operate at
an operating voltage that is less than the nominal battery voltage.
As a result, when a new battery 316 is inserted, the battery
voltage is too high and must be reduced. The extent of the
reduction decreases as the battery 316 wears down, until finally,
no reduction is necessary.
[0102] Voltage reduction is readily carried out by providing a
voltage monitor 312 in electrical communication with the battery
316. The voltage monitor 312 outputs a measured battery voltage to
the control logic 105. In response, the control logic 105 changes
the duty cycle of the pulse-width modulator 301 to maintain a
constant voltage as seen by the motor 306. For example, if the
battery voltage is measured at 1.5 volts, and the motor 306 is
designed to operate at one volt, the control logic 105 will set the
duty cycle ratio to be 75%. This will result in an output voltage
from the pulse-width modulator 301 that is, on average, consistent
with the motor's operating voltage.
[0103] In most cases, the duty cycle is a non-linear function of
the battery voltage. In that case, the control logic 105 is
configured either to perform the calculation using the non-linear
function, or to use a look-up table to determine the correct duty
cycle. Alternatively, the control logic 105 can obtain a voltage
measurement from the output of the pulse-width modulator 301 and
use that measurement to provide feedback control of the output
voltage.
[0104] In another embodiment, the motor 306 is designed to operate
at an operating voltage that is higher than the nominal battery
voltage. In that case, the battery voltage is stepped up by
increasing amounts as the battery 316 wears down. This second
embodiment features a voltage monitor 312 as described above,
together with a voltage converter 314 that is controlled by the
control logic 105. A suitable voltage converter 314 is described in
detail below.
[0105] A third embodiment combines both of the foregoing
embodiments in one device. In this case, the control logic 105
begins by reducing the output voltage when the measured battery
voltage exceeds the motor operating voltage. Then, when the
measured battery voltage falls below the motor operating voltage,
the control logic 105 fixes the duty cycle and begins controlling
the voltage converter 312.
[0106] In a conventional powered razor, the motor speed gradually
decreases as the battery 316 wears down. This gradual decrease
provides the user with ample warning to replace the battery 316.
However, in a powered razor with an indirect power supply, there is
no such warning. Once the battery voltage falls below some lower
threshold, the motor speed decreases abruptly, perhaps even in the
middle of a shave.
[0107] To prevent this inconvenience, the control logic 105, on the
basis of information provided by the voltage monitor 312, provides
a low-battery signal to a low-battery indicator 414. The
low-battery indicator 414 can be a single-state output device, such
as an LED, that lights up when the voltage falls below a threshold,
or conversely, that remains lit when the voltage is above a
threshold and goes out when the voltage falls below that threshold.
Or, the low-battery indicator 414 can be a multi-state device, such
as a liquid crystal display, that provides a graphical or numerical
display indicative of the state of the battery 316.
[0108] The voltage monitor 312, in conjunction with the control
logic 105, can also be used to disable operation of the razor
completely when the battery voltage falls below a deep-discharge
threshold. This feature reduces the likelihood of damage to the
razor caused by battery leakage that may result from deep-discharge
of the battery 316.
[0109] A suitable voltage converter 312, shown in FIG. 14D,
features a switch S1 that controls an oscillator. This switch is
coupled to the actuator button 22. A user who presses the actuator
button 22 thus turns on the oscillator. The oscillator output is
connected to the gate of a transistor T1, which functions as a
switch under the control of the oscillator. A battery 316 provides
a battery voltage V.sub.BAT.
[0110] When the transistor T1 is in its conducting state, a current
flows from the battery 316 through an inductor L1, thus storing
energy in the inductor L1. When the transistor is in its
non-conducting state, the current through the inductor L1 will
continue to flow, this time through the diode D1. This results in
the transfer of charge through the diode D1 and into the capacitor
C1. The use of a diode D1 prevents the capacitor C1 from
discharging to ground through the transistor T1. The oscillator
thus controls the voltage across the capacitor C1 by selectively
allowing charge to accumulate into the capacitor C1, thereby
raising its voltage.
[0111] In the circuit shown in FIG. 14D, the oscillator causes a
time-varying current to exist in the inductor L1. As a result, the
oscillator induces a voltage across the inductor L1. This induced
voltage is then added to the battery voltage, with the resulting
sum being available across the capacitor C1. This results in an
output voltage, at the capacitor C1 that is greater than the
voltage provided by the battery alone.
