HAIR REMOVAL DEVICE

Abstract

A hair removal device includes a housing, an inner disc rotatably mounted to the housing and an outer disc rotatably mounted to the housing. The outer disc includes a body and a peripheral surface. The axial dimension of the peripheral surface is greater than an axial dimension of the body.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of U.S. Provisional Patent Application Nos. 61/449,570, filed Mar. 4, 2011, and 61/368,126, filed Jul. 27, 2010, both of which are incorporated herein by reference in their entireties.

BACKGROUND

The present invention relates generally to the field of hair removal devices. The present invention relates specifically to hair removal devices configured to remove hair by pulling and uprooting the hair from the skin.

Unwanted hair may be removed in a variety of ways. For example, hair may be cut at or near the surface of the skin with a razor or other cutting device. Typically, hair removed in this manner will re-grow quickly requiring frequent removal. In addition, hair may be removed via the application of a chemical, for example a depilatory cream, which acts to dissolve the hair. Alternatively, various devices and techniques exist to remove the entire hair including the root. Examples of such devices and techniques include tweezers, epilators, waxing, etc. These devices and techniques typically involve grasping the hair and the application of force to pull or pluck the hair and the root from the skin. Removal of hair by the root is usually longer-lasting than methods of hair removal that only remove hair at the surface of the skin. However, there may be discomfort associated with removal of hair by the root.

SUMMARY

One embodiment relates to a hair removal device including a housing, an inner disc rotatably mounted to the housing and an outer disc rotatably mounted to the housing. The outer disc includes a body and a peripheral surface. The axial dimension of the peripheral surface is greater than an axial dimension of the body.

In one embodiment, the body of the outer disc includes a central hub and at least one arm extending radially from the central hub, and the peripheral surface is the radially, outermost surface of the at least one arm. In one embodiment, the at least one arm includes an inner section, and the axial dimension of the peripheral surface is greater than an axial dimension of the inner section of the at least one arm. In one embodiment, the axial dimension of the peripheral surface is at least two times greater than the axial dimension of the inner section of at least one arm. In one embodiment, the material forming the peripheral surface of the at least one arm is different than the material of the inner section of the at least one arm. In one embodiment, the material forming the peripheral surface of at least one arm is a polymer material and the material of the inner section of the at least one arm is a metal. In one embodiment, the axial dimension of the at least one arm increases as the radial distance from the center of the outer disc increases. In one embodiment, the axial dimension of the at least one arm reaches a maximum at the peripheral surface.

In one embodiment, the peripheral surface of the outer disc is a skin contacting surface and is configured to reduce discomfort associated with hair removal. In one embodiment, the inner disc and the outer disc have opposing surfaces configured to engage a hair. In one embodiment, the opposing surfaces of the inner disc and outer disc are substantially parallel to the radial axes of the discs, and the peripheral surface is substantially perpendicular to the radial axes of the discs. In one embodiment, the outer disc moves toward the inner disc to engage the hair.

In one embodiment, the hair removal device includes an insert coupled to the outer disc and positioned between the inner disc and the outer disc. In this embodiment, the inner disc includes a first surface, and the insert includes a second surface opposing the first surface, and the insert and the inner disc are configured to engage a hair between the first and second surfaces. In one embodiment, the peripheral surface of the outer disc is made from a first material and the second surface is made from a second material. In one embodiment, the first material is a polymer material and the second material is a metal. In one embodiment, the first surface is made from the second material. In one embodiment, the outer disc includes an inner axial surface and an outer axial surface, and the insert is directly coupled to the inner axial surface of the outer disc.

Another embodiment relates to a hair removal device including a housing, an inner disc rotatably mounted to the housing and an outer disc rotatably mounted to the housing adjacent to the inner disc. The inner disc includes a first hair engagement surface. The outer disc includes an inner axial surface, a peripheral surface positioned to contact skin of a user and an outer axial surface. The hair removal device includes an insert coupled to the inner axial surface of the outer disc, and the insert includes a second hair engagement surface facing the first hair engagement surface. The peripheral surface of the outer disc is made from a first material, and the second hair engagement surface is made from a second material. In one embodiment, the first material is a polymer material, and the second material is a metal. In one embodiment, the first hair engagement surface is made from the second material. In one such embodiment, the second material is metal.

Another embodiment relates to a method of removing hair. The method includes rotating an inner disc and a pair of outer discs of a hair removal device to cause the distance between opposing surfaces of the inner disc and outer discs to decrease and grasping a hair between opposing surfaces of an inner disc and outer discs. The method further includes contacting the surface of the skin on either side of the hair with peripheral surfaces of the outer discs, and resisting upward deformation of the skin during hair removal via the contact between the peripheral surfaces of the outer discs and the skin. In one embodiment, discomfort associated with hair removal is reduced by resisting upward deformation of the skin during hair removal.

