Safety razor and blade unit for safety razor

Abstract

The present disclosure describes a blade unit (10) for a safety razor (8). The blade unit comprises a blade housing (12), a plurality of blades (18) disposed within the blade housing (12) to expose respective cutting edges (20) suitable for shaving, and a blade carrier supporting the plurality of blades (18). The blade housing (12) has a base on which the blade carrier is supported. The plurality of blades (18) and the blade carrier being displaceable downwards towards the base of the blade housing (12) during shaving, wherein an amount of downward displacement of the plurality of blades (18) and the blade carrier is limited by one or more protrusions extending upwards from the base of the blade housing (12).

Claims

1. A blade unit for a safety razor, wherein the blade unit comprises: a blade housing; a plurality of blades disposed within the blade housing to expose respective cutting edges suitable for shaving; and a blade carrier which supports the plurality of blades and comprises a rack on which the plurality of blades is mounted and flexible legs that allow a downward displacement of the plurality of blades and the rack; the blade housing having a base on which the blade carrier is supported; the plurality of blades and the blade carrier being displaceable downwards towards the base of the blade housing during shaving, an amount of downward displacement of the plurality of blades and the blade carrier being limited by one or more protrusions which extend upwards from the base of the blade housing, and the flexible legs comprising pairs of flexible legs, the legs of each pair being connected together by a connecting member, at least one of the one or more protrusions being a connecting member-engaging protrusion extending along a length of the connecting member.

2. The blade unit of claim 1, wherein the one or more protrusions limit the amount of displacement of the plurality of blades and the blade carrier to about halfway between a non-displaced position of the plurality of blades and the blade carrier and the base of the blade housing.

3. The blade unit of claim 1, wherein a maximum downward displacement of the plurality of blades and the blade carrier is from about 0.75 mm to about 0.25 mm.

4. The blade unit of claim 1, wherein a maximum downward displacement of the plurality of blades and the blade carrier is about 0.5 mm.

5. The blade unit of claim 1, wherein with a force of up to 500 gf, the change in exposure of the cutting edges caused by the displacement is not more than 0.4 mm.

6. The blade unit of claim 1, wherein the one or more protrusions limit the downward displacement in that the blade carrier comes into contact with the one or more protrusions only when the blade carrier displaces towards the base during shaving.

7. The blade unit of claim 1, wherein at least another one of the one or more protrusions is a rack-engaging protrusion arranged to engage the rack to limit downward displacement of the plurality of blades and the blade carrier.

8. The blade unit of claim 7, wherein rack-engaging protrusions are provided at each end of the blades.

9. The blade unit of claim 7, wherein heights of the at least one connecting-member engaging protrusion and the at least one rack-engaging protrusion are such that these protrusions engage the at least one connecting member and the rack at the same time.

10. The blade unit of claim 1, wherein a plurality of connecting member-engaging protrusions is arranged on the base to engage along a length of the connecting member.

11. The blade unit of claim 1, wherein the flexible legs have feet, at least one of the feet being in contact with a metal plate disposed on the base of the blade housing.

12. The blade unit of claim 11, wherein the at least one of the feet is in slidable contact with the metal plate.

13. The blade unit of claim 12, wherein there are two pairs of flexible legs, one forward of the plurality of blades and one to a rear of the plurality of blades and wherein the feet of only one pair of flexible legs are in contact with the metal plate.

14. The blade unit of claim 12, wherein the feet of the other pair of flexible legs are in contact with pads disposed on the base of the blade housing.

15. The blade unit of claim 1, wherein there are two pairs of flexible legs, one forward of the plurality of blades and one to a rear of the plurality of blades, a respective plurality of connecting member-engaging protrusions being arranged on the base to engage along lengths of each of the connecting members.

16. The blade unit of claim 12, wherein the blades are in electrical contact with the metal plate via the foot of at least one of the legs, so as to form a galvanic cathodic protection system in which the metal plate functions as a sacrificial anode that corrodes and the plurality of blades function as a cathode that is protected from corrosion.

17. A safety razor comprising the blade unit of claim 1.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The accompanying drawings are incorporated herein and form a part of the specification.

(2) FIG. 1 is a perspective view of a safety razor including a blade unit;

(3) FIG. 2 is a perspective view of the blade unit shown in FIG. 1;

(4) FIG. 3 is a view of the front of the blade unit shown in FIG. 1;

(5) FIG. 4 is a view of the back of the blade unit shown in FIG. 1;

(6) FIG. 5 is an exploded view of parts of the blade unit shown in FIG. 1;

(7) FIG. 6 is a perspective view of blades mounted on a blade carrier;

(8) FIG. 7 is a perspective view of the blades and the blade carrier shown in FIG. 6, mounted on a base of a blade housing;

(9) FIG. 8 is a perspective view of the blades and the blade carrier shown in FIG. 6, mounted on a base of a blade housing of a blade unit according to an embodiment;

(10) FIG. 9 is a perspective view of the base of the blade housing shown in FIG. 8;

(11) FIG. 10(a) is a cross sectional view of FIG. 7;

(12) FIG. 10(b) is a cross-sectional view of FIG. 8; and

(13) FIG. 11 is a graph of blade displacement of exposure versus force.