[0112] The capacitor voltage, which is essentially the output
voltage of the voltage converter 312, is connected to both the
control logic 105 and to the pulse-width modulator 301 that
ultimately drives the motor 306. When the capacitor voltage reaches
a particular threshold, the control logic 105 outputs an oscillator
control signal "osc_ctr" that is connected to the oscillator. The
control logic 105 uses the oscillator control signal to selectively
turn the oscillator on and off, thereby regulating the capacitor
voltage in response to feedback from the capacitor voltage itself.
The set point of this feedback control system, i.e. the voltage
across the capacitor C1, is set to be the constant operating
voltage seen by the motor 306.
[0113] A resistor R1 disposed between the oscillator and ground
functions as part of a decoupling circuit to selectively transfer
control of the oscillator from the switch S1 to the control logic
105. Before initialization of the control logic, the port that
carries the oscillator control signal (the "oscillator control
port") is set to be a high-impedance input port. As a result, it is
the switch S1 that controls the operation of the oscillator. The
resistor R1 in this case prevents a short circuit from the
oscillator control port to ground. Following initialization, the
oscillator control port becomes a low-impedance output port.
[0114] Eventually, the user will complete shaving, in which case he
may want to turn off the motor 306. With the control logic 105 now
controlling the oscillator, there would be no way to turn off the
shaver without removing the battery 316. To avoid this difficulty,
it is useful to periodically determine the state of the external
switch S1. This is achieved by configuring the control logic 105 to
periodically cause the oscillator control port to become a
high-impedance input port, so that the voltage across the resistor
R1 can be sampled.
[0115] In certain types of switches, the state of the switch
indicates the user's intent. For example, a switch S1 in the closed
position indicates that the user wishes to turn on the motor 306,
and a switch S1 in an open position indicates that the user wishes
to turn off the motor 306. If the voltage thus sampled indicates
that the user has opened the switch S1, then, when the oscillator
control port again becomes a low-impedance output port, the control
logic 105 causes the oscillator control signal to shut down the
oscillator, thereby shutting down both motor 306. In doing to, the
control logic 105 also shuts down its own power supply.
[0116] In other types of switches, closing of the switch S1
indicates only that the user wishes to change the state of the
motor from on to off or vice versa. In embodiments that use such
switches, the voltage across the resistor R1 changes only briefly
when the user actuates the switch S1. As a result, the control
logic 105 causes the voltage across the resistor R1 to be sampled
frequently enough to ensure capturing the user's momentary
actuation of the switch S1.
[0117] FIG. 14E shows the interaction between the oscillator
control signal, the oscillator output, and the capacitor voltage.
When the capacitor voltage falls below a lower threshold, the
oscillator control signal turns on, thereby turning the oscillator
on. This causes more charge to accumulate in the capacitor C1,
which in turn raises the capacitor voltage. Once the capacitor
voltage reaches an upper threshold, the oscillator control signal
turns off, thereby turning off the oscillator. With no more charge
accumulating in the capacitor C1 from the battery 316, the
accumulated charge begins to drain away and the capacitor voltage
begins to decrease. It does so until it reaches the lower threshold
once again, at which point the foregoing cycle repeats itself.
[0118] Another embodiment of a voltage converter 312, shown in FIG.
14F is identical to that described in connection with FIG. 14D with
the exception that the diode D1 is replaced by an additional
transistor T2 having a gate controlled by an RC circuit (R2 and
C2). In this embodiment, when the oscillator is inactive, the
voltage between the emitter and the base (V.sub.BE2) of the
additional transistor T2 is zero. As a result, current flow through
the additional transistor T2 is turned off. This means that no
charge is being provided to the capacitor C1 to replace charge that
is being drained from the capacitor C1. When the oscillator is
active, and the oscillator frequency is greater than the cut-off
frequency of the RC circuit, then the voltage between the emitter
and the base V.sub.BE2 will be approximately half the battery
voltage V.sub.BAT. As a result, the additional transistor T2
functions as a diode to pass current to the capacitor C1, while
preventing the capacitor C1 from discharging to ground.
[0119] Another notable feature of the circuit in FIG. 14F is that
the pulse-width modulator 301 is supplied with a voltage directly
from the battery 316. As a result, the output voltage of the
pulse-width modulator 301 can be no higher than the battery
voltage. Thus, in FIG. 14F, the motor 306 is powered by a step down
in voltage, whereas the stepped up voltage, which is the voltage
across the capacitor C1, is used to power the control logic 105.
