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 activated by electromagnetic radiation wherein a wavelength of said radiation is about double a wavelength required to activate the precursor material. A razor blade for use in a razor cartridge or a blade box may be formed using the present invention.

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 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.

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.

In the method for coating a razor blade with a lubricating material, a razor blade is provided having a body portion and a tip end defined by at least one tip surface and a cutting edge. The lubricating material is sprayed on the tip end of the razor blade, wherein spraying the lubricating material is performed steam-aided in that the lubricating material is introduced into a superheated water steam directed towards the tip end of the razor blade. Moreover, a method of making a razor blade by using the afore-mentioned method for coating the razor blade with a lubricating material is provided. Finally, also a razor blade coated in accordance with these methods, and a shaving razor provided with such a razor blade are described.

In the method for coating a razor blade with a lubricating material, a razor blade is provided having a body portion and a tip end defined by at least one tip surface and a cutting edge. The lubricating material is sprayed on the tip end of the razor blade, wherein spraying the lubricating material is performed steam-aided in that the lubricating material is introduced into a superheated water steam directed towards the tip end of the razor blade. Moreover, a method of making a razor blade by using the afore-mentioned method for coating the razor blade with a lubricating material is provided. Finally, also a razor blade coated in accordance with these methods, and a shaving razor provided with such a razor blade are described.

A method of modifying razor blade edges prior to a first use, the method comprising providing at least one razor blade having a coated razor blade edge, and mechanically modifying at least one coating of said coated razor blade edge. Also provided is an apparatus for modifying one or more coated razor blade edges, the apparatus comprising a support member for holding a plurality of razor blades with said coated razor blade edges, and an applicator for contacting a mechanical modifying material with at least a section of said coated razor blade edges.

A method of modifying razor blade edges prior to a first use, the method comprising providing at least one razor blade having a coated razor blade edge, and mechanically modifying at least one coating of said coated razor blade edge. Also provided is an apparatus for modifying one or more coated razor blade edges, the apparatus comprising a support member for holding a plurality of razor blades with said coated razor blade edges, and an applicator for contacting a mechanical modifying material with at least a section of said coated razor blade edges.

This invention relates to a novel application of a compound of chromium and boron, or the application of chromium boride-based coatings (e.g., CrB.sub.n where an atomic percentage of boron ranges from greater than zero atomic percent to less than 100 atomic percent of said compound) to surfaces of razor blades, namely cutting edges. On razor blade edges, these novel coatings are hard, durable, and provide a novel, low cutter force and high-quality coating structure, elevating blade performance, while also simplifying the manufacturing process.