U.S. patent application number 17/231627 was filed with the patent office on 2021-10-21 for coatings for a razor blade.
The applicant listed for this patent is The Gillette Company LLC. Invention is credited to Oliver Heinz Claus, Joseph Allan DePuydt, Ronald Richard Duff, JR., William Owen Jolley, Joe David Lussier, John Lawrence Maziarz, Bin Shen, Kenneth James Skrobis.
Application Number | 20210323184 17/231627 |
Document ID | / |
Family ID | 1000005535921 |
Filed Date | 2021-10-21 |
United States Patent
Application |
20210323184 |
Kind Code |
A1 |
Skrobis; Kenneth James ; et
al. |
October 21, 2021 |
COATINGS FOR A RAZOR BLADE
Abstract
A razor blade including: a substrate having a tip portion
including a tip region, a blade body including a base, and first
and second outer sides disposed opposite a split line of the
substrate, in which the first and second outer sides converge at a
tip, the first outer side comprises a first coating disposed
substantially thereon and extending from the tip region toward the
base, and a first portion of the second outer side is substantially
free of any coating, the first portion extending from the tip
region toward the base or being spaced apart from the tip region
and the base. Also provided is a method of coating the razor
blade.
Inventors: |
Skrobis; Kenneth James;
(Maynard, MA) ; Jolley; William Owen; (Spencer,
MA) ; Maziarz; John Lawrence; (Framingham, MA)
; Shen; Bin; (Shanghai, CN) ; Duff, JR.; Ronald
Richard; (Shrewsbury, MA) ; Lussier; Joe David;
(Milton, MA) ; Claus; Oliver Heinz; (Walpole,
MA) ; DePuydt; Joseph Allan; (Salem, NH) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
The Gillette Company LLC |
Boston |
MA |
US |
|
|
Family ID: |
1000005535921 |
Appl. No.: |
17/231627 |
Filed: |
April 15, 2021 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
63010951 |
Apr 16, 2020 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
B26B 21/60 20130101 |
International
Class: |
B26B 21/60 20060101
B26B021/60 |
Claims
1. A razor blade comprising: a substrate having a tip portion
comprising a tip region, a blade body comprising a base, and first
and second outer sides disposed opposite a split line of said
substrate, wherein said first and second outer sides converge at a
tip, wherein said first outer side comprises a first coating
disposed substantially thereon, said first coating extending from
said tip region toward said base, and wherein a first portion of
said second outer side is substantially free of any coating,
wherein said first portion extends from said tip region toward said
base or is spaced apart from said tip region and said base.
2. The razor blade of claim 1, wherein a second portion of said
second outer side comprises a second coating disposed substantially
thereon, said second coating extending substantially from a first
location to a second location, wherein said first location is
spaced apart from said tip region and said second location is
located toward said base.
3. The razor blade of claim 1, wherein said first portion comprises
substantially an entirety of said second outer side.
4. The razor blade of claim 1, wherein a second portion of said
second outer side comprises a second coating disposed substantially
thereon, said second coating comprising a first section extending
substantially from a first location to a second location and a
second section extending substantially from a third location to a
fourth location, wherein said first location comprises said tip
region, said second location is spaced apart from said third
location, and said first portion of said second outer side that is
substantially free of any coating is located between said first and
second sections of said second coating.
5. The razor blade of claim 1, wherein at least a portion of said
first outer side defines a skin-contacting surface.
6. The razor blade of claim 1, wherein said split line splits said
substrate into two substantially equal halves.
7. The razor blade of claim 1, wherein said split line splits said
substrate into two asymmetrical halves.
8. The razor blade of claim 1, wherein said first coating comprises
a plurality of layers of material.
9. The razor blade of claim 8, wherein said first coating
comprises: a first layer disposed substantially on said first outer
side and extending from said tip region toward said base for a
first distance; and a second layer disposed on top of at least a
section of said first layer and extending from said tip region
toward said base for a second distance that is the same as or less
than said first distance.
10. The razor blade of claim 9, wherein said first layer comprises
a first material and said second layer comprises a second material
that is different from said first material.
11. The razor blade of claim 1, wherein said first coating
comprises a thickness that varies along at least a section of said
first coating in a direction extending from said tip region toward
said base of said razor blade.
12. The razor blade of claim 1, wherein said first coating
comprises an ion-implanted material.
13. The razor blade of claim 1, wherein at least a section of said
first coating defines an outer shape that is different from an
outer shape of an underlying portion of said substrate.
14. The razor blade of claim 1, a second portion of said second
outer side comprises a second coating disposed substantially
thereon.
15. The razor blade of claim 14, wherein said first coating
comprises one or more first materials and said second coating
comprises one or more second materials, at least one of said second
materials being different from at least one of said first
materials.
16. The razor blade of claim 1, wherein said first outer side
comprises one or more first facets and said second outer side
comprises one or more second facets.
17. The razor blade of claim 16, wherein said first coating is
disposed on at least one of said first facets and said first
portion of said second outer side that is substantially free of any
coating comprises at least a portion of one of at least one of said
second facets.
18. The razor blade of claim 16, wherein said first coating
comprises: a first section extending substantially from a first
location to a second location on said first outer side; and a
second section extending substantially from said second location to
a third location on said first outer side, wherein said first
location comprises said tip region and said second location
comprises a junction between (i) two adjacent ones of said first
facets, or (ii) said blade body and one of said first facets.
19. The razor blade of claim 18, wherein said second location
comprises said junction between two adjacent ones of said first
facets and said third location comprises said junction between said
blade body and one of said first facets, said first coating further
comprising a third section extending substantially from said third
location toward said base.
20. A method of coating a razor blade comprising a substrate having
a tip portion comprising a tip region, a blade body comprising a
base, and first and second outer sides disposed opposite a split
line of said substrate, wherein said first and second outer sides
converge at a tip, the method comprising one of: (i) applying a
first coating only to a portion of said first outer side, said
coating extending from said tip region toward said base and being
disposed substantially on said first outer side; or (ii) applying a
first coating to a portion of said first outer side, said first
coating extending from said tip region toward said base and being
disposed substantially on said first outer side, and applying a
second coating to said second outer side such that a first portion
of said second outer side is substantially free of any coating and
a second portion of said second outer side comprises said second
coating, wherein said first portion extends from said tip region
toward said base or is spaced apart from said tip region and said
base.
21. The method of claim 20, wherein said substrate comprises said
second coating.
22. The method of claim 21, wherein said second coating extends
substantially from a first location to a second location, said
first location being spaced apart from said tip region and said
second location being located toward said base.
23. The method of claim 21, wherein said second coating comprises a
first section extending substantially from a first location to a
second location and a second section extending substantially from a
third location to a fourth location, said first location comprising
said tip region and said second location being spaced apart from
said third location, wherein said first portion of said second
outer side that is substantially free of any coating is located
between said first and second sections of said second coating.
24. The method of claim 21, wherein said first coating comprises
one or more first materials and said second coating comprises one
or more second materials, at least one of said second materials
being different from at least one of said first materials.
25. The method of claim 21, wherein said first and second coatings
are applied simultaneously.
26. The method of claim 21, wherein said first and second coatings
are applied sequentially.
27. The method of claim 21, wherein said first and second coatings
are applied using a same technique.
28. The method of claim 21, wherein said first coating is applied
with a first technique and said second coating is applied with a
second technique that is different from said first technique.
29. The method of claim 20, wherein said first coating is applied
such that at least a section of said first coating defines an outer
shape that is different from an outer shape of an underlying
portion of said substrate.
30. The method of claim 20, wherein said first coating is applied
such that said first coating comprises a thickness that varies
along at least a section of said first coating in a direction
extending from said tip region toward said base of said razor
blade.
31. The method of claim 20, wherein applying said first coating
further comprises applying a plurality of layers of material.
32. The method of claim 31, wherein applying said plurality of
layers of material comprises: applying a first layer to said
portion of said first outer side, said first layer extending from
said tip region toward said base for a first distance; and applying
a second layer on top of at least a section of said first layer,
said second layer extending from said tip region toward said base
for a second distance that is the same as or less than said first
distance.
33. The method of claim 32, wherein said first layer comprises a
first material and said second layer comprises a second material
that is different from said first material.
34. The method of claim 20, wherein said first outer side of said
substrate comprises one or more first facets and said second outer
side comprises one or more second facets.
35. The method of claim 34, wherein said first coating is disposed
on at least one of said first facets and said first portion of said
second outer side that is substantially free of any coating
comprises at least a portion of one of at least one of said second
facets.
36. The method of claim 34, wherein said first coating is applied
such that said first coating comprises: a first section extending
substantially from a first location to a second location on said
first outer side; and a second section extending substantially from
said second location to a third location on said first outer side,
wherein said first location comprises said tip region and said
second location comprises a junction between (i) two adjacent ones
of said first facets, or (ii) said blade body and one of said first
facets.
37. The method of claim 36, wherein said second location comprises
said junction between two adjacent ones of said first facets and
the third location comprises said junction between said blade body
and one of said first facets, said first coating being applied such
that said first coating further comprises: a third section
extending substantially from said third location toward said
base.
38. The method of claim 20, further comprising: performing one or
more post-application treatments on at least one section of said
first coating.
39. The method of claim 38, wherein said one or more
post-application treatments comprise one or more of: subjecting at
least one section of said first coating to ion implantation; or
partially removing one or more sections of said first coating.
40. The method of claim 38, wherein said one or more
post-application treatments further comprise selectively applying
material to said first coating following partial removal of said
one or more sections of said first coating.
41. The method of claim 40, wherein at least a portion of said
first outer side with said material defines a skin-contacting
surface.
42. The method of claim 20, wherein said substrate comprises said
second coating, the method further comprising: performing one or
more post-application treatments on at least one section of said
second coating.
43. The method of claim 42, wherein said one or more
post-application treatments comprise partially removing one or more
sections of said second coating.
Description
FIELD OF THE INVENTION
[0001] The invention generally relates to coating of substrates,
and more particularly to improved coatings on razor components,
such as razor blades.
BACKGROUND OF THE INVENTION
[0002] A razor blade is typically formed of a suitable substrate
material, such as stainless steel, with a cutting edge formed with
a wedge-shaped configuration with an ultimate tip having a radius
less than about 1000 angstroms (.ANG.), e.g., about 200-300 .ANG..
One or more hard coatings, such as diamond, amorphous diamond,
diamond-like carbon (DLC) material, nitrides, carbides, oxides, or
ceramics, may be applied to the substrate material, particularly
the cutting edge, to improve strength, corrosion resistance, and
shaving ability and to maintain needed strength while permitting
thinner edges with lower cutting forces to be used. One or more
soft coatings generally of polymeric material, such as
polytetrafluoroethylene (PTFE), may be layered on top of the hard
coating(s) to impart lubricity and reduce friction. Interlayers of
niobium or chromium-containing materials can aid in improving the
binding between the substrate, typically stainless steel, and hard
carbon coatings, such as DLC. The coatings may be applied using any
suitable method, such as Physical Vapor Deposition (PVD) techniques
for the hard coating(s) and dipping, spraying, and/or brushing for
the soft coating(s). Examples of razor blades and processes of
manufacture are described in U.S. Pat. Nos. 5,295,305; 5,232,568;
4,933,058; 5,032,243; 5,497,550; 5,940,975; and 5,669,144; EP
0591339; and PCT 92/03330, which are hereby incorporated by
reference.