However, the circuit shown in FIG. 14F can also feature a
pulse-width modulator 316 that takes its input from the voltage
across the capacitor C1, as shown in FIG. 14D.
[0120] FIG. 14G shows a circuit for driving a voltage converter 312
of the type shown in FIG. 14F in greater detail. The oscillator is
shown in greater detail, as are the connections associated with the
control logic 105. However, the circuit shown in FIG. 14G is
otherwise essentially identical to that described in connection
with FIG. 14D modified as shown in FIG. 14F.
[0121] As described herein, a voltage control system provides a
constant operating voltage to a motor 306. However, a powered razor
may include loads other than a motor. Any or all of these loads may
likewise benefit from a constant operating voltage as provided by
the voltage control system disclosed herein.
[0122] One load that may benefit from a constant operating voltage
is the control logic 105 itself. Commercially available logic
circuits 105, are typically designed to operate at a voltage that
is higher than the 1.5 volts available in a conventional battery.
Hence, a voltage control system that provides a step up in voltage
to the control logic is useful to avoid the need for additional
batteries.
[0123] Cartridge Lifetime Detection
[0124] In the course of slicing through hundreds of whiskers on a
daily basis, the blades of a razor cartridge inevitably grow
duller. This dullness is difficult to detect by visual inspection.
As a rule, dull blades are only detected when it is too late. In
too many cases, by the time a user realizes that a blade is too
dull to use, he has already begun what will be an unpleasant
shaving experience.
[0125] This final shave with a dull blade is among the more
unpleasant aspects of shaving with a razor. However, given the
expense of shaving cartridges, most users are understandably
reluctant to replace the cartridge prematurely.
[0126] To assist the user in determining when to replace a
cartridge, the razor includes a blade lifetime indicator 100, shown
in FIG. 15A, having a counter 102 that maintains a count indicative
of the extent to which the blades have been already used. The
counter is in communication with both the actuator button 22 on the
handle 10, and with a cartridge detector 104, mounted at the distal
end of the razor head 12. A suitable counter 102 can be implemented
in the control logic 105.
[0127] A cartridge detector 104 can be implemented in a variety of
ways. For example a cartridge detector 104 may include a contact
configured to engage a corresponding contact on the cartridge.
[0128] Razor cartridges can include one, two, or more than two
blades. Throughout this description, a single blade is referred to.
It is understood, however, that this blade can be any blade in the
cartridge, and that all the blades are subject to wear.
[0129] In operation, when the user replaces the cartridge, the
cartridge detector 104 sends a reset signal to the counter 102.
Alternatively, a reset signal can be generated manually, for
example by the user pressing a reset button, or by the user
pressing the actuator button according to a pre-determined pattern.
This reset signal causes the counter 102 to reset its count.
[0130] The ability to detect the cartridge can be used for
applications other than resetting the count. For example, the
cartridge detector 104 can be used to determine whether the correct
cartridge has been used, or whether a cartridge has been inserted
improperly. When connected to the control logic 105, the cartridge
detector 104 can cause the motor to be disabled until the condition
is corrected.
[0131] When the user shaves, the counter 102 changes the state of
the count to reflect the additional wear on the blade. There are a
variety of ways in which the counter 102 can change the state of
the count.
[0132] In the implementation shown in FIG. 15A, the counter 102
changes the count by incrementing it each time the motor is turned
on. For users whose shaving time varies little on a shave-to-shave
basis, this provides a reasonably accurate basis for estimating
blade use.
[0133] In some cases, the number of times the motor has been turned
on may misestimate the remaining lifetime of a blade. Such errors
arise, for example, when a person "borrows" one's razor to shave
their legs. This results in the shaving of considerable acreage
with only a single activation of the motor.
[0134] The foregoing difficulty is overcome in an alternative
implementation, shown in FIG. 15B, in which the actuator button 22
and the counter 102 are in communication with a timer 106. In this
case, the actuator button 22 sends signals to both the control
logic 105 and the timer 106.
[0135] As a result, the counter 102 maintains a count indicative of
the accumulated motor-operating time since the last cartridge
replacement.