DETAILED DESCRIPTION OF EMBODIMENTS

(14) The following detailed description refers to the accompanying drawings that illustrate exemplary embodiments consistent with this invention. Other embodiments are possible, and modifications can be made to the embodiments without departing from the spirit and scope of the invention. Therefore, the detailed description is not meant to limit the invention.

(15) Reference will now be made to FIGS. 1 to 5, which are views of a blade unit and safety razor including the blade unit. The safety razor 8 has a blade unit 10 and a handle 16 (only a part of which is shown in FIG. 1). The blade unit 10 includes a connecting structure 14 that fixes the blade unit 10 to the handle 16, a blade housing 12 and a supporting structure 13 of the blade housing 12. The blade housing 12 holds a plurality of blades 18 (five blades in this particular case) having respective cutting edges 20 that lie in a shaving plane P. Thus, as used herein, the term shaving plane generally refers to the place in which the cutting edges lie. The direction perpendicular to the shaving plane can be referred to as the thickness direction.

(16) The supporting structure 13 comprises a cap 24 located behind the blades in a shaving direction d (when assembled) and a guard 30 located in front of the blade in the shaving direction d (when assembled). As such, the guard 30 is arranged next to the plurality of blades 18 in the shaving direction on an opposite side to that of the cap 24. As used herein, the term shaving direction signifies the direction in the shaving plane in which the blade unit is intended to be moved. The cap 24 and the guard 30 are connected by side portions 38. The supporting structure 13 controls the contact of the cutting edges 20 of the blades 18 with the skin during shaving.

(17) The cap 24 of the supporting structure 13 comprises a non-flexible concave back portion 26 to which is mounted a convex lubricating pad 22. The terms concave and convex are employed herein to signify that the lubricating pad has a convex skin-engaging surface and the back portion has a concave surface along the back. The term non-flexible means that the concave back portion 26 has rigidity to an extent such that it does not bend during ordinary use of the safety razor 8.

(18) The blade housing and the cap 24, and in particular the lubricating pad 22 and the non-flexible concave back portion 26 can be, for example, adhered, integrated, bonded and/or otherwise attached to each other.

(19) The radius of curvature of the convex lubricating pad 22 can be set to about 10 mm, which is within a preferred range from 5 to 20 mm. Although the lubricating pad 22 is in a fixed positional relationship relative to the non-flexible concave back portion 26, the lubricating pad 22 can be deformed by, for example, a compressive force. The lubricating pad 22 can return substantially to its shape prior to deformation.

(20) The non-flexible concave back portion 26 comprises a straight member 40 and an arched member 42 that are connected to each other at respective ends, so as to define a gap 44 in which part of the lubricating pad 22 is disposed when mounted thereon. The non-flexible concave back portion 26 and convex lubricating pad 22 meet flush at a rear edge 28 of the cap 24 of the blade unit 10 as can be seen from FIG. 1. The lubricating pad 22 is curved in an arc shape that extends along substantially the entire rear edge 28 between the side portions 38.

(21) The guard 30 of the supporting structure 13 comprises a non-flexible back portion 32 on which is mounted an elongate lubricating strip 34. The non-flexible back portion 32 and elongate lubricating strip 34 meet flush at a front edge 36 of the guard 30 of the blade unit 10.

(22) The terms lubricating strip and lubricating pad are used to signify that the length-to-width ratio in the shaving plane, i.e., the ratio of the size in a direction parallel to the blades (length direction) to the size in a direction parallel to the shaving direction d (width direction), of the elongate lubricating strip 34 and the convex lubricating pad 22 are different. In this particular case, the elongate lubricating strip 34 and convex lubricating pad 22 both extend at least along the length of the exposed cutting edges 20 of the blades 18 and have similar length, though the convex lubricating pad 22 is substantially wider than the elongate lubricating strip 34. In this particular case, the elongate lubricating strip 34 has a length-to-width ratio of about 10:1, while the convex lubricating pad 22 has a length to width ratio of about 4:1 at its widest point.

(23) The composition of the lubricating strip/lubricating pad can include a gliding agent. Materials which may be selected as the gliding agent are: PEG-400/1,4-Butanediol/SMDI Copolymer, PEG-115M, PEG 45M, and PEG-5M, or a combination thereof. The composition of the lubricating strip/lubricating pad can include an antioxidant agent, for example Tocopherol. The composition of the lubricating strip/lubricating pad can include an anti-inflammatory agent, for example aloe barbadensis leaf juice. The composition of the lubricating strip/lubricating pad can include a backbone structure. Materials which may be selected as the backbone structure are: styrenic block copolymers and polystyrene, or a combination thereof. Preferably, the composition of the lubricating strip and the composition of the lubricating pad are the same, but this need not be the case.