Alternative exemplary embodiments relate to other features and combinations of features as may be generally recited in the claims.

BRIEF DESCRIPTION OF THE DRAWINGS

This application will become more fully understood from the following detailed description, taken in conjunction with the accompanying figures, wherein like reference numerals refer to like elements in which:

FIG. 1 is a top view of a hair removal device, according to an exemplary embodiment;

FIG. 2 is an enlarged view of the head portion of the hair removal device of FIG. 1, according to an exemplary embodiment;

FIG. 3 is an exploded view of a disc assembly, according to an exemplary embodiment;

FIG. 4 is a perspective view of the assembled disc assembly of FIG. 3, according to an exemplary embodiment;

FIG. 5 is a top view of the assembled disc assembly of FIG. 4, according to an exemplary embodiment;

FIG. 6 is a cross-sectional view of an outer disc of the disc assembly of FIG. 4, according to an exemplary embodiment;

FIG. 7 is a sectional view showing a portion of the hair removal device of FIG. 1; and

FIG. 8 is a side sectional view of a portion of a disc assembly during hair removal, according to an exemplary embodiment;

FIG. 9 is an exploded view of a disc assembly, according to another exemplary embodiment;

FIG. 10 is a perspective view showing an assembled outer disc and insert, according to an exemplary embodiment;

FIG. 11 is a perspective view of the assembled disc assembly of FIG. 9, according to an exemplary embodiment;

FIG. 12 is a cross-sectional view of a portion of the disc assembly of FIG. 9 in the closed position, according to an exemplary embodiment; and

FIG. 13 is an enlarged view of the head portion of the hair removal device, according to an exemplary embodiment.

DETAILED DESCRIPTION

Before turning to the figures, which illustrate the exemplary embodiments in detail, it should be understood that the present application is not limited to the details or methodology set forth in the description or illustrated in the figures. It should also be understood that the terminology is for the purpose of description only and should not be regarded as limiting.

Referring to FIG. 1, a hair removal device, shown as epilator 10, is depicted according to an exemplary embodiment. Epilator 10 includes a housing 12. Housing 12 generally supports and provides mounting for the various components of epilator 10. In the embodiment shown, housing 12 also defines a handle portion 14 and a head portion 16 of epilator 10. Handle portion 14 is shaped to provide a convenient and comfortable gripping surface to allow a user to hold and manipulate epilator 10 during use. Epilator 10 includes an activation switch 18 located along handle portion 14. Activation switch 18 may be toggled between on and off positions, allowing the user to activate and deactivate epilator 10. Epilator 10 also includes a hair plucking assembly 20 mounted to and supported by housing 12. In the embodiment shown, hair plucking assembly 20 is mounted to head portion 16 of housing 12.

Referring to FIG. 2, an enlarged view of head portion 16 of epilator 10 is shown, according to an exemplary embodiment. As shown, hair plucking assembly 20 includes a plurality of disc assemblies 22. Disc assemblies 22 are rotatably mounted within head portion 16 of housing 12. In the embodiment shown, disc assemblies 22 are mounted to a curved shaft (shown in FIG. 7), resulting in the concave curvature of hair plucking assembly 20 shown in FIG. 2. Further, each disc assembly 22 is identical to the other disc assemblies 22 of epilator 10 except for the rotational orientation of disc assembly 22 relative to the curved shaft.

As explained in more detail below, each disc assembly 22 is configured to move between a “closed” configuration in which disc assembly 22 is configured to engage, grasp or trap a hair to be removed and an “opened” configuration in which any removed hair is released from the disc assembly. As each disc assembly 22 rotates within head portion 16 about the axis of the curved shaft, each disc assembly 22 alternates between the “opened” and “closed” configurations. Further, if disc assembly 22 has engaged a hair in the closed position, subsequent rotation of the disc assembly 22 acts to pull the hair from the skin prior to the disc assembly entering the “opened” configuration.

In the embodiment shown, each disc assembly 22 is rotationally offset about 60 degrees from the adjacent disc assemblies. This arrangement results in a first set of alternating disc assemblies 22 assuming the “closed” configuration and a second set of alternating disc assemblies 22 assuming the “opened” configuration. As shown in FIG. 2, the first, third, and fifth disc assemblies 22 are in the “closed” configuration, and the second and fourth disc assemblies 22 are in the “opened” configuration. In the embodiment shown in FIG. 2, if hair plucking assembly were to rotate 60 degrees about the shaft axis, the first, third, and fifth disc assemblies 22 would assume the “opened” configuration, and the second and fourth disc assemblies 22 would assume the “closed” configuration.