[0136] The accumulated motor-operating time provides an improved
indicator of blade wear. However, as a rule, the blade does not
contact the skin at all times that the motor is operating. Thus, an
estimate based on the motor's operating-time cannot help but
overestimate blade wear. In addition, the motor switch may be
inadvertently turned on, for example when the razor is jostled in
one's luggage. Under those circumstances, not only will the battery
be drained, but the counter 102 will indicate a worn blade, even
though the blade has yet to encounter a single whisker.
[0137] Another implementation, shown in FIG. 15C, includes a
counter 102 in communication with a stroke-detector 108. In this
case, the actuator button 22 signals both the stroke detector 108
and the control logic 105. Thus, turning on the motor also turns on
the stroke-detector 108.
[0138] The stroke-detector 108 detects contact between the blade
and the skin and sends a signal to the counter 102 upon detecting
such contact. In this way, the stroke-detector 108 provides the
counter 102 with an indication that the blade is actually in use.
In the implementation of FIG. 15C, the counter 102 maintains a
count indicative of the accumulated number of strokes that the
blade has endured since the cartridge was last replaced. As a
result, the counter 102 ignores time intervals during which the
motor is running but the blade is not actually in use.
[0139] A variety of implementations are available for the
stroke-detector 108. Some implementations rely on the change
between the electrical properties on or near the skin and
electrical properties in free space. For example, the
stroke-detector 108 can detect skin contact by measuring a change
in resistance, inductance, or capacitance associated with
contacting the skin. Other implementations rely on the difference
between the acoustic signature of a blade vibrating on the skin and
that of a blade vibrating in free space. In these implementations,
the stroke-detector 108 can include a microphone connected to a
signal processing device configured to distinguish between the two
signatures. Yet other implementations rely on changes to the
motor's operating characteristics when the blade touches the skin.
For example, because of the increased load associated with skin
contact, the motor's appetite for current may increase and the
motor's speed may decrease. These implementations include ammeters
or other current indicating devices, and/or speed sensors.
[0140] An estimate that relies on the number of strokes may
nevertheless be inaccurate because not all strokes have the same
length. For example, a stroke down a leg may wear the blade more
than the several strokes needed to shave a moustache. The
stroke-detector 108, however, cannot tell the difference between
strokes of different lengths.
[0141] Another implementation, shown in FIG. 15D, includes both a
stroke-detector 108 in communication with the actuator button 22
and a timer 106. The timer 106 is in communication with the counter
102. Again, the actuator button signals both the stroke detector
108 and the control logic 105. The stroke detector 108 stops and
starts the timer 106 in response to detecting the beginning and end
of a stroke respectively. This implementation is identical to that
in FIG. 15C except that the counter 102 now maintains a count
indicative of the accumulated time that the cartridge has been in
contact with the skin (referred to as "stroke time") since the last
cartridge replacement.
[0142] A stroke-detector 108 in conjunction with a timer 106 as
described in connection with FIG. 15D has applications other than
providing information indicative of blade wear. For example, the
absence of a stroke for an extended period of motor operation may
indicate that the motor has been turned on or left on
inadvertently. This may occur when the razor is jostled in one's
luggage. Or it may occur because one has absent-mindedly overlooked
the need to turn off the motor after shaving.
[0143] In the embodiments of FIGS. 1A-1D, the counter 102 is in
communication with a replacement indicator 110. When the count
reaches a state indicative of a worn blade, the counter 102 sends a
replacement signal to the replacement indicator 110. In response,
the replacement indicator 110 provides the user with a visual,
audible, or tactile cue to indicate that the blade is worn out.
Exemplary cues are provided by an LED, a buzzer, or a governor that
varies the motor speed, or otherwise introduces an irregularity,
such as a stutter, into the operation of the motor.
[0144] The counter 102 includes an optional remaining-lifetime
output that provides a remaining-life signal indicative of an
estimate of the remaining life of the blade. The remaining-life
estimate is obtained by comparing the count and an expected
lifetime. The remaining life signal is provided to a remaining-life
indicator 112. A suitable remaining-life indicator 112 is a
low-power display showing the expected number of shaves remaining
before the worn-out signal activates the worn-out indicator.
Alternatively, the remaining lifetime estimate may be shown
graphically, for example by flashing a light with a frequency
indicative of a remaining lifetime estimate, or by selectively
illuminating several LEDs according to a pre-defined pattern.
[0145] Travel Lock
[0146] In some cases, it is possible to inadvertently turn on the
motor of a powered wet razor. This may occur, for example, during
travel when other items in a toilet kit shift and press the
actuator button 22. If this occurs, the motor will draw on the
battery until the battery runs down.