[0003] Conventional blades typically include a generally equal
amount of material(s) on both sides of the substrate, often applied
by vapor deposition parallel to the cutting edge. The coatings on
these blades are highly symmetrical and include a substantially
similar composition, coverage area, microstructure, etc. on both
sides of the cutting edge. While current razor blades perform
adequately, in order for next generation products to perform
better, improvements to interactions between the blade and skin and
the blade and hair can be made.
SUMMARY OF THE INVENTION
[0004] In accordance with an aspect of the present disclosure, a
razor blade is provided, which includes: a substrate having a tip
portion comprising a tip region, a blade body including a base, and
first and second outer sides disposed opposite a split line of the
substrate, wherein the first and second outer sides converge at a
tip. The first outer side includes a first coating disposed
substantially thereon, the first coating extending from the tip
region toward the base, and a first portion of the second outer
side is substantially free of any coating, in which the first
portion extends from the tip region toward the base or is spaced
apart from the tip region and the base.
[0005] In accordance with another aspect of the present disclosure,
a method of coating a razor blade is provided, in which the razor
blade includes a substrate having a tip portion including a tip
region, a blade body including a base, and first and second outer
sides disposed opposite a split line of the substrate, wherein the
first and second outer sides converge at a tip, the method
including one of: (i) applying a first coating only to a portion of
the first outer side, the coating extending from the tip region
toward the base and being disposed substantially on the first outer
side; or (ii) applying a first coating to a portion of the first
outer side, the first coating extending from the tip region toward
the base and being disposed substantially on the first outer side,
and applying a second coating to the second outer side such that a
first portion of the second outer side is substantially free of any
coating and a second portion of the second outer side comprises the
second coating, wherein the first portion extends from the tip
region toward the base or is spaced apart from the tip region and
the base.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] While the specification concludes with claims particularly
pointing out and distinctly claiming the subject matter which is
regarded as forming the present invention, it is believed that the
invention will be better understood from the following description
which is taken in conjunction with the accompanying drawings in
which like designations are used to designate substantially
identical elements, and in which:
[0007] FIG. 1 is a front view of a razor system comprising a handle
and a razor cartridge in accordance with the present
disclosure;
[0008] FIG. 2 is a side view of a razor blade with a symmetrical
substrate in accordance with the present disclosure;
[0009] FIG. 3 is a perspective view of a tip portion of another
razor blade with a symmetrical substrate in accordance with the
present disclosure;
[0010] FIGS. 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, and 17
are side views of the tip portion of the razor blade of FIG. 3
comprising one or more coatings in accordance with the present
disclosure;
[0011] FIG. 18 is a side view of a razor blade with an asymmetrical
substrate in accordance with the present disclosure;
[0012] FIG. 19 is a side view of another razor blade with an
asymmetrical substrate in accordance with the present
disclosure;
[0013] FIGS. 20A, 20B, 21A, 21B, 22A, 22B, 23A, 23B, 24A, 24B, 25A,
25B, 26A, 26B, 27A, 27B, 28A, 28B, 29A, 29B, 30A, 30B, 31, 32 and
33 are side views of a tip portion of the razor blade of FIG. 18
comprising one or more coatings in accordance with the present
disclosure;
[0014] FIG. 34 is a detailed side view of a tip region of the razor
blade of FIGS. 4 and 20;
[0015] FIGS. 35, 36, and 37 are additional detailed side views
similar to FIG. 34 of tip regions of razor blades comprising one or
more coatings in accordance with the present disclosure;
[0016] FIG. 38 is a schematic of a chamber showing razor blades
capable of being coated via a deposition technique in accordance
with the present disclosure; and
[0017] FIG. 39 is a flow diagram illustrating an exemplary method
of coating a razor blade in accordance with the present
disclosure.
DETAILED DESCRIPTION OF THE INVENTION
[0018] The term "asymmetric blade," as used herein, means a blade
defined by a substrate having a first portion comprising a blade
body and a second portion comprising a tip portion wherein a split
line passes through a tip of the tip portion, extends through the
first and second portions and separates the second portion into
generally asymmetric first and second sections. The outer surface
of the first section of the second portion is asymmetric with
regards to the outer surface of the second section. The outer
surface of the first section of the second portion may function as
a skin-contacting surface, and the outer surface of the second
section may function as a hair-cutting surface.
[0019] A "split line," as used herein, means a line extending
through the tip of the tip portion of the blade substrate,
separates the second portion into asymmetrical first and second
sections and is generally parallel with first and second generally
parallel outer surfaces of the first portion defining the blade
body of the blade substrate.
[0020] With reference to FIG. 1, a shaving razor system 10
comprises a handle 12 and a razor cartridge 14. In some examples,
the razor cartridge 14 may be detachably mounted to the handle 12
with a connector 20, as shown, and in other examples, the razor
cartridge 14 may be attached permanently to the handle 12. The
razor cartridge 14 may pivot relative to the handle 12. The razor
cartridge 14 may include a cartridge housing 16 having one or more
razor blades 18. Although three blades are shown in FIG. 1, it is
understood that any number of blades, more or less, may be mounted
within the razor cartridge 14. The razor blades 18 may be mounted
within the cartridge housing 16 and secured with clips 24a and 24b
as shown. The cartridge housing 16 may further comprise a cap 22
located near a back of the cartridge housing 16 and one or more
guard structures 26 located near a front of the cartridge housing
16. The cap 22 may comprise one or more lubrication members (not
labeled).
[0021] FIG. 2 is a side view of a razor blade 8 in accordance with
the present disclosure, and FIGS. 3 and 4 are detailed perspective
and side views, respectively, of elements of a razor blade 18 in
accordance with the present disclosure. The razor blades 8 and 18
shown in FIGS. 2-4 may each comprise a substrate 28 comprising a
first portion with a blade body 30 and a second portion with a tip
portion 34. As used herein, a "substrate" signifies the substance
or material acted upon by the deposition process(es) in the present
disclosure. Illustrative embodiments herein relate to a stainless
steel substrate commonly used for razor blade formation. It is
contemplated that the substrate of the present invention may also
be comprised of other metals, plastic, ceramic, or any other
material. The blade body 30 may comprise a base 32, and the tip
portion 34 may comprise flanks 36 that converge at a tip 40 to
define a cutting edge 42 of the substrate 28, which performs the
cutting of hair. The flanks 36 may each comprise one or more bevels
or facets 38, as described herein.
[0022] In the example illustrated in FIGS. 2-4, the substrate 28 is
substantially symmetrical and may comprise a split line SL.sub.28
that passes through the tip 40 and divides or separates the
substrate 28 into substantially equal first and second sections or
halves 44 and 46. One outer side 48 (also referred to herein as a
first outer side) of the substrate 28 is disposed opposite the
split line SL.sub.28 with respect to the other outer side 50 (also
referred to herein as the second outer side). As used herein, the
terms "first" and "second" are for reference only and are not
intended to be limiting.
[0023] At least a portion of one outer side of the substrate 28,
e.g., the first outer side 48, may define a skin-contacting
surface, and at least a portion of the other outer side, e.g., the
second outer side 50, may define a hair-cutting surface. It was
determined that the two sides of the razor blade generally perform
different functions (e.g., a bottom side that contacts the skin and
a top side that performs cutting of the hair, in which both sides
perform cutting of the hair with the top side (e.g., away from the
skin) having a larger influence). Studies have shown that placing
Teflon on one bevel and no Teflon on the other display completely
different cutting forces depending on whether the Teflon coated
bevel is placed skin side up (e.g., away from the skin) versus skin
side down (e.g., closer to the skin). When razor blades with no
Teflon coating on one side are placed such that that side (e.g., no
Teflon coating) is skin side down, only small cutting force
increases were noted when compared to blades having Teflon on both
sides, but when razor blades with no Teflon coating are placed skin
side up very significant cutting force increases were measured when
compared to blades having Teflon on both sides.
[0024] With reference to FIG. 4, the tip portion 34 may comprise a
first flank 36A defined by a portion of the first outer side 48 and
a second flank 36B defined by a portion of the second outer side
50, in which the first and second flanks 36A and 36B converge at
the tip 40. The first flank 36A may comprise one or more first
facets, e.g., first and third facets 38A and 38C, and the second
flank 36B may comprise one or more second facets, e.g., second and
fourth facets 38B and 38D. The first facet 38A meets the blade body
30 at a first junction 39-1 and extends between the blade body 30
and the third facet 38C on the first outer side 48 of the substrate
28. The third facet 38C meets the first facet 38A at a second
junction 39-2 and extends between the first facet 38A and the tip
40 on the first outer side 48. On the second outer side 50 of the
substrate 28, the second facet 38B meets the blade body 30 at a
third junction 39-3 and extends between the blade body 30 and the
fourth facet 38D. The fourth facet 38D meets the second facet 38B
at a fourth junction 39-4 and extends between the second facet 38B
and the tip 40 on the second outer side 50. The third and fourth
facets 38C and 38D, which may also be referred to as end facets,
converge at the tip 40 to define the cutting edge 42. In other
examples, the flanks 36 may each include one facet 38 (see the
razor blade 8 in FIG. 2) or three or more facets (not shown). In
the razor blades 8 and 18 shown in FIGS. 2-4, an outer shape or
geometry of the first outer side 48 may be substantially the same
as an outer shape or geometry of the second outer side 50. For
example, the first facet 38A may substantially correspond to the
second facet 38B and may comprise a substantially similar length,
as defined between the first and second junctions 39-1 and 39-2 and
between the third and fourth junctions 39-3 and 39-4, respectively.
The third facet 38C may similarly substantially correspond to the
fourth facet 38D and may comprise a substantially similar length,
as defined between the tip 40 and the second junction 39-2 and the
tip 40 and the fourth junction 39-4, respectively. It follows that
the angles at the junctions 39-1 and 39-3, and the angles at the
junctions 39-2 and 39-4 may also generally be substantially
similar.
[0025] With continued reference to FIG. 4, the razor blade 18 may
comprise a plurality of outer surfaces, including first and second
blade body outer surfaces 31A and 31B defined by outer surfaces of
the first and second portions 30A and 30B, respectively, of the
blade body 30; and first, second, third, and fourth facet outer
surfaces 39A, 39B, 39C, and 39D defined by outer surfaces of the
first, second, third, and fourth facets 38A, 38B, 38C, and 38D,
respectively. The first outer side 48 of the substrate 28 includes
the first blade body outer surface 31A and the first and third
facet outer surfaces 39A and 39C. The second outer side 50 includes
the second blade body outer surface 31B and the second and fourth
facet outer surfaces 39B and 39D. The first and second blade body
outer surfaces 31A and 31B may be generally parallel to each other,
and the split line SL.sub.28 may be generally parallel with the
first and second blade body outer surfaces 31A and 31B. The first
and second outer sides 48 and 50 converge at the tip 40 to define
the cutting edge 42 of the substrate 28.