In one embodiment, hair plucking assembly 20 of epilator 10 may include a first row and a second row of substantially parallel disc assemblies 22. In another embodiment, hair plucking assembly 20 of epilator 10 may include a single row of disc assemblies 22. In other embodiments, hair plucking assembly 20 may include more than two rows of disc assemblies 22 (e.g., three, four, five, six, etc.). Further, while FIG. 2 shows hair plucking assembly 20 including five disc assemblies 22, in other embodiments, each row may include more than five or less than five disc assemblies. In one embodiment, each row of hair plucking assembly 20 may include an odd number (e.g., one, three, seven, nine, etc.) of disc assemblies 22, and, in another embodiment, each row of hair plucking assembly 20 may include an even number (e.g., two, four, six, eight, etc.) of disc assemblies 22.

Referring to FIG. 3, an exploded view of disc assembly 22 is shown according to an exemplary embodiment. Each disc assembly 22 includes an inner disc, shown as internal disc assembly 24, and two outer discs 26. Each outer disc 26 includes a body 27 having a central hub 28 and three radially extending arms 30. As shown, arms 30 are evenly spaced around central hub 28, such that the radial center axes of arms 30 are spaced about 120 degrees from each other. As explained in more detail below, each arm 30 includes an inner section 32 and a wider outer section 34. Each outer section 34 of arms 30 includes an outer or peripheral surface, shown as skin contacting surface 36, and a pair of lateral surfaces, shown as hair engagement surfaces 37. Skin contacting surface 36 is the radial, outermost surface of arms 30 that contacts the user's skin during use of epilator 10 and is positioned substantially perpendicular to the radial center axis of each arm 30. The pair of hair engagement surfaces 37 are positioned on either side of skin contacting surface 36 and are positioned substantially parallel to the radial center axis of each arm 30. Each outer disc 26 includes a central aperture 38.

Internal disc assembly 24 includes an internal disc 40 and a disc carrier 42. Internal disc assembly 24 includes a mounting hub 44, a central aperture 46 defined through mounting hub 44, and three engagement protrusions 48 surrounding central aperture 46. When assembled to create hair plucking assembly 20, central aperture 46 receives the curved shaft, and engagement protrusions 48 act to couple internal disc assembly 24 to the shaft such that rotation of the shaft is transferred to internal disc assembly 24. Further, engagement protrusions 48 act to couple together adjacent disc assemblies 22 within hair plucking assembly 20.

Internal disc 40 includes three radially extending arms 50 evenly spaced around mounting hub 44 such that the radial center axes of arms 50 are spaced about 120 degrees from each other. Each arm 50 includes a radially outer or peripheral section 52. Each peripheral section 52 includes a pair of lateral surfaces, shown as hair engagement surfaces 54. Hair engagement surfaces 54 are positioned substantially parallel to the radial center axis of each arm 50 and, in the orientation of FIG. 3, form the upper and lower surfaces of arms 50. As explained in more detail below, during hair removal, when a disc assembly 22 is rotated to the closed position, a hair may be grasped or engaged between hair engagement surface 37 of outer disc 26 and hair engagement surface 54 of internal disc 40 prior to removal.

Disc carrier 42 includes three U-shaped sections 56 spaced in between arms 50. Each U-shaped section 56 includes a pair of circumferentially facing surfaces 58. As can be seen in FIG. 4, when assembled, circumferentially facing surfaces 58 of U-shaped section 56 engage outer discs 26, such that rotation of internal disc assembly 24 is imparted to outer discs 26 causing the components of disc assembly 22 to rotate together. Disc carrier 42 also includes protrusions 60 extending from the upper and lower surfaces of each of the U-shaped sections 56. In operation, protrusions 60 exert a force on the arms 30 of the outer discs of the adjacent disc assemblies 22. As can be best seen in FIG. 7, the interaction between protrusions 60 and arms 30 of adjacent disc assemblies result in the movement of disc assemblies between the opened and closed configurations.

Referring to FIG. 4 and FIG. 5, disc assembly 22 is shown following assembly. As shown, outer discs 26 are coupled to inner disc assembly 24 by central aperture 38 of outer discs 26 receiving mounting hub 44. Further, each arm 50 of internal disc assembly 24 is positioned between a pair of arms 30 of outer discs 26. Further, as shown best in FIG. 5, circumferential facing surfaces 58 of U-shaped section 56 engage circumferential surfaces of arms 30 of outer discs 26 such that rotation of inner disc assembly 24 is imparted to outer discs 26.