[0147] To avoid this difficulty, the razor can include a lock. One
such lock is a mechanical lock 200 on the actuator button 22
itself. An example of a mechanical lock 200 is a sliding cover, as
shown in FIG. 16A, that covers the actuator button 22 when the
razor is put away. Other examples of mechanical locks are
associated with a holder for the razor, rather than with the razor
itself. For example, the switch can be configured to cover the
actuator button 22 when the razor is stowed in the holder.
[0148] Other locks are electronic in implementation. One example of
an electronic lock is a locking circuit 202, as shown in FIG. 16B,
that receives a switch signal 204 from the actuator button 22
(labeled "1/0" in the figure) and an arming signal 206 from an
arming circuit 208 (labeled "arming-signal source" in the figure).
The locking circuit 202 outputs a motor control signal 210 to the
control logic 105 in response to the states of the switch signal
204 and the arming signal 206.
[0149] The arming circuit 208 is said to arm and disarm the locking
circuit 202 using the arming signal 206. As used herein, the
locking circuit 202 is considered armed when pressing the actuator
button 22 starts and stops the motor. The locking circuit 202 is
considered disarmed when pressing the actuator button 22 fails to
operate the motor at all.
[0150] Arming circuits 208 and locking circuits 202 typically
include digital logic circuits that change the state of their
respective outputs in response to state changes in their respective
inputs. As such, they are conveniently implemented within the
control logic 105. However, although digital logic elements provide
a convenient way to build such circuits, nothing precludes the use
of analog or mechanical components to carry out similar functions.
Examples of arming circuits 208, or portions thereof, are described
below.
[0151] One example of an arming circuit 208 includes an arming
switch. In this implementation, the user operates the arming switch
to change the state of the arming signal 206. The user then presses
the actuator button 22 to start the motor. After shaving, the user
again presses the actuator button 22, this time to stop the motor.
He then operates the arming switch to disarm the locking circuit
202.
[0152] Alternatively, the arming circuit 208 can be configured to
disarm the locking circuit automatically upon detecting that the
motor has been turned off. In this case, the arming circuit 208
will generally include an input to receive a signal indicating that
that the motor has been turned off.
[0153] As used herein, "switch" includes buttons, levers, sliders,
pads, and combinations thereof for effecting a change in the state
of a logic signal. Switches need not be actuated by physical
contact but can instead be activated by radiant energy carried, for
example, optically or acoustically. A switch can be directly
user-operable. One example of such a switch is the actuator button
22. Alternatively, the switch can be operated by a change in the
disposition of the razor, for example by replacing a razor in its
holder, or by removing and installing a cartridge.
[0154] As suggested by FIG. 16B, the locking circuit 202 can be
viewed abstractly as an "AND" gate. Although the locking circuit
can be implemented as an "AND" gate, any digital logic circuit with
a suitable truth table can be used to carry out the arming function
of the locking circuit 202. For example, the locking circuit 202
can be implemented by placing an arming switch in series with the
actuator button 22.
[0155] In another implementation, the arming circuit 208 includes a
timer. The output of the timer causes the arming circuit 208 to
initially arm the locking circuit 202. Upon the lapse of a
predetermined shaving interval, the timer causes the arming circuit
208 to disarm the locking circuit 202, thereby turning off the
motor. The length of the shaving interval corresponds to a typical
shaving time. A suitable length is between about five and seven
minutes.
[0156] In this implementation, upon pressing the actuator button
22, the motor will run either until the actuator button 22 is
pressed again, or until the lapse of the shaving interval. Should
the user take longer than the shaving interval to shave, the motor
will turn off, in which case, the user must press the actuator
button 22 again to restart the motor and complete the shave. To
avoid this, the arming circuit 208 can be provided with an adaptive
feedback loop that extends the default shaving interval in response
to "extensions" requested by the user.
[0157] When the arming circuit 208 includes a timer, a reset input
on the timer is connected to either the output of the locking
circuit 202 or to the actuator button 22. This enables the timer to
reset itself in response to a change in the state of the switch
signal 204. In particular, the timer resets itself whenever the
switch signal 204 turns off the motor. This can occur when either
the user presses the actuator button 22 prior to the lapse of the
shaving interval, or upon the lapse of the shaving interval.