[0026] FIGS. 18 and 19 are side views illustrating exemplary
embodiments of razor blades 118 and 118' in accordance with the
present disclosure. Each razor blade 118, 118' may comprise a
substrate 128, 128' comprising a first portion comprising a blade
body 130, 130' and a second portion comprising a tip portion 134,
134'. The blade body 130, 130' may comprise a base 132 (not shown
in FIG. 19), and the tip portion 134, 134' may comprise flanks
136A, 136B and 136A', 136B' that converge at a respective tip 140,
140' to define a cutting edge (not labeled) of the respective
substrate 128, 128'. The flanks 136, 136' may each comprise one or
more respective bevels or facets, as described herein. The
substrates 128, 128' may be asymmetrical, with a split line
SL.sub.128, SL.sub.128' that passes through the tip 140, 140', is
parallel to the blade body outer surfaces 131A and 131B, and
divides or separates the substrate 128, 128' into asymmetrical
first and second sections or halves 144, 144' and 146, 146'. With
reference to FIG. 18, a first outer side 148 of the substrate 128
is disposed opposite the split line SL.sub.128 with respect to a
second outer side 150. With reference to FIG. 19, a first outer
side 148' of the substrate 128' is disposed opposite the split line
SL.sub.128' with respect to a second outer side 150'. At least a
portion of one outer side of each respective substrate 128, 128',
e.g., the first outer side 148, 148', may define a skin-contacting
surface, and at least a portion of the other outer side, e.g., the
second outer side 150, 150', may define a hair-cutting surface.
[0027] In the example shown in FIG. 18, the tip portion 134 of the
substrate 128 may comprise a first flank 136A defined by a portion
of the first outer side 148 and a second flank 136B defined by a
portion of the second outer side 150. The first flank 136A may
comprise one or more first facets, e.g., first and third facets
138A and 138C, and the second flank 136B may comprise one or more
second facets, e.g., second and fourth facets 138B and 138D. On the
first outer side 148 of the substrate 128, the first facet 138A
meets the blade body 130 at a first junction 139-1 and extends
between the blade body 130 and the third facet 138C; and the third
facet 138C meets the first facet 138A at a second junction 139-2
and extends between the first facet 138A and the tip 140. On the
second outer side 150 of the substrate 128, the second facet 138B
meets the blade body 130 at a third junction 139-3 and extends
between the blade body 130 and the fourth facet 138D; and the
fourth facet 138D meets the second facet 138B at a fourth junction
139-4 and extends between the second facet 138B and the tip 140.
The third and fourth facets 138C and 138D, which may also be
referred to as end facets, converge at the tip 140 to define the
cutting edge of the substrate 128.
[0028] In the example shown in FIG. 19, the tip portion 134' of the
substrate 128' may comprise a first flank 136A' defined by a
portion of the first outer side 148' and a second flank 136B'
defined by a portion of the second outer side 150'. The first flank
136A' may comprise one or more first facets, e.g., first and third
facets 138A' and 138C', and the second flank 136B' may comprise one
or more second facets, e.g., a second facet 138B'. On the first
outer side 148' of the substrate 128', the first facet 138A' meets
the blade body 130' at a first junction 139-1' and extends between
the blade body 130' and the third facet 138C'; and the third facet
138C' meets the first facet 138A' at a second junction 139-2' and
extends between the first facet 138A' and the tip 140'. On the
second outer side 150' of the substrate 128', the second facet
138B' meets the blade body 130 at a third junction 139-3' and
extends between the blade body 130' and the tip 140'. The second
and third facets 138B' and 138C', which may also be referred to as
end facets, converge at the tip 140' to define the cutting edge of
the substrate 128'.
[0029] Because the substrates 128, 128' are asymmetrical, an outer
shape or geometry of the first outer side 148, 148' is different
from an outer shape or geometry of the second outer side 150, 150'.
For example, with reference to FIG. 18, the first facet 138A may
comprise a different length, as compared to the second facet 138B,
with the lengths being defined between the first and second
junctions 139-1 and 139-2 and the third and fourth junctions 139-3
and 139-4, respectively. In some examples, the length of the first
facet 138A may be greater than the length of the second facet 138B,
and in other examples, the length of the first facet 138A may be
less than the length of the second facet 138B. The third facet 138C
may similarly comprise a different length, as compared to the
fourth facet 138D, with the lengths being defined between the tip
140 and the second junction 139-2 and the fourth junction 139-4,
respectively. In some examples, the length of the third facet 138C
may be greater than the length of the fourth facet 138D, and in
other examples, the length of the third facet 138C may be less than
the length of the fourth facet 138D.
[0030] With reference to FIG. 19, the first outer side 148'
comprises two facets 138A' and 138C', and the second outer side
150' comprises only one facet 138B'. The third facet 138C' may
similarly comprise a different length, as compared to the second
facet 138B', with the lengths being defined between the tip 140'
and the second junction 139-2' and the third junction 139-3',
respectively. In some examples, the length of the third facet 138C'
may be greater than the length of the second facet 138B', and in
other examples, the length of the third facet 138C' may be less
than the length of the second facet 138B'.
[0031] Each of the razor blades 118, 118' may comprise a plurality
of outer surfaces. With reference to FIG. 18, the razor blade 118
comprises first and second blade body outer surfaces 131A and 131B
defined by outer surfaces of first and second portions 130A and
130B, respectively, of the blade body 130; and first, second,
third, and fourth facet outer surfaces 139A, 139B, 139C, and 139D
defined by outer surfaces of the first, second, third, and fourth
facets 138A, 138B, 138C, and 138D, respectively. The first and
second blade body outer surfaces 131A and 131B may be generally
parallel to each other, and the split line SL.sub.128 may be
generally parallel with the first and second blade body outer
surfaces 131A and 131B. The first outer side 148 of the substrate
128 15702 9 includes the first blade body outer surface 131A and
the first and third facet outer surfaces 139A and 139C, and the
second outer side 150 includes the second blade body outer surface
131B and the second and fourth facet outer surfaces 139B and 139D.
The first and second outer sides 148 and 150 converge at the tip
140 to define the cutting edge of the substrate 128. The second and
fourth facets 138B and 138D may be located closer to the split line
SL.sub.128 than the first and third facets 138A and 138C, such that
the first half 144 of the substrate 128 is larger than the second
half 146.
[0032] With reference to FIG. 19, the razor blade 118' comprises
first and second blade body outer surfaces 131A' and 131B' defined
by outer surfaces of the first and second portions 130A' and 130B',
respectively, of the blade body 130'; and first, second, and third
facet outer surfaces 139A', 139B', and 139C' defined by outer
surfaces of the first, second, and third facets 138A', 138B', and
138C', respectively. The first and second blade body outer surfaces
131A' and 131B' may be generally parallel to each other, and the
split line SL.sub.128' may be generally parallel with the first and
second blade body outer surfaces 131A' and 131B'. The first outer
side 148' of the substrate 128' includes the first blade body outer
surface 131A' and the first and third facet outer surfaces 139A'
and 139C', and the second outer side 150' includes the second blade
body outer surface 131B' and the second facet outer surface 139B'.
The first and second outer sides 148' and 150' converge at the tip
140' to define the cutting edge of the substrate 128'. The second
facet 138B' may be located closer to the split line SL.sub.128'
than the first and third facets 138A' and 138C', such that the
first half 144' of the substrate 128' is larger than the second
half 146'.
[0033] Razor blades in accordance with the present disclosure may
comprise a coating disposed substantially on one or both outer
sides of the razor blade, in which at least a portion of one outer
side is free of any coating. A "layer" as used herein may signify
at least one material on a razor blade satisfied by a variety of
factors, including but not limited to, the composition, morphology,
or structure of the layer(s); the presence of a boundary between
layers; whether the process used to make the product is expected to
result in one or more layers; and whether there is a sufficient
change in composition or morphology as to result in one or more
layers. As one example, there may be only one type of material on
the razor blade but with distinguishable layers, each layer having
a different morphology. As used herein, a "coating" may signify one
or more layers on a razor blade, in which each layer comprises one
or more materials. Thus, the present invention "coating" may be
defined by a single layer or by multiple layers. The present
invention also contemplates the term "coating" to signify the
overall or total coating on one side of the razor blade, which
includes all of the layers on that one side of the razor blade.
[0034] In particular, a "coating" as used herein includes all
layer(s) of material(s) applied to one outer side of the razor
blade. For example, a coating may include one or more layers as
defined herein, such as a first layer that is disposed
substantially on a portion or the entirety of one outer side of the
razor blade; a second layer that is formed on top of at least a
portion of the first layer; a third layer that is formed on top of
at least a portion of the second layer; and so on. A coating may
further include a plurality of sections that are disposed
substantially on one outer side of the razor blade, wherein each
section may comprise one or more layers of material(s). For
example, the coating may comprise a first section that extends
substantially from a first point or location on one outer side of a
razor blade to a second point or location on the one outer side; a
second section that extends substantially from the second point or
location to a third point or location on the one outer side; a
third section that extends substantially from the third point or
location to a fourth point or location on the one outer side; and
so on, in which each section is substantially different from an
adjacent section, as described in detail herein.
[0035] As used herein to, the phrases "disposed substantially on,"
"extending substantially from," and similar phrases are used to
describe a location or position of each coating, including one or
more layers and/or sections thereof, and signifies that a majority
of the coating/layer/section is disposed on an indicated outer side
and/or surface(s) of the razor blade and/or that a majority of the
coating/layer/section extends between two indicated points or
locations on the outer side and/or surface(s) of the razor blade.
As described herein with respect to FIGS. 34-37, these phrases may
encompass structures in which a portion of the
coating/layer/section extends over the tip and onto the other outer
side or surface; overlaps onto an adjacent outer side or surface;
extends slightly beyond the two indicated points or locations on
the surface; or extends slightly past, or stops slightly short of,
an identified junction between adjacent facets or between the blade
body and a facet.
[0036] In accordance with the present disclosure, one outer side of
a razor blade comprises a coating, and at least a portion of the
other outer side of the razor blade is free of any coating. FIGS.
4-17 illustrate exemplary coatings with respect to an asymmetrical
razor blade 18 having a symmetrical substrate 28, and FIGS. 20-33
illustrate exemplary coatings with respect to an asymmetrical razor
blade 118 having an asymmetrical substrate 128. Some labeling in
FIGS. 5-17 and 20-33 is removed to illustrate other aspects of the
structure in detail.