In various embodiments, outer discs 26 are configured to reduce discomfort associated with the hair plucking process and are configured such that the contact between the outer discs and the skin of the user is more comfortable. Referring to FIG. 6, a side sectional view of an outer disc 26 is shown according to an exemplary embodiment. As noted above, in various embodiments, outer discs 26 include arms 30 having an inner section 32 and a wider outer section 34. Outer section 34 has a skin contacting surface 36. As shown in FIG. 6, the axial dimension of skin contacting surface 36, shown as W1, is greater than the axial dimension, shown as W2, of inner section 32. Thus, by providing a wider or thicker end section 34, skin contacting surface 36 of each arm 30 has a greater surface area than if arms 30 had a constant narrower width of W2 in the radial direction. Further, by providing only the end section 34 of arm 30 with the increased width or thickness, the overall weight of outer disc 26 is less than if arms 30 had a constant greater width of W1 along the radial length.

The contact between the user's skin and arms 30 may be made more comfortable by increasing the contact surface area between the skin and outer discs 26. Further, the increased surface area of skin contacting surface 36 may tend to compress and/or to increase the local skin tension around the hair. This increase in skin tension around the hair tends to resist upward deformation of the skin during hair removal. Thus, by increasing the surface area of skin contacting surface 36, the tendency of the skin on either side of the hair to be pulled or stretched upward during hair removal is reduced resulting in increased comfort during hair plucking. Further, the efficiency of hair removal may also be increased by the resistance of upward deformation of the skin provided by skin contacting surface 36. When the skin deformation is minimized, less force may be needed to be applied to the hair to cause removal.

As shown in FIG. 6, end section 34 has a substantially rectangular cross-section in the radial direction with an abrupt, stepped transition 62 between inner section 32 and end section 34. In other embodiments, arms 30 of outer disc 26 may be of other shapes that provided for a larger skin contacting surface 36. For example, the radial cross-section of end section 34 may have a substantially triangular or trapezoidal shape such that the axial dimension W1 of the end section increases gradually as the radial distance from the center of outer disc 26 increases. In other embodiments, end section 34 may have a rounded radial cross-sectional shape. In various embodiments, the axial dimension of arm 30 reaches a maximum at skin contacting surface 36.

As shown in FIG. 6, W1 is greater than W2 such that the area of skin contacting surface 36 is larger than the circumferential cross-sectional area of inner section 32 of arm 30. In one embodiment, W1 is at least two times greater than W2, and, in another embodiment, W1 is at least three times greater than W2. In one embodiment, W1 is between about three and four times greater than W2, and specifically is about three and a half times greater than W2. In various embodiments, W1 is between about 0.5 mm and about 2.5 mm, specifically between about 1 mm and 2 mm and more specifically is between about 1.2 mm and 1.6 mm. In one embodiment, W1 is about 1.4 mm. In various embodiments, W2 is between about 0.1 mm and 1 mm, specifically between about 0.1 mm and 0.6 mm, and more specifically between about 0.3 mm and 0.5 mm. In one embodiment, W2 is about 0.4 mm. In another exemplary embodiment, W1 is about 1.4 mm and W2 is about 0.4 mm. In another embodiment, W1 is about 1.7 mm.

In one embodiment, end section 34 may be made from a material selected to provide increased comfort associated with the contact between outer disc 26 and the user's skin. In one embodiment, end section 34 may be made from a polymer or plastic material. In one such embodiment, the material of end section 34 may be different from the material of inner section 32. For example, end section 34 may be made from a polymer or plastic material and other portions of outer disc 26, including inner section 32, may be made from metal (e.g., stainless steel). In other embodiments, end section 34 and inner section 32 of arm 30 may be made from the same material. In one such embodiment, end section 34 may include a layer or coating of material comprising skin contacting surface 36. In one such embodiment, end section 34 and inner section 32 may be made of metal (e.g., stainless steel) and the coating may be a polymer or plastic material. In another embodiment, outer disc 26 may be made from a single material. In one such embodiment, outer disc 26 may be made from a plastic material, and specifically may be integrally molded from a polymer or plastic material.

As noted above, removal of hair by plucking may be uncomfortable or painful. In the past, hair removal devices have addressed the discomfort associated with hair removal in various ways. Some devices have utilized additional components or systems to decrease discomfort. For example, U.S. Pat. No. 6,436,106, which is incorporated herein by reference in its entirety, discloses a hair removal device with a vibration system that applies vibration to the skin to reduce discomfort associated with the hair removal process. Other devices are designed such that hairs are removed quickly from the skin thereby reducing discomfort. However, these devices do not provide for an increased skin contacting area to reduce discomfort. Further, these devices typically do not include an end section composed of a different material selected to increase the comfort of skin contact. In one exemplary embodiment, epilator 10 does not include a vibration system or other separate system to decrease discomfort. In another embodiment, epilator 10 may include both outer discs 26 with larger skin contacting surface 36 and a vibration system or other system to reduce discomfort.