(24) The handle 16 has a proximal portion 46 closer to the blade unit 10 and a distal portion 48 (not shown in the Figures) farther from the blade unit 10. The connecting structure 14 of the blade unit 10 connects (either fixedly or detachably) to the proximal portion 46 of the handle 16. Thus, the blade unit 10 may be configured for use with a separate handle or may be permanently attached to the handle 16. The proximal portion 46 of the handle 16 also includes a pivot mechanism that allows the blade unit 10 to pivot back-and-forth in a plane perpendicular to the shaving plane P. The pivot mechanism can, of course, allow other pivoting motions such as side-to-side. The proximal portion 46 arcuately bends away from the shaving plane P, to permit the cap 24 of the blade unit 10 to pivot backwards, i.e., to bend away from the shaving plane, over a large angular range.

(25) FIG. 6 shows an exemplary blade arrangement in which four blades 18 are mounted on a blade carrier 50 which comprises a rack 52, flexible legs 54, and connecting members 56 between the rack 52 and the flexible legs 54. The rack 52 is formed of runners (hidden from view in FIG. 6 by the blades 18) on which the blades 18 are mounted and which extend in the same direction as the blades 18, and cross pieces 73 joining the runners. The blades 18 are attached to the runners at several places, for example by spot welding or the like. The runners have downwardly extending fins 74 (reinforcement parts) that provide additional stiffness to the runners. The flexible legs 54 are grouped into pairs in which two flexible legs 54 are connected together by the connecting member 56 that is parallel to the longitudinal direction of the blades 18. One pair of flexible legs 54 is located in front of the plurality of blades 18 and another pair of flexible legs 54 is located to the rear of the plurality of blades 18 (the pair of flexible legs 54 located to the rear of the plurality of blades 18 is partially obscured from view in FIG. 6 by the blades 18.) Each flexible leg 54 is inclined downwards from the connecting member 56 to form a foot 58.

(26) FIG. 7 shows how the blade arrangement of FIG. 6 can be disposed on a base 60 of a blade housing (only part of which is shown). The base 60 of the blade housing includes a metal plate 62 on an inner surface 66 of the base 60. As shown, the pair of flexible legs 54 located in front of the plurality of blades 18 are in permanent slidable contact with pads 64 of the inner surfaces 66, while the pair of flexible legs 54 located to the rear of the plurality of blades 18 are in permanent slidable contact with the metal plate 62. When the blades 18 are displaced down in the blade housing 12 during shaving, the blade carrier 50 is elastically deformed and the feet 58 slide easily along the metal plate 62 and pads 64, without limiting the downward movement. The blade carrier 50 and in particular the flexible legs 54 act as springs to return the blades 18 to the non-displaced position after shaving. However, if the displacement is too large, there may be permanent deformation of the blade carrier 50 and/or blades 18. Apart from a possible change to the shaving geometry (the relationship between the cutting edges of the blades as exposed in the blade unit with respect to the guard and/or the cap), one serious disadvantage of such permanent deformation is that the feet 58 may lose contact with the metal plate 62.

(27) FIG. 8 shows how the blade carrier 50 of FIG. 6 can be disposed on a base 60 of a blade housing 12 (only part of which is shown), according to an embodiment in which protrusions 68, 70 extend upwards from the base 60. FIG. 9 shows the base 60 of the blade housing 12 of FIG. 8 in more detail. (Components shown in FIGS. 8 and 9 that have the same reference numbers as those of FIGS. 6 and 7 are the same and are therefore not described.) The protrusions 68, 70 include connecting member-engaging protrusions 68 and rack-engaging protrusions 70. As described with reference to FIG. 7, when the blades 18 are displaced down in the blade housing 12 during shaving, the blade carrier 50 is elastically deformed and the feet 58 slide easily along the metal plate 62 and pads 64. However, now, once the connecting member 56 reaches the connecting-member engaging protrusions 68, further downward movement of the blade carrier 50 and the blades is prevented. Likewise, once the rack 52 (i.e., the runners) reach the rack-engaging protrusions 70, further downward movement blade carrier 50 is prevented. Here, the heights of the connecting-member engaging protrusions 68 and rack-engaging protrusions 70 are such that they engage the connecting member 56 and the rack 52 (i.e., the runners) at substantially the same time. Since the displacement of the blade carrier 50 and blades 18 is limited, deformation of the blade carrier 50 and/or blades 18 can be prevented or reduced. Consequently, it can be ensured, firstly, that the shaving geometry is maintained and, secondly, that the feet 58 remain in contact with the metal plate 62. In this regard, the metal plate 62 functions as a sacrificial (galvanic) anode of a galvanic cathodic protection (CP) system for protecting the blades 18 from corrosion. That is, the metal plate 62 is made of a metal with a more active voltage (more negative reduction potential/more positive electrochemical potential) than the metal of the blades. For example, the blades 18 can be made of stainless steel and the metal plate 62 can be made of aluminium. The difference in potential between the two metals means that the galvanic anode corrodes, so that the anode material is consumed in preference to the blades. By ensuring that the feet 58 remain in contact with the metal plate 62, corrosion of the blades 18 can be prevented or reduced.