[0037] As used herein, the terms "symmetrical," "asymmetrical," and
derivatives thereof may refer to an outer shape of a substrate that
defines a razor blade and/or to coating(s) formed thereon, as
determined with respect to a split line of the substrate. For
example, the substrate 28 in FIG. 4 is substantially symmetrical
(i.e., the split line SL.sub.28 divides the substrate 28 into
substantially equal sections/halves 44 and 46 with substantially
similar outer shapes that are generally mirror images of each
other), but the coating(s) formed on the substrate 28 in accordance
with the present disclosure may be asymmetrical, as described
herein in detail, such that the razor blade 18 is asymmetrical. The
substrate 128 in FIG. 18 and the coatings formed thereon are both
asymmetrical, as described herein, such that the razor blade 118 is
asymmetrical.
[0038] In FIGS. 4-17, one outer side, e.g., the first outer side
48, of the substrate 28 may comprise a coating, and at least a
portion 51 of the other outer side, e.g., the second outer side 50,
of the substrate 28 may be substantially free of any coating. In
some examples, at least a portion of the first outer side 48 may
define a skin-contacting surface. The portion 51 may extend from
the tip region 35 toward the base 32, as shown in FIGS. 4-16, or
may be spaced apart from the tip region 35 and the base 32, as
shown in FIG. 17. It is reemphasized that the terms "first" and
"second" as used herein are for reference only and are not intended
to be limiting. For example, although the lefthand side of the
substrate 28 in FIGS. 4-17 is referred to as the "first" outer
side, it is understood that the righthand side of the substrate 28
could also be the "first" outer side.
[0039] With reference to FIGS. 4-6, the razor blade 18 may comprise
a coating 60 disposed substantially on the first outer side 48 of
the substrate 28. In some examples, the coating 60 may comprise a
single layer of material, as shown in FIG. 4. In other examples,
the coating 60 may comprise a plurality of layers of material(s),
as shown in FIGS. 5 and 6 and described in detail herein. The
coating 60 extends from a tip region 35 toward the base 32 (see
FIG. 4) along the first outer side 48 of the substrate 28. As shown
in FIG. 4, the tip portion 34 of the substrate 28 comprises the tip
region 35, in which the tip region 35 encompasses, i.e., includes,
the tip 40 plus a portion of the substrate 28 extending from the
tip 40 toward the base 32 by about 1 .mu.M along the first and
second outer sides 48 and 50, as shown in FIG. 34.
[0040] With reference to FIG. 5, in some examples, the coating 60
may comprise first and second layers 60A and 60B, in which the
first layer 60A is disposed substantially on the first outer side
48 and the second layer 60B is formed on top of at least a portion
of the first layer 60A. With reference to FIG. 6, in other
examples, the first coating 60 may comprise at first, second, and
third layers 60A-60C, in which the first layer 60A is disposed
substantially on the first outer side 48, the second layer 60B is
formed on top of at least a portion of the first layer 60A, and the
third layer 60C is formed on top of at least a portion of the
second layer 60B. As described herein, the coating 60 and/or any of
the layers 60A-60C thereof may be subjected to ion implantation to
generate, for example, a layer 60' comprising an ion-implanted
material 61 shown in FIG. 13.
[0041] In the examples shown in FIGS. 4-6, the coating 60
(including all layers 60A-60C thereof) is depicted as extending
along the first outer side 48 of the substrate 28 from the tip
region 35 onto the blade body 30, and in some instances, all the
way to the base 32 of the razor blade 18 as shown in FIG. 4. In
other examples, as shown in FIGS. 7 and 8, the coating and/or one
or more layers thereof may stop short of the blade body 30 and/or
the base 32, and in some particular examples, the coating and/or
one or more layers thereof may be disposed substantially only on
the tip portion 34 of the substrate 28, e.g., on one or both of the
first and third facets 38A and 38C.
[0042] With reference to FIGS. 7 and 8 and the labeling of the
substrate 28 in FIG. 4, a coating 64, 68 may comprise one or more
layers including a respective first layer 64A, 68A and second layer
64B, 68B. The first layer 64A, 68A is disposed substantially on,
and extends along a portion of, the first outer side 48 of the
substrate 28 from the tip region 35 toward the base 32 for a
respective first distance D.sub.1, D.sub.1'. The second layer 64B,
68B is formed on top of at least a portion of the respective first
layer 64A, 68B and extends from the tip region 35 toward the base
32 for a respective second distance D.sub.2, D.sub.2'. In some
examples, the second distance D.sub.2, D.sub.2' may be less than
the respective first distance D.sub.1, D.sub.1'. In FIG. 7, the
first layer 64A may extend along the first outer side 48 from the
tip region 35 onto the blade body 30 and toward the base 32, and
the second layer 64B may be disposed substantially on the first and
third facets 38A and 38C, with the second layer 64B extending from
the tip region 35 to about the first junction 39-1 between the
first facet 38A and the blade body 30. In FIG. 8, the first layer
68A may extend along the first outer side 48 from the tip region 35
onto the blade body 30 and toward the base 32, and the second layer
68B may be disposed substantially on the third facet 38C, with the
second layer 68B extending from the tip region 35 to about the
second junction 39-2 between the first and second facets 38A and
38B. In other examples, the second distance D.sub.2, D.sub.2' may
be about the same as the respective first distance D.sub.1,
D.sub.1'. In some instances, the first and second layers may both
be disposed on the first and third facets 38A and 38C or only on
the third facet 38C. With continued reference to FIGS. 7 and 8, in
some configurations, the coatings 64 and 68 may comprise two or
more layers, e.g., the first layer 64A, 68A and the second layer
64B, 68B. In other configurations, the coatings 64 and 68 may
comprise only the second layer 64B and 68B (the first 64A and 68A
are shown in dashed lines in FIGS. 7 and 8 indicating that they are
optional).
[0043] With reference to FIGS. 9-11, in further examples, a coating
72 substantially disposed on the first outer side 48 may comprise
two or more sections. As shown in FIGS. 9 and 10, the coating 72
may comprise a first section 72-1 and a second section 72-2. The
first section 72-1 of the coating 72 may extend along the first
outer side 48 substantially from a first point or location 73-1,
which may substantially correspond to a tip region 35 of the
substrate 28, to a second point or location 73-2 on the first outer
side 48. The second section 72-2 may extend substantially from the
second location 73-2 to a third point or location 73-3 on the first
outer side 48. With reference to FIG. 9 and the labeling of the
substrate 28 in FIG. 4, the second location 73-2 may be positioned
at about a junction between a facet and the blade body 30, e.g.,
junction 39-1 between the first facet 38A and the blade body 30,
such that the first section 72-1 may be located substantially on
the first and third facets 38A and 38C on the first outer side 48
and the second section 72-2 may be located substantially on the
blade body 30. With reference to FIG. 10 and the labeling of the
substrate 28 in FIG. 4, the second location 73-2 may be positioned
at about a junction between two adjacent facets, e.g., junction
39-2 between the first and third facets 38A and 38C, such that the
first section 72-1 is located substantially on the third facet 38C.
In the examples depicted in FIGS. 9 and 10, the third location 73-3
may be spaced apart from the second location 73-2 and may be
located, for example, toward or near the base 32 of the substrate
28, as shown in FIG. 9.
[0044] As shown in FIG. 11, the coating 72 may comprise first,
second, and third sections 72-1, 72-2, and 72-3. The first section
72-1 may extend along the first outer side 48 substantially from a
first point or location 73-1, which may substantially correspond to
a tip region 35 of the substrate 28, to a second point or location
73-2 on the first outer side 48; the second section 72-2 may extend
substantially from the second location 73-2 to a third point or
location 73-3 on the first outer side 48; and the third section
72-3 may extend substantially from the third location 73-3 to a
fourth point or location (not shown) on the first outer side 48.
With reference to FIG. 11 and the labeling of the substrate 28 in
FIG. 4, the second location 73-2 may be positioned at about the
junction 39-2 between the first and third facets 38A and 38C, and
the third location 73-3 may be positioned at about the junction
39-1 between the first facet 38A and the blade body, such that the
first and second sections 72-1 and 72-2 may be disposed
substantially on the first and third facets 38A and 38C,
respectively, and the third section 72-3 may be located
substantially on the blade body 30. The fourth location may be
spaced apart from the third location 73-3 and may be located, for
example, toward or near the base 32 of the substrate 28.
[0045] With reference to FIG. 12, in further examples, the
substrate 28 may comprise a coating 76 with a thickness that varies
along at least a section of the coating 76 in a direction extending
from the tip region 35 toward the base 32, in which the thickness
is measured between an outer surface 76A of the coating 76 and an
outer surface 28A of the substrate 28. The coating 76 may, for
example, increase in thickness, as shown in FIG. 12.
[0046] In the examples shown in FIGS. 4-12, an outer shape of the
coatings 60, 64, 68, 72, and 76 (and all layers or sections
thereof) generally conform to and/or mirror an outer shape of the
underlying portions of the substrate 28 on which the coatings are
formed. In other examples, as shown in FIG. 14, the substrate 28
may comprise a coating 80 with one or more sections that define an
outer shape that is different from an outer shape of an underlying
portion of the substrate 28. The coating 80 may comprise a
thickened section 80A where the coating 80 bulges outward from the
substrate 28 and forms an outer shape that is different from an
outer shape of one or more of the underlying portions of the
substrate 28, e.g., the first and third facet outer surfaces (not
labeled; see facet outer surfaces 39A and 39C in FIG. 4). The
coating 80 may optionally comprise a second section 80B with an
outer shape that conforms more closely to the outer shape of the
underlying portion(s), e.g., the first blade body outer surface
(not labeled; see blade body outer surface 31A in FIG. 4), of the
substrate 28.
[0047] In FIGS. 4-17, the coating 60, 64, 68, 72, 76, and 80 may be
disposed on one or both of the first facets (i.e., the first and/or
third facets 38A and 38C) on the first outer side 48, and the
portion 51 of the second outer side 50 that is free of any coating
may comprise at least a portion of one or both of the second facets
(i.e., the second and/or fourth facets 38B and 38D). In the
examples shown in FIGS. 4-14, the portion 51 of the second outer
side 50 that is substantially free of any coating may comprise
substantially an entirety of the second outer side 50. In the
examples shown in FIGS. 15-17, the portion 51 that is substantially
free of any coating may comprise only part of the second outer side
50 (also referred to herein as a first portion or an uncoated
portion). A second portion 53 of the second outer side 50 may
comprise a second coating 62 disposed substantially thereon, such
that only part of the second outer side 50 is uncoated.
[0048] With reference to FIGS. 15 and 16 and the labeling of the
substrate 28 in FIG. 4, the first portion 51 of the second outer
side 50 that is substantially free of any coating may extend from
the tip region 35 toward the base 32, and the second coating 62 may
extend substantially from a first location 75-1 to a second
location 75-2, in which the first location 75-1 is spaced apart
from the tip region 35 and the second location 75-2 is located
toward the base 32. In FIG. 15, the first location 75-1 may
substantially correspond to the junction 39-3 between the blade
body 30 and the fourth facet 38D, such that the uncoated portion 51
of the second outer side 50 may comprise substantially an entirety
of the second and fourth facets 38B and 38D. In FIG. 16, the first
location 75-1 may substantially correspond to the junction 39-4
between the second and fourth facets 38B and 38D, such that the
uncoated portion 51 of the second outer side 50 may comprise
substantially an entirety of the fourth facet 38D. It may be
understood that the second coating 62 may be disposed so that the
uncoated portion 51 of the second outer side 50 is located at any
desired location within these parameters.
