A functional polymeric cutting edge structure and methods for the manufacturing of cutting edge structures comprised of polymeric materials are provided. The cutting edge structures may be produced on a substrate having a blade body or blade support type. The polymeric material is produced by curing a precursor material by electromagnetic radiation wherein a wavelength of said radiation is about double a wavelength required to cure the precursor material. A razor blade for use in a razor cartridge or a blade box may be formed using the present invention.

A razor blade including a substrate with a cutting edge portion ending in a sharpened tip. The substrate having a thickness of between 1.55 and 1.97 micrometers measured at a distance of five micrometers from the tip, a thickness of between 4.6 and 6.34 micrometers measured at a distance of twenty micrometers from the tip, and a thickness of between 19.8 and 27.12 micrometers measured at a distance of one hundred micrometers from the tip.

A razor head that includes a housing having a top face defining a shaving window delimited by a front guard and a rear cap together defining a tangent plane, at least one rigid cutting member, each freely mounted in the housing, and having a cutting edge portion extending along a cutting edge portion axis, and having a cutting edge accessible through the shaving window, a guided portion extending along a guided portion axis, and a bent portion intermediate the cutting edge portion and the guided portion. An angle measured between the cutting edge axis and the tangent plane is between 5° and 30°.

A razor head that includes a housing having a top face defining a shaving window delimited by a front guard and a rear cap together defining a tangent plane, at least one rigid cutting member, each freely mounted in the housing, and having a cutting edge portion extending along a cutting edge portion axis, and having a cutting edge accessible through the shaving window, a guided portion extending along a guided portion axis, and a bent portion intermediate the cutting edge portion and the guided portion. An angle measured between the cutting edge axis and the tangent plane is between 5° and 30°.

Methods are provided for the manufacture of razor blades from silicon material. In some implementations, the method includes aligning a mono-crystalline silicon wafer comprising a {100} surface at an angle where {111} planes intersect the {100} surface parallel and perpendicular to the wafer; etching the mono-crystalline silicon wafer to expose an {111} plane and a second plane to provide a blade edge having between about a 20 degree included blade angle and about a 35 degree included blade angle; applying a hard coating on the blade edge; providing a radius of curvature of the blade edge between about 20 nanometers and about 100 nanometers after deposition of the hard coating; applying a soft coating on the blade edge; and removing the razor blade from the mono-crystalline silicon wafer.

Methods are provided for the manufacture of razor blades from silicon material. In some implementations, the method includes aligning a mono-crystalline silicon wafer comprising a {100} surface at an angle where {111} planes intersect the {100} surface parallel and perpendicular to the wafer; etching the mono-crystalline silicon wafer to expose an {111} plane and a second plane to provide a blade edge having between about a 20 degree included blade angle and about a 35 degree included blade angle; applying a hard coating on the blade edge; providing a radius of curvature of the blade edge between about 20 nanometers and about 100 nanometers after deposition of the hard coating; applying a soft coating on the blade edge; and removing the razor blade from the mono-crystalline silicon wafer.

The present invention generally relates to blades. Specifically, embodiments of the present invention relate to blades with an hourglass notch in which the hourglass notch functions to secure the blade onto a utility application.

The present invention generally relates to blades. Specifically, embodiments of the present invention relate to blades with an hourglass notch in which the hourglass notch functions to secure the blade onto a utility application.

A razor blade including a substrate with a cutting edge portion ending in a sharpened tip. The substrate having a thickness of between 1.55 and 1.97 micrometers measured at a distance of five micrometers from the tip, a thickness of between 4.6 and 6.34 micrometers measured at a distance of twenty micrometers from the tip, and a thickness of between 19.8 and 27.12 micrometers measured at a distance of one hundred micrometers from the tip.

A novel cutting-edge structure and method and apparatus for manufacturing the cutting-edge structure is provided. The cutting-edge structure is comprised of naturally derived or renewable material at greater than 50% by volume fraction. In one embodiment, the naturally derived material is a cellulose nanostructure such as a cellulose nanocrystal. The cellulose nanocrystal is processed using a base or mold structure to provide a cutting edge of any shape such as linear or circular edge structures. The process includes dual cure steps to produce an optimal cutting-edge structure without shrinkage. The formed cutting-edge structure can be utilized as a razor blade as it is formed with very sharp tip and edge suitable for cutting hair. The base structure can form one or more cutting-edge structures simultaneously.