(28) FIGS. 10(a) and 10(b) are cross-sectional views of part of the blade housing 12 in which the blade carrier 50 and blades 18 are housed. More specifically, FIG. 10(a) is a cross-sectional view of part of the blade housing 12 shown in FIG. 7 while FIG. 10(b) is a cross-sectional view through section A-A of part of the blade housing 12 shown in FIG. 8. The double-headed arrows shown in FIGS. 10(a) and 10(b) represent the amount of downward/upward movement that the blade carrier 50 and blades 18 can make. The blade carrier 50 and blades 18 shown in FIG. 10(a) can be displaced downward by a distance y of about 1 mm. In contrast, the blade carrier 50 and blades 18 shown in FIG. 10(b) can be displaced downward by a distance y of about 0.5 mm. In more detail, when the blade carrier 50 and blades 18 shown in FIG. 10(b) are displaced down in the blade housing 12 during shaving, the rack 52 (and in particular the runners 72 on which the blades 18 are mounted) engages with the rack-engaging member 70, and the connecting members 56 engage with the connecting member-engaging protrusions 68. (It is noted that although the rack-engaging protrusion 70 does not lie in the plane of section A-A of FIG. 8, it is nevertheless shown in FIG. 10b to allow comparison with the connecting-member engaging protrusions 68. Thus, it will be apparent that in this particular embodiment the fins 74 do not contact the rack-engaging protrusion 70.)

(29) FIG. 11 is a graph showing displacement of exposure (i.e., how far the blades are displaced down in the blade housing 12) when subjected to a force (e.g., during shaving). The dashed line represents the case where no protrusions are provided on the base 60 (e.g., as in FIG. 7), while the solid line represents the case where protrusions are provided on the base 60 (e.g., as in FIG. 9). As can be seen from the graph, when no protrusions are provided on the base 60 the blades 18 are displaced downwards by about 1 mm when subjected to a force of 500 gf. By contrast, when protrusions are provided on the base 60 the blades are displaced downwards by no more than 0.4 mm when subjected to a force of 500 gf.

(30) The foregoing description of the specific embodiments will so fully reveal the general nature of the invention that others can, by applying knowledge within the skill of the art, readily modify and/or adapt for various applications such specific embodiments, without undue experimentation, without departing from the general concept of the present invention. Therefore, such adaptations and modifications are intended to be within the meaning and range of equivalents of the disclosed embodiments, based on the teaching and guidance presented herein.

(31) Although blade units are described in which four or five parallel blades lying in a shaving plane are provided, the blade housing may comprise more than five blades or fewer than four blades, i.e., the blade housing may comprise at least one blade. When more than one blade is provided, these do not have to lie in a shaving plane, for example the blades could be staggered.

(32) It is to be understood that the phraseology or terminology herein is for the purpose of description and not of limitation, such that the terminology or phraseology of the present specification is to be interpreted by the skilled artisan in light of the teachings and guidance.

(33) For example, expressions such as perpendicular, parallel, conform to and the like are defined to mean substantially perpendicular, substantially parallel and substantially conform to. Likewise, 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 30% is intended to mean about 30%.

(34) The Summary and Abstract sections may set forth one or more but not all exemplary embodiments of the present invention as contemplated by the inventor(s), and thus, are not intended to limit the present invention and the appended claims in any way.

(35) The breadth and scope of the present invention should not be limited by any of the above-described exemplary embodiments, but should be defined only in accordance with the following claims and their equivalents.

REFERENCE NUMBERS

(36) d shaving direction P shaving plane 8 safety razor 10 blade unit 12 blade housing 13 supporting structure 14 connecting structure 16 handle 18 blades 20 cutting edges 22 convex lubricating pad 24 cap 25 non-flexible portion 26 non-flexible (concave) back portion 28 rear edge 30 guard 32 non-flexible back portion 34 elongate lubricating strip 36 front edge 38 side portions 40 straight member 42 arched member 44 gap 46 proximal portion 48 distal portion 50 blade carrier 52 rack 54 flexible leg 56 connecting member 58 foot 60 base 62 metal plate 64 pad 66 inner surface 68 connecting member-engaging protrusion 70 rack-engaging protrusion 72 runners 73 cross pieces 74 fins