[0049] With reference to FIG. 17 and the labeling of the substrate
28 in FIG. 4, in further examples, the second coating 62 may
comprise first and second sections 62-1 and 62-2, and the uncoated
portion 51 of the second outer side 50 may be located between the
first and second sections 62-1 and 62-2 of the second coating 62
such that the uncoated portion 51 is spaced apart from the tip
region 35 and the base 32. For example, the first section 62-1 of
the second coating 62 may extend substantially from a first
location 75-1 to a second location 75-2, and the second section
62-2 may extend substantially from a third location 75-3 to a
fourth location 75-4. The first location 75-1 may substantially
correspond to the tip region 35 of the substrate 28, and the second
location 75-2 may be spaced apart from the third location 75-3. In
the example shown in FIG. 17, the second location 75-2 may
substantially correspond to the junction 39-4 between the second
and fourth facets 38B and 38D; the third location 75-3 may
substantially correspond to the junction 39-3 between the blade
body 30 and the fourth facet 38D; and the fourth location 75-4 may
be located toward the base 32 of the substrate 28, such that the
uncoated portion 51 of the second outer side 50 may comprise
substantially an entirety of the second facet 38B. It is understood
that the sections 62-1 and 62-2 of the second coating 62 may be
disposed so that the uncoated portion 51 of the second outer side
50 is located at any desired location within these parameters.
[0050] In all examples, each coating may comprise one or more
materials. In examples in which the substrate 28 comprises a
coating with multiple layers as shown in FIGS. 5-8, the layers may
comprise the same materials or one or more different materials, as
compared to each other. For example, a first layer of a coating may
comprise one or more first materials, and a second layer of the
coating may comprise one or more second materials, in which at
least one of the second materials is different from at least one of
the first materials. In examples in which the substrate 28
comprises a coating with two or more sections as shown in FIGS.
9-11, each section may comprise a different material, as compared
to an adjacent or neighboring section. In examples in which the
substrate 28 comprises first and second coatings as shown in FIGS.
15-17, the coatings may comprise the same materials or one or more
different matierals, as compared to each other. For example, the
first coating may comprise one or more first materials, and the
second coating may comprise one or more second materials, in which
at least one of the second materials is different from at least one
of the first materials.
[0051] The materials may comprise one or more carbon-containing
materials (e.g., diamond, amorphous diamond, nano-crystalline
diamond, or diamond like carbon (DLC)); nitrides (e.g., boron
nitride, niobium nitride, chromium nitride, titanium nitride,
aluminum titanium nitride, titanium carbon nitride), carbides
(e.g., silicon carbide or chromium carbide), oxides (e.g., alumina,
zirconia), titanium diboride, one or more ceramic materials, a
fluorinated polymer (e.g., polytetrafluoroethylene (PTFE)), a
polyolefin (e.g., polypropylene), niobium, chromium, and platinum
chromium. The carbon-containing materials can be doped with other
elements, such as tungsten, titanium, or chromium by including
these additives, for example, in the target during application by
sputtering. The materials can also incorporate hydrogen, e.g.,
hydrogenated DLC. The materials may comprise one or more
nanocomposites such as carbon-based nanocomposites, metal-matrix
nanocomposites, and/or ceramic-matrix nanocomposites; e.g., diamond
and carbon and nanocomposites.
[0052] The material(s) may be selected based, at least in part, on
a coefficient of friction of the material(s), with the materials of
the various coatings and/or layers and/or sections thereof
comprising one or more materials with a different coefficient of
friction, as compared to each other. For example, the coating 60 in
FIG. 4 or an outer layer 60B, 60C, 64B, 68B thereof in FIGS. 5-7
may comprise a material with a low coefficient of friction such as
PTFE, particularly when the first outer side 48 of the substrate 28
at least partially defines the skin-contacting surface. When
present, the second coating 62 (see FIGS. 15-17) may comprise a
material with a higher coefficient of friction than PTFE, such as
polypropylene.
[0053] The material(s) of the coatings and/or layers and/or
sections thereof may also be selected based, at least in part, on
morphology, which may include microstructure (e.g., amorphous,
columnar, crystalline, dense, porous, etc.) A porous microstructure
may improve adhesion of a subsequent polymer coating. The desired
morphology may be obtained, for example, by applying the coatings
and/or layers and/or sections thereof via different application
techniques or via the same application technique with differing
application speeds, as described herein.
[0054] The material(s) of the coatings and/or layers and/or
sections thereof may further be selected based, at least in part,
on a hardness of the material(s). One coating and/or layer and/or
section thereof may comprise a first hardness, and another coating
and/or layer and/or section thereof may comprise a second hardness.
In some examples, the first hardness may be greater than about 7
GPa, and the second hardness may be greater than about twice the
first hardness, e.g., greater than about 15 GPa. In other examples,
the first hardness may be between about 7 GPa to about 10 GPa, and
the second hardness may be between about 15 GPa to about 60 GPa. As
used herein with respect to hardness, the term "about" may mean
.+-.0.5 GPa.
[0055] A texture of the coatings and/or layers and/or sections
thereof may also be selected. For example, the coating 60 in FIG. 4
or an outer layer 60B, 60C, 64B, 68B thereof in FIGS. 5-7 may
comprise a substantially smooth texture, particularly when the
first outer side 48 of the substrate 28 at least partially defines
the skin-contacting surface. When present, the second coating 62
(see FIGS. 15-17) may comprise a discontinuous or more coarse
texture that may include protrusions. The desired texture may be
obtained by, for example, applying the coatings and/or layers
and/or sections thereof via different application techniques or via
the same application technique with differing application speeds,
as described herein. The texture may also be altered via one or
more post-application treatment methods, as described herein.
[0056] In further examples, at least a section of the coatings
and/or layers and/or sections thereof may be subjected to one or
more post-application treatments (e.g., modification of a surface
of the coating and/or modification of one or more layers of the
coating). For instance, one or more sections of the coatings and/or
layers and/or sections thereof may be subjected to ion
implantation. With reference to FIG. 13, at least a section of a
coating 60' may comprise an ion-implanted material 61. The
ion-implanted material 61 may comprise, for example, a
plasma-nitrided material or a plasma-borided material. The ion
implantation may be performed as described herein and may be
performed on all or part of the coating 60'. The one or more
post-application treatments may also comprise altering a texture of
the coatings and/or layers and/or sections thereof. For example,
the coatings and/or layers and/or sections thereof may be subjected
to chemical modification (e.g., solvent treatment) and/or
mechanical modification (e.g., ion etching, ion implantation,
abrading, rubbing, polishing, etc.) to alter a surface texture.
[0057] The one or more post-application treatments may further
comprise partially removing the coatings and/or layers and/or
sections thereof, e.g., by solvent treatment, ion etching, etc.
Partial removal may comprise, for example, removal of all or part
of a thickness of the coating (i.e., in a direction substantially
perpendicular to an underlying portion of the substrate) along one
or more sections of the second coating, in which at least a portion
of the the coating remains intact. In some examples, the partial
removal of the one or more portions of the coating may be followed
by one or more additional post-application treatments comprising
selectively applying material to the coating from which material
was partially removed. The selectively-applied material may be
applied using any suitable method. The selectively-applied material
may comprise, for example, a polymer or an organic compound, such
as a fluropolymer, PTFE, or polypropylene. In some particular
examples, the portion(s) of the coating to which material is
selectively applied may define a skin-contacting surface of the
razor blade.
[0058] With reference now to FIGS. 20-33, the razor blade 118 may
comprise one or more coatings that are substantially similar to the
razor blade 18 depicted in FIGS. 4-17 and described herein in
detail, in which one of the first or the second outer side 148 or
150 of the substrate 128 may comprise a coating and at least a
portion 149 or 151 of the other of the first or the second outer
side 148 or 150 of the substrate 128 may be substantially free of
any coating. In some particular examples in which the first outer
side 148 comprises the coating, at least a portion of the first
outer side 148 may define a skin-contacting surface. The portion
149, 151 may extend from the tip region 135 toward the base 132, as
shown in FIGS. 20-32, or may be spaced apart from the tip region
135 and the base 132, as shown in FIG. 33.
[0059] As shown in FIGS. 20A, 21A, and 22A, the razor blade 118 may
comprise a coating 160 disposed substantially on the first outer
side 148 of the substrate 128 and extending along the first outer
side 148 from the tip region 135 toward the base (not shown; see
base 132 in FIG. 18). The portion 151 of the second outer side 150
that is substantially free of any coating may extend from the tip
region 135 toward the base. The coating 160 may comprise a single
layer of material, as shown in FIG. 20A, or a plurality of layers
of material(s), e.g., first, second, and/or third layers 160A,
160B, and/or 160C, as shown in FIGS. 21A and 22A. The first layer
160A is disposed substantially on the first outer side 148; the
second layer 160B is formed on top of at least a portion of the
first laye 160A; and when present, the third layer 160C is formed
on top of at least a portion of the second layer 160B. FIGS. 20B,
21B, and 22B depict alternative configurations of respective ones
of FIGS. 20A, 21A, and 22A, in which the razor blade 118 comprises
a coating 162 disposed substantially on the second outer side 150
of the substrate 128 and the first outer side 148 comprises the
portion 149 that is substantially free of any coating. The coating
162 extends along the first outer side 150 from the tip region 135
toward the base (not shown; see base 132 in FIG. 18). The portion
149 that is substantially free of any coating may extend from the
tip region 135 toward the base. The coating 162 may comprise a
single layer of material, as shown in FIG. 20B, or a plurality of
layers of material(s), e.g., first, second, and/or third layers
162A, 162B, and/or 162C, as shown in FIGS. 21B and 22B. As
described herein, the coating(s) 160, 162 and/or any of the layers
160A-160C, 162A-162C thereof may be subjected to ion implantation
to generate, for example, a layer 160' or 162' comprising an
ion-implanted material 161 or 163, respectively, shown in FIGS. 29A
and 29B.
[0060] In the examples shown in FIGS. 20-22, the coatings 160 and
162 (including all layers 160A-160C and 162A-162C thereof) are
depicted as extending along the respective outer side 148 or 150 of
the substrate 128 from the tip region 135 onto the blade body (not
labeled; see blade body 130 in FIG. 18), and in some instances, may
extend all the way to the base (not shown; see base 132 in FIG. 18)
of the razor blade 118. In other examples, the coatings and/or one
or more layers thereof may stop short of the blade body and/or the
base, and in some particular examples, the coatings and/or one or
more layers thereof may be disposed substantially only on the tip
portion (not labeled; see 134 in FIG. 18) of the substrate 128,
e.g., on one or both of the first and third facets or one or both
of the second and fourth facets (not labeled; see facets 138A to
138D in FIG. 18).