[0158] In another implementation, the arming circuit 208 includes a
decoder having an input connected to either the actuator button 22
or to a separate decoder input-button. In this case, the state of
the arming signal 206, which depends on the decoder's output is
controlled manually by the user, either by pressing the actuator
button 22 according to a predefined pattern, or, in the alternative
implementation, by operating the decoder input-button.
[0159] For example, in the case in which the decoder takes its
input from the actuator button 22, the decoder may be programmed to
respond to an extended press of the actuator button 22 or a rapid
double-click of the actuator button 22 by causing a change to the
state of the arming signal 206. Alternatively, in the case in which
the decoder accepts input from a separate decoder input-switch, the
user need only operate the decoder input-switch. There is no need
for the user to remember how to lock and unlock the motor with the
actuator button 22.
[0160] In those implementations that rely on the user to change the
state of the arming signal 206, it is useful to provide an
indicator, such as an LED, that provides the user with feedback on
whether he has successfully changed the state of the arming signal
206.
[0161] In other implementations, the arming circuit 208 relies on
the disposition of the razor to determine whether it should disarm
the locking circuit 202. For example, the arming circuit 208 may
include a contact switch that detects the installation and removal
of a shaving cartridge. When the cartridge is removed, the arming
circuit 208 disarms the locking circuit 202. Alternatively, the
arming circuit 208 can include a contact switch that detects
whether or not the razor has been stowed in its holder. In this
case, when the arming circuit 208 detects that the razor has been
stowed in its holder, it disarms the locking circuit 202.
[0162] In the case in which the arming circuit 208 responds to the
presence of a cartridge, a user prevents the motor from
accidentally turning on by removing the cartridge from the handle.
To operate the razor normally the user re-installs the cartridge on
the handle.
[0163] In the case in which the arming circuit 208 responds to the
presence of a holder, the user prevents the motor from accidentally
turning on by stowing it in its holder. The operate the razor
normally, the user removes it from its holder, which is something
he would have to do in any case.
[0164] While the embodiment described herein controls the operation
of a motor, the disclosed methods and devices can be used to
prevent battery drain from inadvertent consumption of energy by any
load.
[0165] Shaving Force Measurement
[0166] During the course of a shave, the user applies a force that
presses the blade against the skin. The magnitude of this shaving
force affects the quality of the shave. A shaving force that is too
low may be insufficient to force the whiskers into an optimum
cutting position. One that is too high may result in excessive skin
abrasion. Because of the varying contours of the face, it is
difficult for the user to maintain even a constant shaving force,
much less an optimal shaving force.
[0167] This difficulty is overcome in razors that include
force-measurement circuits 400 as shown in FIGS. 4A and 4B. The
illustrated force-measurement circuits 400 exploit the fact that in
a motorized razor, the shaving force governs, in part, the load
applied to the motor 306 that drives the blade. The operating
characteristics of this motor 306 thus change in response to the
shaving force.
[0168] The force-measurement circuit 400 shown in FIG. 17A exploits
the change in the current drawn by the motor 306 in response to
different loads. As the shaving force increases, the motor 306
draws more current in response. The implementation in FIG. 17A thus
features a current sensor 402 that senses the magnitude of the
current drawn by the motor 306. The current sensor provides a force
signal 408 to the control logic 105.
[0169] The force-measurement circuit shown in FIG. 17B exploits the
change in motor speed that results from different loads on the
motor 306. As the shaving force increases, the motor speed
decreases. The implementation shown in FIG. 17B thus features a
speed sensor 410 for sensing the motor speed. This speed sensor
provides a force signal 408 to the control logic 105.
[0170] The control logic 105 receives the force signal 408 and
compares it with a nominal force signal indicative of what the
force signal would be under a known load. Typically, the known load
is selected to correspond to a razor vibrating in free space,
without contacting any surface. Alternatively, the control logic
105 compares the force signal 408 with a pair of nominal force
signals corresponding to a razor vibrating with two known loads,
one corresponding to a minimum shaving force and another
corresponding to a maximum shaving force.
[0171] The control logic 105 then determines whether the applied
shaving force falls outside the band defined by the upper and lower
shaving force thresholds. If the applied shaving force falls
outside the band, the control logic 105 sends a correction signal
412 to an indicator 414. The indicator 414 then transforms the
correction signal 412 into an observable signal that is observable
by the user, either because it is visible, audible, or provides
some tactile stimulation.