Referring back to FIG. 4, the relative size of skin contacting surface 36 to components of inner disc assembly 24 can be seen. In the embodiment shown, the axial dimension, W1, of skin contacting surface 36 is greater than the axial dimension of radial arm 50 of inner disc assembly 24 (W3 shown in FIG. 8). In one embodiment, W1 is at least two times greater than the axial dimension of radial arm 50 of inner disc assembly 24, and, in another embodiment, W1 is at least three times greater than the axial dimension of radial arm 50 of inner disc assembly 24. In one embodiment, W1 is between about three and four times greater than the axial dimension of radial arm 50 of inner disc assembly 24, and specifically is about three and a half times greater than the axial dimension of radial arm 50 of inner disc assembly 24. In another embodiment, W1 is between about four and five times greater than the axial dimension of radial arm 50 of inner disc assembly 24, specifically between about 4 and 4.5 times greater than the axial dimension of radial arm 50 of inner disc assembly 24 and more specifically is about 4.25 times greater than the axial dimension of radial arm 50 of inner disc assembly 24. In various embodiments, the axial dimension of radial arm 50 of inner disc assembly 24 is between about 0.1 mm and 1 mm, specifically between about 0.1 mm and 0.6 mm, and more specifically between about 0.3 mm and 0.5 mm. In one embodiment, the axial dimension of radial arm 50 of inner disc assembly 24 is about 0.4 mm. In another exemplary embodiment, W1 is about 1.4 mm and the axial dimension of radial arm 50 of inner disc assembly 24 is about 0.4 mm. In another exemplary embodiment, W1 is about 1.7 mm and the axial dimension of radial arm 50 of inner disc assembly 24 is about 0.4 mm.

Referring to FIG. 7, a cross-sectional view of epilator 10 is shown according to an exemplary embodiment. Epilator 10 includes a motor 70 configured to cause rotation of hair plucking assembly 20. In one embodiment, motor 70 may be a D.C. motor. Epilator 10 may include a battery and/or other power source (e.g., photovoltaic cell). In other embodiments, epilator 10 may include an AC power converter such that epilator 10 may be plugged to a conventional wall outlet. Epilator 10 includes a transmission system 72 configured to transmit energy generated by motor 70 to hair plucking assembly 20. Transmission system 72 includes a motor gear 74, a first step down gear 76, a second step down gear 78, a transmission gear 80 and an action gear 82. As shown in FIG. 7, hair plucking assembly 20 includes a bearing plate 84, a curved shaft 86 and a bearing support 88. Rotation generated by motor 70 is transmitted via the gears of transmission system 72 to shaft 86, and rotation of shaft 86 in turn causes rotation of disc assemblies 22 of hair plucking assembly 20. The gears of transmission system 72 are configured such that the rotation generated by motor 70 is converted to the proper rotational speed for hair plucking assembly 20. Bearing plate 84 and bearing support 88 are configured to provide smooth rotation of shaft 86.

The alternating operation of disc assemblies 22 of hair plucking assembly 20 can be seen in FIG. 7. Disc assemblies 22 are coupled to curved shaft 86 and to the adjacent disc assemblies 22 so that all disc assemblies 22 rotate together at the same rate (i.e., in synch). As shown, shaft 86 includes a concave curvature causing compression of the portions of disc assemblies 22 in front of shaft 86 (i.e., above shaft 86 in the orientation of FIG. 7) and also causing separation of the portions of disc assemblies 22 behind shaft 86 (i.e., below shaft 86 in the orientation of FIG. 7).

Operation of hair plucking assembly will be explained with reference to central disc assembly 90 shown in FIG. 7 with the understanding that the one or more disc assemblies of the hair plucking assembly operates in a similar fashion. As noted above, during rotation of hair plucking assembly 20, each disc assembly alternates between opened and closed configurations, and, as shown in FIG. 7, central disc assembly 90 is shown in the closed, hair grasping position. As disc assembly 90 rotates, the compression caused by shaft 86 forces the protrusions 60 of the inner disc assemblies 24 on either side of disc assembly 90 to engage the lateral surfaces of inner sections 32 of arms 30 of outer discs 26. The engagement between protrusions 60 and outer discs 26 causes hair engagement surfaces 37 to move toward and to engage the lateral surfaces of arm 50 of inner disc assembly 24. As shown in FIG. 8, if a hair is present between arm 50 of inner disc assembly 24 and one of the hair engagement surface 37 of outer discs 26 at this time, the hair 100 will be engaged or grasped between arm 50 and hair engagement surface 37. As rotation of central disc assembly 90 continues, hair 100 will be plucked from skin 102.

Each bearing support 88 includes an inwardly facing protrusion 104. Protrusion 104 operates in a manner similar to protrusions 60 of inner disc assembly 24, in that protrusions 104 apply a force to the left most and the right most outer discs 26 within hair plucking assembly 20. This causes the hair engagement surfaces 37 of the left most and the right most outer discs 26 to move toward and to engage the outermost lateral surfaces of the left most and right most arms 50.