[0061] With reference to FIGS. 23A and 24A and the labeling of the
substrate 128 in FIG. 18, a coating 164, 168 may comprise one or
more layers including a first layer 164A, 168A that is disposed
substantially on, and extends along a portion of, the first outer
side 148 of the substrate 128 from the tip region 135 toward the
base 132 for a respective first distance D.sub.10, D.sub.10'; and a
second layer 164B, 168B that is formed on top of at least a portion
of the respective first layer 164A, 168B and extends from the tip
region 135 toward the base 132 for a respective second distance
D.sub.20, D.sub.20'. In some examples, the second distance
D.sub.20, D.sub.20' may be less than the respective first distance
D.sub.10, D.sub.10'. In FIG. 23A, the first layer 164A may extend
along the first outer side 148 from the tip region 135 onto the
blade body 130 and toward the base 132, and the second layer 164B
may be disposed substantially on the first and third facets 138A
and 138C, with the second layer 164B extending from the tip region
135 to about the first junction 139-1 between the first facet 138A
and the blade body 130. In FIG. 24A, the first layer 168A may
extend along the first outer side 148 from the tip region 135 onto
the blade body 130 and toward the base 132, and the second layer
168B may be disposed substantially on the third facet 138C, with
the second layer 168B extending from the tip region 135 to about
the second junction 139-2 between the first and second facets 138A
and 138B. In other examples, the second distance D.sub.20,
D.sub.20' may be about the same as the respective first distance
D.sub.10, D.sub.10'. In some instances (not shown), the first and
second layers may both be disposed on the first and third facets
138A and 138C or only on the third facet 138C.
[0062] FIGS. 23B and 24B depict alternative configurations of FIGS.
23A and 24A, respectively, in which the second outer side 150
comprises a coating 166, 170 disposed substantially thereon, in
which each coating 166, 170 may comprise one or more layers
including a respective first layer 166A, 170A and second layer
166B, 170B. Each first layer 166A, 170A extends along a portion of
the second outer side 150 from the tip region 135 toward the base
(not shown; see base 132 in FIG. 18) for a respective third
distance D.sub.30, D.sub.30'; and each second layer 166B, 170B
extends from the tip region 135 toward the base for a respective
fourth distance D.sub.40, D.sub.40'. In some examples, the fourth
distance D.sub.40, D.sub.40' may be less than the respective third
distance D.sub.30, D.sub.30', e.g., the second layer 166B of the
coating 166 in FIG. 23B is disposed substantially on the second and
fourth facets (not labeled; see facets 138B and 138D in FIG. 18)
and the second layer 170B of the coating 170 in FIG. 24B is
disposed substantially on the fourth facet. In other examples, the
fourth distance D.sub.40, D.sub.40' may be about the same as the
respective third distance D.sub.30, D.sub.30'. In the examples
depicted in FIGS. 23 and 24, the coatings 164, 166, 168, and 170
may comprise two layers, e.g., respective first layers 164A, 166A,
168A, and 170A and second layers 164B, 166B, 168B, and 170B. In
other configurations, the coatings 164, 166, 168, and 170 may
comprise only the second layer 164B, 166B, 168B, and 170B (the
first layers 164A, 166A, 168A, and 170A are shown in dashed lines
in FIGS. 23 and 24 indicating that they are optional).
[0063] With reference to FIGS. 25A, 26A, and 27A, in further
examples, a coating 172 may comprise two or more sections,
including a first section 172-1, a second section 172-2, and a
third section 172-3. The first section 172-1 may extend along the
first outer side 148 substantially from a first point or location
173-1, which may substantially correspond to a tip region 135 of
the substrate 128, to a second point or location 173-2; the second
section 172-2 may extend substantially from the second location
173-2 to a third point or location 173-3; and when present, the
third section 172-3 may extend substantially from the third
location 173-3 to a fourth point or location (not shown). With
reference to FIG. 25A and the labeling of the substrate 118 in FIG.
18, the second location 173-2 may be positioned at about the
junction 139-1 between the first facet 138A and the blade body 130,
such that the first section 172-1 may be located substantially on
the first and third facets 138A and 138C, and the second section
172-2 may be located substantially on the blade body 130. With
reference to FIG. 26A and the labeling of the substrate 118 in FIG.
18, the second location 173-2 may be positioned at about the
junction 139-2 between the first and third facets 138A and 138C,
such that the first section 172-1 may be located substantially on
the third facet 138C. In the examples depicted in FIGS. 25A and
26A, the third location 173-3 may be spaced apart from the second
location 173-2 and may be located, for example, toward or near the
base 132 of the substrate 128, as shown in FIG. 25A. With reference
to FIG. 27A and the labeling of the substrate 118 in FIG. 18, the
second location 173-2 may be positioned at about the junction 139-2
between the first and third facets 138A and 138C, and the third
location 173-3 may be positioned at about the junction 139-1
between the first facet 138A and the blade body 130, such that the
first and second sections 172-1 and 172-2 may be disposed
substantially on the first and third facets 138A and 138C,
respectively, and the third section 172-3 may be located
substantially on the blade body 130. The fourth location (not
shown) may be spaced apart from the third location 173-3 and may be
located, for example, toward or near the base 132 of the substrate
128.
[0064] FIGS. 25B, 26B, and 27B depict alternative configurations of
FIGS. 25A, 26A, and 27A, respectively, in which the second outer
side 150 comprises a coating 174 comprising two or more sections,
including a first section 174-1, a second section 174-2, and a
third section 174-3. The first section 174-1 may extend along the
second outer side 150 substantially from a first point or location
175-1 (may substantially correspond to a tip region 135 of the
substrate 128) to a second point or location 175-2; the second
section 174-2 may extend substantially from the second location
175-2 to a third point or location 175-3, and when present, the
third section 174-3 may extend substantially from the third
location 175-3 to a fourth point or location (not shown).
[0065] With reference to FIGS. 28A and 28B, in further examples,
one of the first or the second outer side 148 or 150 of the
substrate 128 may comprise a respective coating 176 or 178 with a
thickness that varies along at least a section of the coating 176
and 178 in a direction extending from the tip region 135 toward the
base 132. The thickness of the coating 176 and 178 may be measured
between an outer surface 176A, 178A of the respective coating 176
and 178 and an outer surface 128A of the substrate 128. The
coatings 176 and 178 may, for example, increase in thickness, as
shown in FIGS. 28A and 28B.
[0066] In the examples shown in FIGS. 20-28, an outer shape of the
coatings 160, 162, 164, 166, 168, 170, 172, 174, 176, and 178 (and
all layers or sections thereof) generally conform to and/or mirror
an outer shape of the underlying portions of the substrate 128 on
which the coatings are formed. In other examples, as shown in FIGS.
30A and 30B, the substrate 128 may comprise a coating 180 or 182
with one or more sections that define an outer shape that is
different from an outer shape of an underlying portion of the
substrate 128. As shown in FIG. 30A, the coating 180 may be
disposed substantially on the first outer side 148 and may comprise
a thickened section 180A where the coating 180 bulges outward from
the substrate 128 and forms an outer shape that is different from
an outer shape of one or more of the underlying portions of the
substrate 128, e.g., the third facet outer surface and at least a
portion of the first facet outer surface (not labeled; see facet
outer surfaces 139A and 139C in FIG. 18). As shown in FIG. 30B, the
coating 182 may be disposed substantially on the second outer side
150 and may comprise a thickened section 182A where the coating 182
bulges outward from the substrate 128 and forms an outer shape that
is different from an outer shape of one or more of the underlying
portions of the substrate 128, e.g., the fourth facet outer surface
and at least a portion of the second facet outer surface (not
labeled; see facet outer surfaces 139B and 139D in FIG. 18). The
coatings 180 and 182 may optionally comprise a respective second
section 180B and 182B with an outer shape that conforms more
closely to the outer shape of the underlying portion(s), e.g., the
first or second blade body outer surface (not shown; see blade body
outer surface 131A, 131B in FIG. 18), of the substrate 128.
[0067] In FIGS. 20A, 21A, 22A, 23A, 24A, 25A, 26A, 27A, 28A, 29A,
and 30A, the coatings 160, 164, 168, 172, 176, and 180 may be
disposed on one or both of the first facets (i.e., the first and/or
third facets 138A and 138C in FIG. 18) on the first outer side 148
of the substrate 128, and the portion 151 of the second outer side
150 that is free of any coating may comprise at least a portion of
one or both of the second facets (i.e., the second and/or fourth
facets 138B and 138D in FIG. 18). In FIGS. 20B, 21B, 22B, 23B, 24B,
25B, 26B, 27B, 28B, 29B, and 30B, the coatings 162, 166, 170, 174,
178, and 182 may be disposed on one or both of the second facets
(i.e., the second and/or fourth facets 138B and 138D in FIG. 18) on
the second outer side 150 of the substrate 128, and the portion 149
of the first outer side 148 that is free of any coating may
comprise at least a portion of one or both of the first facets
(i.e., the first and/or third facets 138A and 138C in FIG. 18). In
the examples shown in FIGS. 20-30, the portion 149 or 151 of the
outer side 148 or 150 that is substantially free of any coating may
comprise substantially an entirety of the respective outer side 148
or 150. In the examples shown in FIGS. 31-33, the portion 151 that
is substantially free of any coating may comprise only part of the
second outer side 150 (also referred to herein as a first portion
or an uncoated portion). A second portion 153 of the second outer
side 150 may comprise a second coating 162 disposed substantially
thereon, such that only part of the second outer side 150 is
uncoated.
[0068] With reference to FIGS. 31 and 32 and the labeling of the
substrate 128 in FIG. 18, the first portion 151 of the second outer
side 150 that is substantially free of any coating may extend from
the tip region 135 toward the base 132, and the second coating 162
may extend substantially from a first location 175-1 to a second
location 175-2, in which the first location 175-1 is spaced apart
from the tip region 135 and the second location 175-2 is located
toward the base 132. In FIG. 31, the first location 175-1 may
substantially correspond to the junction 139-3 between the blade
body 130 and the fourth facet 138D, such that the uncoated portion
151 of the outer side 150 may comprise substantially an entirety of
the second and fourth facets 138B and 138D. In FIG. 32, the first
location 175-1 may substantially correspond to the junction 139-4
between the second and fourth facets 138B and 138D, such that the
uncoated portion 151 of the outer side 150 may comprise
substantially an entirety of the fourth facet 138D. It may be
understood that the second coating 162 may be disposed so that the
uncoated portion 151 of the outer side 150 is located at any
desired location within these parameters.
