Abstract: An apparatus for testing a razor blade comprises a base, a material support table, a material sample, a transport carriage, a blade retention assembly, and a razor blade. The material support table is supported by the base. The transport carriage is movably coupled with the base and is movable with respect to the material support table between a start position and an end position. The blade retention assembly is movably coupled with the transport carriage and is movable with respect to the material support table between a blade-engaged position and a blade disengaged position. The blade retention assembly is movable together with the transport carriage between the start position and the end position. The blade is releasably attached to the blade retention assembly. The razor blade contacts the material sample when the blade retention assembly is in the blade-engaged position. Methods are also provided.

Abstract: The invention discloses utilizing isostatic-press (IP) processes apply a polymeric material (e.g, a PTFE foil) to uncoated razor blade edges forming thin, dense, and uniform coatings on blade edges which in turn exhibit low initial cutting forces correlating with more comfortable shaves. The isostatic press may be a hot isostatic press (HIP) or a cold isostatic press (CIP) or any other isostatic press process. The HIP conditions may include an environment of elevated temperatures and pressures in an inert atmosphere. The CIP conditions may include room temperature and elevated pressure. The polymeric material may be a fluoropolymer or non-fluoropolymeric material or any composite thereof. The lower surface of the polymeric material may be modified (e.g., chemical etching) to enhance adhesion to the blade edge. Two or more layers of polymeric material of similar or different properties may be isostatically pressed onto the uncoated blades.

Abstract: 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.

Abstract: 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.

Abstract: 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.

Abstract: The invention discloses isostatic-pressing (IP) applied to polymer (e.g., PTFE) coated razor blade edges to produce thin, dense, and uniform blade edges which in turn exhibit low initial cutting forces correlating with a more comfortable shaves. The isostatic press utilized may be a hot isostatic press (HIP) or cold isostatic press (CIP) or any other isostatic press process. The HIP conditions may include an environment of elevated temperatures and pressures in an inert atmosphere. The HIP conditions may be applied to non-sintered coatings or sintered coatings or before or after a FLUTEC® process is applied to coatings. CIP conditions may include room temperature and elevated pressure. The polymeric material may be a fluoropolymer or a non-fluoropolymer material or any composite thereof. It may be deposited initially by any method, including but not limited to, dipping, spin coating, sputtering, or thermal Chemical Vapor Deposition (CVD).

Abstract: An apparatus for testing a razor blade comprises a base, a material support table, a material sample, a transport carriage, a blade retention assembly, and a razor blade. The material support table is supported by the base. The transport carriage is movably coupled with the base and is movable with respect to the material support table between a start position and an end position. The blade retention assembly is movably coupled with the transport carriage and is movable with respect to the material support table between a blade-engaged position and a blade disengaged position. The blade retention assembly is movable together with the transport carriage between the start position and the end position. The blade is releasably attached to the blade retention assembly. The razor blade contacts the material sample when the blade retention assembly is in the blade-engaged position. Methods are also provided.

Abstract: The invention discloses a novel solution and process comprising a modified solvent for providing enhanced blade edge attributes.

Abstract: The invention discloses a novel solution and process comprising a modified solvent for providing enhanced blade edge attributes.

Abstract: A method of treating one or more coated razor blade edges comprising the steps of: (a) treating said one or more coated razor blade edges in a solvent, thereby modifying said one or more coated razor blade edges in said solvent; (b) treating said modified one or more coated razor blade edges in said modified solvent and further modifying said one or more modified coated razor blade edges and said modified solvent; and (c) repeating step (b) one or more times.

Abstract: 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.

Abstract: A razor blade is disclosed having one or more coatings formed by the atomic layer deposition (ALD) process, the formed coatings being uniform, conformal, and dense. The coatings may be on an entire surface of a blade flank, and at least a portion or an entire surface of a blade body. The coating may be etched. A razor blade having a first coating of a first material and a second coating of a second material, at least one of the first and second coatings being deposited using an ALD process, the second coating being deposited on a top surface of the first coating is also disclosed. The first and second materials may be similar or different. A razor component such as a clip or having one coating of at least one layer of one or more materials formed using an ALD process is also disclosed.

Abstract: A novel application of the atomic layer deposition (ALD) process for producing a conformal coating on a razor blade is disclosed where a uniform, conformal, dense coating is deposited on an entire surface of a blade flank and at least a portion or an entire surface of a blade body. To improve the shaving ability of the coated blade edge (e.g., decrease the blade tip radius), the ALD-produced coating may be etched during, after, or both during and after, the ALD process.

Abstract: Razors cartridges including a guard, a cap, and at least two blades with parallel sharpened edges located between the guard and cap are provided. A first blade defines a blade edge nearest the guard and a second blade defines a blade edge nearest the cap. The first blade has a cutter force less than the cutter force of the second blade.

Abstract: 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.

Abstract: A razor blade having a substrate with a cutting edge being defined by a sharpened tip. The substrate has a thickness of between about 1.3 and 1.6 micrometers measured at a distance of four micrometers from the blade tip, a thickness of between about 2.2 and 2.7 micrometers measured at a distance of eight micrometers from the blade tip, a thickness of between about 3.8 and 4.9 micrometers measured at a distance of sixteen micrometers from the blade tip, a ratio of thickness measured at four micrometers from the blade tip to the thickness measured at eight micrometers from the blade tip of at least 0.55 and a ratio of thickness measured at four micrometers from the blade tip to the thickness measured at sixteen micrometers from the blade tip of at least 0.30.

Abstract: Razors are described herein. In some instances the razors include a safety razor blade unit that includes a guard, a cap, and at least two blades with parallel sharpened edges located between the guard and cap. A first blade defines a blade edge nearer the guard and a second blade defines a blade edge nearer the cap. The first blade has a cutter force greater than the cutter force of the second blade. In some instances the razors provide a comfortable shave having improved closeness.

Abstract: This invention relates to a novel application of liquid-infused surface materials (LISM) to at least a portion of one or more surfaces of razor components (e.g., frame, housing, clips, blade supports, blade body, blade edge, lubricating bodies, guard, handle, grip, button). If applied to a skin contacting surface of a component, the one or more LISM layers may generally be abrasion-resistant, long-lasting or non-erodible, desirably elevating shaving performance, such as glide, comfort, rinsing, and cleanliness, while also simplifying the manufacturing process.

Abstract: Provided is a method for forming a fluorocarbon polymer on a surface of a structure. A feedstock gas is directed through a porous heat member having a temperature sufficient to crack the feedstock gas and produce a reactive species that includes (CF2)n wherein n=1 or 2 radicals in the vicinity of a structure surface on which the fluorocarbon polymer is to be formed. The structure surface is maintained at a temperature lower than that of the porous heat member to induce deposition and polymerization of the (CF2)n wherein n=1 or 2 radicals on the structure surface.

Abstract: Provided is a method for forming a fluorocarbon polymer on a surface of a structure. A feedstock gas is directed through a porous heat member having a temperature sufficient to crack the feedstock gas and produce a reactive species that includes (CF2)n wherein n=1 or 2 radicals in the vicinity of a structure surface on which the fluorocarbon polymer is to be formed. The structure surface is maintained at a temperature lower than that of the porous heat member to induce deposition and polymerization of the (CF2)n wherein n=1 or 2 radicals on the structure surface.