FIG. 8 shows the operations of skin contacting surfaces 36 during hair removal according to an exemplary embodiment. As shown in FIG. 8, skin contacting surfaces 36 contact the outer surface of skin 102 on either side of hair 100. Because of the increased surface area of the contact, particularly in relation to the diameter of hair 100, skin contacting surfaces 36 resist the upward pull or deformation of a substantial section of skin 102 surrounding hair 100 as hair 100 is plucked. This resistance of upward pull of the skin on either side of the hair is believed to decrease the discomfort associated with hair removal and increase efficiency of hair removal as discussed above.

In various embodiments, such as the embodiment shown in FIGS. 9-12, the outer disc assembly may be constructed such that the hair engagement surface provides for efficient or improved hair engagement properties. In some embodiments, the outer disc assembly may be constructed such that the hair engagement surface is made from a different material than the skin contacting surface. Further, in some embodiments, the outer disc assembly may be configured to increase the radial dimension of the hair engagement surface to increase the surface area of the outer disc assembly that participates in the grasping of the hair.

Referring to FIG. 9, an exploded view of an another exemplary disc assembly is shown. Disc assembly 110 includes an internal disc assembly 24, two outer discs 112, and two outer disc inserts 114. Outer discs 112 are similar to outer discs 26 in most respects, except as discussed below. Like outer discs 26, outer discs 112 have a body 27, a central hub 28, and three radially extending arms 30. Outer discs 112 have an expanded or wider end section 116 at the end of each arm 30. Each end section 116 has a peripheral surface, shown as skin contacting surface 118, and a recess 120. Recess 120 is an axial depression formed on the side of end section 116 generally facing internal disc assembly 24. Recesses 120 receive inserts 114 and act to facilitate the attachment insert 114 to outer discs 112.

As shown in FIG. 9, disc assembly 110 includes two inserts 114, each positioned between one of the outer discs 112 and internal disc assembly 24. Outer disc 112 includes an inner axial surface 122 generally facing the outer axial surface 124 of insert 114. Insert 114 is a substantially planar element and includes three arms 126 generally shaped to match the shape of the inner axial surface 122 of body 27 of outer disc 112. As shown in FIG. 10, insert 114 is received within recess 120 of outer disc 112 to couple insert 114 to outer disc 112. Insert 114 is coupled to outer disc 112 to form an outer disc assembly 130. With insert 114 coupled to outer disc 112 as shown in FIG. 10, outer axial surface 124 of insert 114 is in contact with and is substantially flush with the inner axial surface of outer disc 112 (both axial surfaces are shown in FIG. 9). Insert 114 is coupled to outer disc 112 such that insert 114 rotates as outer disc 112 rotates within the housing of the epilator, as discussed above.

As noted above, end section 116 of outer disc 112 includes a peripheral, skin contacting surface 118. Insert 114 also includes a peripheral surface, shown as skin contacting surface 128, located on the peripheral face of each arm 126. When insert 114 is coupled to outer disc 112, skin contacting surface 118 of outer disc 112 and skin contacting surface 128 together define a peripheral surface, shown as skin contacting surface 132, of the outer disc and insert assembly 130. Further, with insert 114 coupled to outer disc 112, the inner axial facing surface 134 of insert 114 faces inner disc assembly 24. As explained in more detail below, a portion of inner axial facing surface 134 defines the hair engagement surface of outer disc assembly 130.

As shown in FIGS. 9 and 10, insert 114 and outer disc 112 are separate components that are coupled or mounted together. In one embodiment, insert 114 may be directly coupled to outer disc 112 by mechanical engagement or mechanical coupling between the components, such as by snap-fit or press-fit arrangements. In other embodiments, insert 114 may be coupled to outer disc 112 using other mechanisms. For example, in one embodiment insert 114 is coupled to outer disc 112 using an adhesive material placed between insert 114 and outer disc 112. In another embodiment, insert 114 may be welded (e.g., via ultrasonic welding) to outer disc 112. In another embodiment, insert 114 may not be independently coupled directly to outer disc 112 and may be held in place between outer disc 112 and inner disc assembly 24 once assembled to the curved shaft (e.g., shaft 86). In one embodiment, outer disc 112 may be made of plastic and may be molded on to insert 114.

Referring to FIG. 11, disc assembly 110 is shown following assembly. As shown, outer discs 112 are coupled to inner disc assembly 24 as discussed above. As shown in FIG. 11, disc assembly 110 includes two inserts 114, each positioned between inner disc assembly 24 and one of the outer discs 112. Further, each arm 50 of inner disc assembly 24 is positioned between each of the inserts 114. When assembled, end sections 116 of upper and lower outer discs 112, the upper and lower inserts 114 and arm 50 of the inner disc assembly 24 form a tweezer assembly 136.