[0069] With reference to FIG. 33 and the labeling of the substrate
128 in FIG. 18, in further examples, the second coating 162 may
comprise first and second sections 162-1 and 162-2, and the
uncoated portion 151 of the second outer side 150 may be located
between the first and second sections 162-1 and 162-2 of the second
coating 162, such that the uncoated portion 151 is spaced apart
from the tip region 135 and the base 132. For example, the first
section 162-1 of the second coating 162 may extend substantially
from a first location 175-1 to a second location 175-2, and the
second section 162-2 may extend substantially from a third location
175-3 to a fourth location 175-4. The first location 175-1 may
substantially correspond to the tip region 135 of the substrate
128, and the second location 175-2 may be spaced apart from the
third location 175-3. In the example shown in FIG. 33, the second
location 175-2 may substantially correspond to the junction 139-4
between the second and fourth facets 138B and 138D; the third
location 175-3 may substantially correspond to the junction 139-3
between the blade body 130 and the fourth facet 138D; and the
fourth location 175-4 may be located toward the base 132 of the
substrate 128, such that the uncoated portion 151 of the outer side
150 may comprise substantially an entirety of the second facet
138B. It is understood that the sections 162-1 and 162-2 of the
second coating 162 may be disposed so that the uncoated portion 151
of the second outer side 150 is located at any desired location
within these parameters. In addition, although the uncoated portion
151 is depicted in FIGS. 31-33 as being located on the second outer
side 150, it is understood that the uncoated portion 151 could also
be located on the first outer side 148 (not shown).
[0070] The coatings depicted in FIGS. 20-33 and/or layers and/or
sections thereof may comprise one or more materials, as described
herein in detail with respect to FIGS. 4-17. The material(s) may be
selected for any of the properties and characteristics described
herein (e.g., coefficient of friction, morphology, texture,
hardness, etc.), and at least a section of the coatings and/or
layers and/or sections thereof may be subjected to one or more
post-application treatments, as described herein in detail. For
example, one or more sections of the coatings and/or layers and/or
sections thereof may be subjected to ion implantation, as shown in
FIGS. 29A and 29B in which at least a section of a coating 160',
162' may comprise an ion-implanted material 161, 163.
[0071] FIGS. 34-37 are detailed views of a tip region 35 of a
substrate 28, which may represent any of the substrates 28 and 128
in FIGS. 4-17 and 20-33. FIG. 34 depicts an idealized
representation of a the tip region 35 in which a coating 60 is
disposed only on the first outer side 48 of the substrate 28, i.e.,
on the left side of a split line S.sub.28 of the substrate 28, and
at least a portion 51 of the second outer side 50 of the substrate
28, i.e., on the right side of a split line S.sub.28, is free of
any coating.
[0072] However, application of material(s) to a substrate 228 may
produce a tip region 235 with slight imperfections, as illustrated
in FIGS. 35-37. In FIGS. 35-37, a first outer side 248 of a
substrate 228 (as defined by a split line SL.sub.228) may comprise
a coating 260 with a first layer 260A and a second layer 260B, and
a portion 251 of a second outer side 250 may be substantially free
of any coating. As shown in FIGS. 35 and 36, in some examples, a
small portion of the coating 260 (may include one or both of the
layers 260A and 260B) may be disposed on the second outer side 250
of the substrate 228 at the tip region 235, i.e., a small portion
(extending less than or equal to about 1 .mu.M back from the tip
240 toward the base) of the coating 260 may be located to the right
of the split line SL.sub.228. FIG. 37 provides a further example in
which the coating 260 stops slightly short of the tip 240, such
that there is a small gap (less than or equal to about 1 .mu.M)
between the coating 260 and the tip 240.
[0073] In the examples described herein, notwithstanding a small
amount (extending less than or equal to about 1 .mu.M back from the
tip 240 toward the base) of overlap by the coating 260 onto the
second outer side 250 or a gap (less than or equal to about 1
.mu.M) between the coating 260 and the tip 240 in the tip region
235, the coating 260, including all layers 260A and 260B thereof,
is considered to be disposed "substantially" on the first outer
side 248 of the substrate 228 and to extend "from the tip region"
when the majority of the coating 260 is disposed on the first outer
side 248 of the substrate 228. In addition, the portion of the
second side 250 extending "from the tip region toward the base" in
FIGS. 35 and 36 is considered to be "substantially free of any
coating," notwithstanding the small amount of overlap by the
coating 260 onto the second outer side 250. Although the examples
shown in FIGS. 34-37 depict the coating as being located on the
first outer side 248 of the substrate 228, it is understood that
the coating could also be located on the second outer side 250.
[0074] In examples in which the first and/or second coating
comprise two or more layers (see FIGS. 5-8 and 21-24) and/or two or
more sections (see FIGS. 9-11 and 25-27), each layer or section is
described as extending from one point or location to another point
or location on the substrate (e.g., a junction between adjacent
ones of the facets or a junction between the blade body and one of
the facets) and, in some examples, a section may adjoin and contact
at least a portion of an adjacent section.
[0075] Similar to the structures depicted in FIGS. 35-37, the
layers and/or sections may extend slightly beyond (less than or
equal to about 1 .mu.M), or stop slightly short of (less than or
equal to about 1 .mu.M), one or both of the identified locations.
In some cases, there may be a small amount of mixing of materials
at an interface between two adjacent sections or a small gap
between the adjacent sections (less than or equal to about 1
.mu.M). Notwithstanding these slight imperfections, a layer or
section of a coating may be considered to extend "substantially"
from one location to another location when the majority of the
layer/section is disposed between the two identified locations.
[0076] The coatings described herein may be applied or selectively
removed using one more techniques. FIG. 38 is a block diagram of a
system 300 having one or more chambers and/or stations 302-1 to
302-n that may be used to apply one or more coatings to one or more
portions of a plurality of razor blades 318 and/or to perform one
or more post-application treatments following application of the
one or more coatings. As shown, the razor blades 318 may be
positioned within a first chamber 302-1 for application of one or
more coatings using one or more techniques, such as vacuum
deposition, spraying, dipping, brushing, molding, sintering,
printing, etching, application via a pad or paint, ink-jet nozzle,
or any combination thereof, any of which may or may not include
masking one or more portions of the razor blades 318. In some
examples, the chamber 302-1 may comprise a vacuum chamber with a
vacuum pump 390. The system 300 may optionally comprise one or more
additional chambers 302-n for performing different coating
techniques and/or to perform different post-application
treatments.
[0077] The razor blades 318 may represent any razor blade described
herein. The razor blades 318 may be arranged in any manner within
the chamber 302-1. As shown, the razor blades 318 may be positioned
adjacent to each other in an arrangement that may be referred to as
a razor blade spindle. The blades 318 may also be disposed with a
space in between each other (not shown) using spacers, which may
allow coating coverage onto the blade bodies 330 of the razor
blades 318 to be increased. The blades 318 may also be disposed
with the edges (not labeled) and tips 340 facing in opposite
directions or at different angles from each other (not shown). Any
feasible orientation of the razor blades 318 is contemplated in the
present disclosure.
[0078] The system 300 may be used to apply coatings to a razor
blade, in which the razor blade comprises a substrate with first
and second outer sides disposed opposite a split line. First and
second coatings are applied to at least a portion of the first and
second outer sides, with the first and second coatings extending
from a tip region of the substrate toward a base and being disposed
substantially on the respective first or second outer side. The
coatings may each comprise one or more layers.
[0079] The system 300 may be configured to accommodate the
application of multiple different kinds of materials, as described
herein, including metals, fluorinated polymers, etc. The first and
second coatings may be applied simultaneously or sequentially and
may be applied using the same or different technique. In some
examples, selective application of one or more materials may be
accomplished by, for example, masking one or more portions of the
substrate and applying the material(s) to the unmasked portion(s)
of the substrate. The system 300 may also be configured to apply
the first and second coatings to generate one or more desired
properties for each coating, including a particular thickness,
outer shape, morphology, texture, etc., as described herein. The
system 300 may further be configured to perform one or more
post-application treatments on at least one section of the first
coating or the second coating, including ion implantation and/or
altering a texture of the coating(s).
[0080] FIG. 39 is a flow diagram illustrating an exemplary method
400 of coating a razor blade in accordance with the present
disclosure. With reference to FIGS. 4 and 18, the razor blades 18,
118 may comprise a substrate 28, 128 having a tip portion 34, 134
comprising a tip region 35, 135, a blade body 30, 130 comprising a
base 32, 132, and first and second outer sides 48, 148 and 50, 150
disposed opposite a split line SL.sub.28, SL.sub.128 of the
substrate 28, 128, in which the first and second outer sides 48,
148 and 50, 150 converge at a tip 40, 140. The method 400 comprises
either Step 410, which includes applying a first coating only to a
portion of the first outer side, in which the coating extends from
the tip region toward the base and is disposed substantially on the
first outer side, or Step 420, which includes applying a first
coating to a portion of the first outer side, in which the first
coating extends from the tip region toward the base and is disposed
substantially on the first outer side, and applying a second
coating to the second outer side such that a first portion of the
second outer side is substantially free of any coating and a second
portion of the second outer side comprises the second coating, in
which the first portion extends from the tip region toward the base
or is spaced apart from the tip region and the base, after which
the method 400 may conclude.
[0081] In some particular examples, the substrate may comprise the
second coating. In some instances, the second coating may extend
substantially from a first location to a second location, the first
location being spaced apart from the tip region and the second
location being located toward the base. In other instances, the
second coating may comprise a first section extending substantially
from a first location to a second location and a second section
extending substantially from a third location to a fourth location,
in which the first location may comprise the tip region, the second
location may be spaced apart from the third location, and the first
portion of the second outer side that is substantially free of any
coating may be located between the first and second sections of the
second coating. The first coating may comprise one or more first
materials and the second coating may comprise one or more second
materials, in which at least one of the second materials may be
different from at least one of the first materials. The first and
second coatings may be applied simultaneously or sequentially
and/or using a same technique or different technique.
[0082] The first coating may be applied such that at least a
section of the first coating defines an outer shape that is
different from an outer shape of an underlying portion of the
substrate or such that the first coating comprises a thickness that
varies along at least a section of the first coating in a direction
extending from the tip region toward the base of the razor
blade.
[0083] In some examples, the Step 410 of applying the first coating
may further comprise applying a plurality of layers of material.
Applying the plurality of layers of material may comprise: applying
a first layer to the portion of the first outer side, in which the
first layer extends from the tip region toward the base for a first
distance; and applying a second layer on top of at least a section
of the first layer, in which the second layer extends from the tip
region toward the base for a second distance that is the same as or
less than the first distance. The first layer may comprise a first
material and the second layer may comprise a second material that
is different from the first material.
[0084] In other examples, the first outer side of the substrate may
comprise one or more first facets and the second outer side may
comprise one or more second facets. The first coating may be
disposed on at least one of the first facets and the first portion
of the second outer side that is substantially free of any coating
may comprise at least a portion of one of at least one of the
second facets. The first coating may be applied such that the first
coating comprises: a first section extending substantially from a
first location to a second location on the first outer side; and a
second section extending substantially from the second location to
a third location on the first outer side, in which the first
location may comprise the tip region and the second location may
comprise a junction between (i) two adjacent ones of the first
facets, or (ii) the blade body and one of the first facets. The
second location may comprise the junction between two adjacent ones
of the first facets and the third location may comprise the
junction between the blade body and one of the first facets, in
which the first coating may be applied such that the first coating
further comprises a third section extending substantially from the
third location toward the base.