[0172] For an acoustic observable signal, the indicator 414 can be
a speaker that provides an audible signal to the user. For an
optically observable signal, the indicator 414 can be an LED that
provides a visible signal to the user. For a tactile observable
signal, the motor 306 itself is used as an indicator 414. Upon
detecting an incorrect shaving force, the control logic 105 sends a
correction signal 412 to the motor 306 to introduce a disturbance
into its normal operation. For example, the control logic 105 might
send a correction signal 412 that causes the motor 306 to
stutter.
[0173] In all the foregoing cases, the signal for an insufficient
shaving force can differ from that for an excessive shaving force
so that the user will know how to correct the applied shaving
force.
[0174] A number of embodiments of the invention have been
described. Nevertheless, it will be understood that various
modifications may be made without departing from the spirit and
scope of the invention.
[0175] For example, while the razors described above include a
vibration motor and provide a vibrating functionality, other types
of battery-operated functionality may be provided, such as
heating.
[0176] Moreover, while in the embodiment described above a
receiving member containing a window is welded into an opening in
the grip tube, if desired the window may be molded into the grip
tube, e.g., by molding a transparent membrane into the grip
tube.
[0177] In some implementations, other types of battery shell
attachment may be used. For example, the male and female portions
of the battery shell and grip tube may be reversed, so that the
battery shell carries the male portion and the grip tube carries
the female portion. As another example, the battery shell may be
mounted on the grip tube using the approach described in U.S. Ser.
No. 11/115,885, filed on Apr. 27, 2005, the complete disclosure of
which is incorporated herein by reference. Other mounting
techniques may be used in some implementations, e.g., latching
systems that are released by a push button or other actuator.
[0178] Additionally, in some implementations the razor may be
disposable, in which case the battery shell may be permanently
welded to the grip tube, as it is not necessary or desirable that
the consumer access the battery. In disposable implementations, the
blade unit is also fixedly mounted on the razor head, rather than
being provided as a removable cartridge.
[0179] Other venting techniques may also be used, for example
venting systems that employ sealing valve members rather than a
microporous membrane. Such venting systems are described, for
example, in U.S. Ser. No. 11/115,931, filed on Apr. 27, 2005, the
complete disclosure of which is incorporated herein by
reference.
[0180] Some implementations include some of the features described
above, but do not include some or all of the electronic components
discussed herein. For example, in some cases the electronic switch
may be replaced by a mechanical switch, and the printed circuit
board may be omitted.
[0181] Accordingly, other embodiments are within the scope of the
following claims.
[0182] A number of embodiments of the invention have been
described. Nevertheless, it will be understood that various
modifications may be made without departing from the spirit and
scope of the invention.
[0183] For example, while the razors described above include a
vibration motor and provide a vibrating functionality, other types
of battery-operated functionality may be provided, such as
heating.
[0184] Moreover, while in the embodiment described above a
receiving member containing a window is welded into an opening in
the grip tube, if desired the window may be molded into the grip
tube, e.g., by molding a transparent membrane into the grip
tube.
[0185] In some implementations, other types of battery shell
attachment may be used. For example, the male and female portions
of the battery shell and grip tube may be reversed, so that the
battery shell carries the male portion and the grip tube carries
the female portion. As another example, the battery shell may be
mounted on the grip tube using the approach described in U.S. Ser.
No. 11/115,885, filed on Apr. 27, 2005, the complete disclosure of
which is incorporated herein by reference. Other mounting
techniques may be used in some implementations, e.g., latching
systems that are released by a push button or other actuator.
[0186] Additionally, in some implementations the razor may be
disposable, in which case the battery shell may be permanently
welded to the grip tube, as it is not necessary or desirable that
the consumer access the battery. In disposable implementations, the
blade unit is also fixedly mounted on the razor head, rather than
being provided as a removable cartridge.
[0187] Other venting techniques may also be used, for example
venting systems that employ sealing valve members rather than a
microporous membrane. Such venting systems are described, for
example, in U.S. Ser. No. 11/115,931, filed on Apr. 27, 2005, the
complete disclosure of which is incorporated herein by
reference.
[0188] Some implementations include some of the features described
above, but do not include some or all of the electronic components
discussed herein. For example, in some cases the electronic switch
may be replaced by a mechanical switch, and the printed circuit
board may be omitted.
[0189] Accordingly, other embodiments are within the scope of the
following claims.
* * * * *