Polymeric cutting edge structures and method of manufacturing polymeric cutting edge structures

Patent metadata

Field	Value
Publication number	US-11059194-B2
Application number	US-201615188100-A
Country	US
Kind code	B2
Filing date	Jun 21, 2016
Priority date	Jun 30, 2015
Publication date	Jul 13, 2021
Grant date	Jul 13, 2021

Abstract

A functional polymeric cutting edge structure and methods for manufacturing cutting edge structures using polymeric materials are provided. A razor blade for use in a razor cartridge or a blade box for assembly in a razor cartridge frame may be formed using the present invention.

First claim

What is claimed is:

1. A method for manufacturing at least one cutting edge structure comprising the steps of:
providing a base structure of a first polymeric material;
pressing at least one cutting edge template into said base structure;
removing said at least one cutting edge template to obtain at least one cavity in said base structure;
filling said at least one cavity with a second material, said second material being a precursor for a second polymeric material;
curing said second material; and
separating said base structure and said cured second material, said at least one cutting edge structure comprised of said cured second material and wherein a tip radius of said at least one cutting edge structure is less than 1 micrometer.

2. The method of claim 1 , wherein said precursor material is comprised of a monomer material, an oligomer material, or any combination thereof.

3. The method of claim 1 , wherein at least one of the precursor material, said cured second material and at least one side of the at least one cavity is transparent to electro-magnetic radiation at a wavelength in the range of 250 to 1500 nanometers.

4. The method of claim 1 , wherein the separating step comprises physical or chemical removal of the base structure from the cured second polymeric material cutting edge structure.

5. The method of claim 1 , wherein a photo-initiator of about 1 to about 3% by weight of composition is added to the second precursor material prior to the curing step.

6. The method of claim 1 , wherein said at least one cutting edge structure comprises a gothic arch, a roman arch, or one or more undercuts.

7. The method of claim 1 , wherein said first polymeric material is comprised of Poly (methyl methacrylate) (PMMA) or Polydimethylsiloxane (PDMS).

8. The method of claim 1 , wherein said second precursor material is comprised of an acrylic based material or epoxy based material.

9. The method of claim 1 , wherein a viscosity of said second precursor material is less than about 10000 centiPoise.

10. The method of claim 1 , wherein said base structure is comprised of only one part.

11. The method of claim 1 , wherein the at least one cavity is entirely comprised in a single part in said base structure.

12. The method of claim 1 , wherein a portion of the at least one cavity is not enclosed by said base structure after formation.

13. The method of claim 1 , wherein the first polymeric material is compliant.

14. The method of claim 1 , wherein said separated base structure is reused at said filling step.

15. The method of claim 1 wherein said step of curing comprises cross-linking or polymerization.

16. The method of claim 1 , wherein said step of curing comprises heat, light, or any combination thereof.

17. The method of claim 16 , wherein said curing step comprises UV light.

18. The method of claim 1 , wherein said at least one cutting edge structure is a razor blade or a portion of a blade box.

19. The method of claim 18 , further comprising the step of securing said razor blade or said blade box into a razor cartridge housing or frame.

20. The method of claim 18 wherein said blade box is comprised of different types of cutting edge structures.

Assignees

• Gillette Co
• Gillette Co Llc

Inventors

• Gester Matthias
• Kiyan Roman
• Hinze Ulf
• Kurselis Kestutis

Classifications

• B29C33/005 Primary

  characterised by the location of the parting line of the mould parts · CPC title

• B29K2883/00

  Use of polymers having silicon, with or without sulfur, nitrogen, oxygen, or carbon only, in the main chain, as mould material · CPC title

• B26B21/58

  characterised by the material · CPC title

• B29C39/26

  Moulds or cores · CPC title

• B26B21/4068

  Mounting devices; Manufacture of razors or cartridges (B26B21/528 takes precedence) · CPC title