[0085] In further examples, the method may further comprise option
Step 430, which includes performing one or more post-application
treatments on at least one section of the first coating and/or when
the substrate comprises the second coating, performing one or more
post-application treatments on at least one section of the second
coating. In some instances, the one or more post-application
treatments may comprise one or more of: subjecting the at least one
section of the first and/or second coating to ion implantation; or
partially removing one or more sections of the first and/or second
coating. In other instances, the one or more post-application
treatments may further comprise selectively applying material to
the first and/or second coating following partial removal of the
one or more sections of the first and/or second coating. At least a
portion of the first or the second outer side with the selective
applied material may define a skin-contacting surface.
[0086] Representative embodiments of the present disclosure
described above can be described as follows:
[0087] A. A razor blade comprising: [0088] a substrate having a tip
portion comprising a tip region, a blade body comprising a base,
and first and second outer sides disposed opposite a split line of
the substrate, wherein the first and second outer sides converge at
a tip, [0089] wherein the first outer side comprises a first
coating disposed substantially thereon, the first coating extending
from the tip region toward the base, and [0090] wherein a first
portion of the second outer side is substantially free of any
coating, wherein the first portion extends from the tip region
toward the base or is spaced apart from the tip region and the
base.
[0091] B. The razor blade of paragraph A, wherein a second portion
of the second outer side comprises a second coating disposed
substantially thereon, the second coating extending substantially
from a first location to a second location, wherein the first
location is spaced apart from the tip region and the second
location is located toward the base.
[0092] C. The razor blade of paragraph A or B, wherein the first
portion comprises substantially an entirety of the second outer
side.
[0093] D. The razor blade of any paragraphs A or C, wherein a
second portion of the second outer side comprises a second coating
disposed substantially thereon, the second coating comprising a
first section extending substantially from a first location to a
second location and a second section extending substantially from a
third location to a fourth location, wherein the first location
comprises the tip region, the second location is spaced apart from
the third location, and the first portion of the second outer side
that is substantially free of any coating is located between the
first and second sections of the second coating.
[0094] E. The razor blade of any of paragraphs A to D, wherein at
least a portion of the first outer side defines a skin-contacting
surface.
[0095] F. The razor blade of any of paragraphs A to E, wherein the
split line splits the substrate into two substantially equal
halves.
[0096] G. The razor blade of any of paragraphs A to F, wherein the
split line splits the substrate into two asymmetrical halves.
[0097] H. The razor blade of any of paragraphs A to G, wherein the
first coating comprises a plurality of layers of material.
[0098] I. The razor blade of paragraph H, wherein the first coating
comprises: [0099] a first layer disposed substantially on the first
outer side and extending from the tip region toward the base for a
first distance; and [0100] a second layer disposed on top of at
least a section of the first layer and extending from the tip
region toward the base for a second distance that is the same as or
less than the first distance.
[0101] J. The razor blade of paragraph I, wherein the first layer
comprises a first material and the second layer comprises a second
material that is different from the first material.
[0102] K. The razor blade of any of paragraphs A to J, wherein the
first coating comprises a thickness that varies along at least a
section of the first coating in a direction extending from the tip
region toward the base of the razor blade.
[0103] L. The razor blade of any of paragraphs A to K, wherein the
first coating comprises an ion-implanted material.
[0104] M. The razor blade of any of paragraphs A to L, wherein at
least a section of the first coating defines an outer shape that is
different from an outer shape of an underlying portion of the
substrate.
[0105] N. The razor blade of of any of paragraphs A, C, or E to M,
a second portion of the second outer side comprises a second
coating disposed substantially thereon.
[0106] O. The razor blade of paragraph N, wherein the first coating
comprises one or more first materials and the second coating
comprises one or more second materials, at least one of the second
materials being different from at least one of the first
materials.
[0107] P. The razor blade of any of paragraphs A to 0, wherein the
first outer side comprises one or more first facets and the second
outer side comprises one or more second facets.
[0108] Q. The razor blade of paragraph P, wherein the first coating
is disposed on at least one of the first facets and the first
portion of the second outer side that is substantially free of any
coating comprises at least a portion of one of at least one of the
second facets.
[0109] R. The razor blade of paragraph P, wherein the first coating
comprises: [0110] a first section extending substantially from a
first location to a second location on the first outer side; and
[0111] a second section extending substantially from the second
location to a third location on the first outer side, wherein the
first location comprises the tip region and the second location
comprises a junction between (i) two adjacent ones of the first
facets, or (ii) the blade body and one of the first facets.
[0112] S. The razor blade of paragraph R, wherein the second
location comprises the junction between two adjacent ones of the
first facets and the third location comprises the junction between
the blade body and one of the first facets, the first coating
further comprising a third section extending substantially from the
third location toward the base.
[0113] T. A method of coating a razor blade comprising a substrate
having a tip portion comprising a tip region, a blade body
comprising a base, and first and second outer sides disposed
opposite a split line of the substrate, wherein the first and
second outer sides converge at a tip, the method comprising one of:
[0114] (i) applying a first coating only to a portion of the first
outer side, the coating extending from the tip region toward the
base and being disposed substantially on the first outer side; or
[0115] (ii) applying a first coating to a portion of the first
outer side, the first coating extending from the tip region toward
the base and being disposed substantially on the first outer side,
and applying a second coating to the second outer side such that a
first portion of the second outer side is substantially free of any
coating and a second portion of the second outer side comprises the
second coating, wherein the first portion extends from the tip
region toward the base or is spaced apart from the tip region and
the base.
[0116] U. The method of paragraph T, wherein the substrate
comprises the second coating.
[0117] V. The method of paragraph U, wherein the second coating
extends substantially from a first location to a second location,
the first location being spaced apart from the tip region and the
second location being located toward the base.
[0118] W. The method of paragraph U, wherein the second coating
comprises a first section extending substantially from a first
location to a second location and a second section extending
substantially from a third location to a fourth location, the first
location comprising the tip region and the second location being
spaced apart from the third location, wherein the first portion of
the second outer side that is substantially free of any coating is
located between the first and second sections of the second
coating.
[0119] X. The method of any of paragraphs U to W, wherein the first
coating comprises one or more first materials and the second
coating comprises one or more second materials, at least one of the
second materials being different from at least one of the first
materials.
[0120] Y. The method of any of paragraphs U to X, wherein the first
and second coatings are applied simultaneously.
[0121] Z. The method of any of paragraphs U to X, wherein the first
and second coatings are applied sequentially.
[0122] AA. The method of any of paragraphs U to Z, wherein the
first and second coatings are applied using a same technique.
[0123] BB. The method of any of parargraphs U to Z, wherein the
first coating is applied with a first technique and the second
coating is applied with a second technique that is different from
the first technique.
[0124] CC. The method of any of paragraphs T to BB, wherein the
first coating is applied such that at least a section of the first
coating defines an outer shape that is different from an outer
shape of an underlying portion of the substrate.
[0125] DD. The method of any of paragraphs T to CC, wherein the
first coating is applied such that the first coating comprises a
thickness that varies along at least a section of the first coating
in a direction extending from the tip region toward the base of the
razor blade.
[0126] EE. The method of any of paragraphs T to DD, wherein
applying the first coating further comprises applying a plurality
of layers of material.
[0127] FF. The method of paragraph EE, wherein applying the
plurality of layers of material comprises: [0128] applying a first
layer to the portion of the first outer side, the first layer
extending from the tip region toward the base for a first distance;
and [0129] applying a second layer on top of at least a section of
the first layer, the second layer extending from the tip region
toward the base for a second distance that is the same as or less
than the first distance.
[0130] GG. The method of paragraph FF, wherein the first layer
comprises a first material and the second layer comprises a second
material that is different from the first material.
[0131] HH. The method of any of paragraphs T to GG, wherein the
first outer side of the substrate comprises one or more first
facets and the second outer side comprises one or more second
facets.
[0132] II. The method of paragraph HH, wherein the first coating is
disposed on at least one of the first facets and the first portion
of the second outer side that is substantially free of any coating
comprises at least a portion of one of at least one of the second
facets.
[0133] JJ. The method of paragraph HH, wherein the first coating is
applied such that the first coating comprises: [0134] a first
section extending substantially from a first location to a second
location on the first outer side; and [0135] a second section
extending substantially from the second location to a third
location on the first outer side, wherein the first location
comprises the tip region and the second location comprises a
junction between (i) two adjacent ones of the first facets, or (ii)
the blade body and one of the first facets.
[0136] KK. The method of paragraph JJ, wherein the second location
comprises the junction between two adjacent ones of the first
facets and the third location comprises the junction between the
blade body and one of the first facets, the first coating being
applied such that the first coating further comprises: [0137] a
third section extending substantially from the third location
toward the base.
[0138] LL. The method of any of paragraphs T to JJ, further
comprising: [0139] performing one or more post-application
treatments on at least one section of the first coating.
[0140] MM. The method of paragraph MM, wherein the one or more
post-application treatments comprise one or more of: [0141]
subjecting at least one section of the first coating to ion
implantation; or [0142] partially removing one or more sections of
the first coating.
[0143] NN. The method of paragraph MM, wherein the one or more
post-application treatments further comprise selectively applying
material to the first coating following partial removal of the one
or more sections of the first coating.
[0144] OO. The method of paragraph NN, wherein at least a portion
of the first outer side with the material defines a skin-contacting
surface.
[0145] PP. The method of any of paragraphs TT to JJ, wherein the
substrate comprises the second coating, the method further
comprising: [0146] performing one or more post-application
treatments on at least one section of the second coating.
[0147] QQ. The method of paragraph PP, wherein the one or more
post-application treatments comprise partially removing one or more
sections of the second coating.
[0148] The illustrations presented herein are not intended to be
actual views of any particular substrate, apparatus (e.g., device,
system, etc.), or method, but are merely idealized and/or schematic
representations that are employed to describe and illustrate
various embodiments of the disclosure.
[0149] The dimensions and values disclosed herein are not to be
understood as being strictly limited to the exact numerical values
recited. Instead, unless otherwise specified, each such dimension
is intended to mean both the recited value and a functionally
equivalent range surrounding that value. For example, a dimension
disclosed as "40 mm" is intended to mean "about 40 mm."
[0150] Every document cited herein, including any cross referenced
or related patent or application and any patent application or
patent to which this application claims priority or benefit
thereof, is hereby incorporated herein by reference in its entirety
unless expressly excluded or otherwise limited. The citation of any
document is not an admission that it is prior art with respect to
any invention disclosed or claimed herein or that it alone, or in
any combination with any other reference or references, teaches,
suggests or discloses any such invention. Further, to the extent
that any meaning or definition of a term in this document conflicts
with any meaning or definition of the same term in a document
incorporated by reference, the meaning or definition assigned to
that term in this document shall govern.
[0151] While particular embodiments of the present invention have
been illustrated and described, it would be obvious to those
skilled in the art that various other changes and modifications can
be made without departing from the spirit and scope of the
invention. It is therefore intended to cover in the appended claims
all such changes and modifications that are within the scope of
this invention.
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