FIG. 12 shows a partial cross-sectional view of the assembled disc assembly 110, showing tweezer assembly 136 in the closed position. As shown in FIG. 12, the hair engagement surfaces 134 of inserts 114 face hair engagement surface 52 of arm 50. When disc assembly 110 assumes the closed configuration shown in FIG. 12, at least a portion of hair engagement surface 134 comes into contact with hair engagement surface 52 of arm 50, and if a hair is present between the two surfaces, the hair may be grasped between the surfaces. As discussed above, with a hair grasped or clasped between the two hair engagement surfaces, disc assembly 110 rotates pulling the hair from the user's skin.

In one exemplary embodiment, outer disc 112 is made from one material and insert 114 is made from a second, different material. The material of outer disc 112 may be selected to provide good skin-contacting performance (e.g., increased comfort, decreased irritation, etc.), and the material of insert 114 may be selected to improve the ability of insert 114 to grasp the user's hair. In one specific embodiment, outer disc 112 is made from a plastic or polymer material, and both insert 114 and arm 50 of inner disc assembly 24 are made from metal (e.g., stainless steel, aluminum, etc.). In this embodiment, the polymer material of skin contacting surface 118 of outer disc 112 may provide for a comfortable skin contacting surface. Further in this embodiment, the metal to metal contact of hair engagement surfaces 134 and 52 provides for effective hair engagement. Thus, this embodiment provides for the combination of the increased comfort associated with a substantially plastic skin contacting surface and the efficient hair grip provided by the metal to metal hair engagement surfaces. In addition, utilizing inserts 114 may decrease the noise generated during operation compared to a disc assembly including only plastic outer discs 112. However, in other embodiments, outer disc 112 may be made from one type of polymer material, and insert 114 may be made from another type of material, such as a second type of polymer material, a ceramic material, etc.

In various embodiments, the sizes or dimensions of the components of disc assembly 110 may be selected to provide improved comfort during hair removal and for providing effective hair removal. As shown in FIG. 12, W3 is the axial dimension of arm 50 of inner disc assembly 24, W4 is the axial dimension of insert 114, W5 is the axial dimension of skin contacting surface 118 of outer disc 112, and W6 is the axial dimension of the entire skin contacting surface of tweezer assembly 136. In one embodiment, W3 and W4 are substantially the same. In another embodiment, W5 is at least two times greater than W3 and/or W4, and, in another embodiment, W5 is between two and five times greater than W3 and/or W4. In one embodiment, W5 is between about three and four times greater than W3 and/or W4. In various embodiments, W3 and/or W4 is between about 0.1 mm and 1 mm, specifically between about 0.1 mm and 0.6 mm, and more specifically between about 0.3 mm and 0.5 mm. In one embodiment, W3 and/or W4 is about 0.4 mm. In various embodiments, W5 is between about 0.5 mm and about 3 mm, specifically between about 1 mm and 2 mm, and more specifically between about 1.4 mm and 2 mm. In one embodiment, W5 is about 1.7 mm. In one embodiment, W3 and W4 are about 0.4 mm and W5 is about 1.7 mm, and W6 is about 3.8 mm.

The circumferential length of tweezer assembly 136 may also be selected to provide for efficient and comfortable hair removal. Referring back to FIG. 10, L1 represents the circumferential length of the skin contacting portion of insert 114 which is also the same as the circumferential length of tweezer assembly 136. In various embodiments, L1 is between about one time and three times greater than W6, specifically is between about 1.3 and 2 times greater than W6, and more specifically between about 1.5 and 1.6 times greater than W6. In various embodiments, L1 is between about 3 mm and 9 mm, specifically between about 5 mm and 7 mm, and more specifically, between about 5.5 mm and 6.5 mm. In one embodiment, L1 is about 6 mm.

FIG. 13 shows an enlarged view of the head portion of an epilator 10 including disc assemblies 110. Similar to hair plucking assembly 20 shown in FIG. 2, in the embodiment shown in FIG. 13, epilator 10 includes a hair plucking assembly 138 including a plurality of disc assemblies 110. Hair plucking assembly 138 operates in the same manner as hair plucking assembly 20 discussed above, except that inserts 114 contact arms 50 of inner discs 24 during hair removal.

Further modifications and alternative embodiments of various aspects of the invention will be apparent to those skilled in the art in view of this description. Accordingly, this description is to be construed as illustrative only. The construction and arrangements, shown in the various exemplary embodiments, are illustrative only. While the current application recites particular combinations of features in the claims appended hereto, various embodiments of the invention relate to any combination of any of the features described herein whether or not such combination is currently claimed, and any such combination of features may be claimed in this or future applications. Any of the features, elements, steps or components of any of the exemplary embodiments discussed above may be used alone or in combination with any of the features, elements, or components of any of the other embodiments discussed above. Although only a few embodiments have been described in detail in this disclosure, many modifications are possible (e.g., variations in sizes, dimensions, structures, shapes and proportions of the various elements, values of parameters, mounting arrangements, use of materials, colors, orientations, etc.) without materially departing from the novel teachings and advantages of the subject matter described herein. Some elements shown as integrally formed may be constructed of multiple parts or elements, the position of elements may be reversed or otherwise varied, and the nature or number of discrete elements or positions may be altered or varied. The order or sequence of any process, or method steps may be varied or re-sequenced according to alternative embodiments. Other substitutions, modifications, changes and omissions may also be made in the design, operating conditions and arrangement of the various exemplary embodiments without departing from the scope of the present invention.

Claims

1. A hair removal device comprising:

a housing;

an inner disc rotatably mounted to the housing; and

an outer disc rotatably mounted to the housing, the outer disc comprising: a body; and a peripheral surface;

wherein the axial dimension of the peripheral surface is greater than an axial dimension of the body.

2. The hair removal device of claim 1, wherein the body of the outer disc comprises a central hub and at least one arm extending radially from the central hub, wherein the peripheral surface is the radially, outermost surface of the at least one arm.

3. The hair removal device of claim 2, wherein the at least one arm comprises an inner section, wherein the axial dimension of the peripheral surface is greater than an axial dimension of the inner section of the at least one arm.

4. The hair removal device of claim 3, wherein the axial dimension of the peripheral surface is at least two times greater than the axial dimension of the inner section of the at least one arm.

5. The hair removal device of claim 3, wherein the material forming the peripheral surface of the at least one arm is a polymer material.

6. The hair removal device of claim 5, wherein the material of the inner section of the at least one arm is a metal.

7. The hair removal device of claim 2, wherein the axial dimension of the at least one arm increases as the radial distance from the center of the outer disc increases.

8. The hair removal device of claim 7, wherein the axial dimension of the at least one arm reaches a maximum at the peripheral surface.

9. The hair removal device of claim 1, wherein the peripheral surface is a skin contacting surface and is configured to reduce discomfort associated with hair removal.

10. The hair removal device of claim 1, wherein the inner disc and the outer disc include opposing surfaces configured to engage a hair.

11. The hair removal device of claim 10, wherein the opposing surfaces of the inner disc and outer disc are substantially parallel to the radial axes of the discs, and the peripheral surface is substantial perpendicular to the radial axes of the discs.

12. The hair removal device of claim 10, wherein the outer disc moves toward the inner disc to engage the hair.

13. The hair removal device of claim 1, further comprising an insert coupled to the outer disc and positioned between the inner disc and the outer disc, wherein the inner disc includes a first surface and the insert includes a second surface opposing the first surface, wherein the insert and the inner disc are configured to engage a hair between the first and second surfaces.

14. The hair removal device of claim 13, wherein the peripheral surface of the outer disc is made from a first material and the second surface is made from a second material.

15. The hair removal device of claim 14, wherein the first material is a polymer material and the second material is a metal.

16. The hair removal device of claim 14, wherein the first surface is made from the second material.

17. The hair removal device of claim 13, wherein the outer disc includes an inner axial surface and an outer axial surface, wherein the insert is directly coupled to the inner axial surface of the outer disc.

18. A hair removal device comprising:

a housing;

an inner disc rotatably mounted to the housing, the inner disc including a first hair engagement surface; and

an outer disc rotatably mounted to the housing adjacent the inner disc, the outer disc comprising: an inner axial surface; a peripheral surface positioned to contact skin of a user; and an outer axial surface; and

an insert coupled to the inner axial surface of the outer disc, the insert including a second hair engagement surface facing the first hair engagement surface;

wherein the peripheral surface of the outer disc is made from a first material and the second hair engagement surface is made from a second material

19. The hair removal device of claim 18, wherein the first material is a polymer material and the second material is a metal.

20. The hair removal device of claim 18, wherein the first hair engagement surface is made from the second material.

21. The hair removal device of claim 20, wherein the second material is metal.

22. A method of removing hair comprising:

rotating an inner disc and a pair outer discs of a hair removal device to cause the distance between opposing surfaces of the inner disc and outer discs to decrease;

grasping a hair between opposing surfaces of an inner disc and outer discs;

contacting the surface of the skin on either side of the hair with peripheral surfaces of the outer discs; and

resisting upward deformation of the skin during hair removal via the contact between the peripheral surfaces of the outer discs and the skin.

23. The method of claim 22 wherein discomfort is reduced by resisting upward deformation of the skin during hair removal.