Patent Application
20230314470
The present invention relates generally to manufacturing processes for razor blades and the design of blade arrays for razor cartridges and, more particularly, to methods of using blade inspection technology for optimizing manufacturing processes for razor blades and for optimizing a blade array of a razor cartridge using spatial information for a tip portion of a razor blade.
There are numerous methods and apparatus currently in use to measure and determined spatial information for razor blades. However, there is a need for a way to use these measurements and spatial information to improve blade edge design and understand the connection between blade characteristics, the manufacturing processes used to manufacture the razor blades, and the design of the blade arrays and cartridges the razor blades are ultimately used in. It would be beneficial to be able to use the measurements and spatial information obtained to determine the likelihood of skin damage, to determine how blade edges, hair, and skin interact, to provide insight into implementation of the razor blades into a blade array and/or into razor cartridges, and/or to understand drivers of cutting performance methods such as wool felt cutting and single fiber cut force, which would reduce the cutting force needed to cut hair.
In accordance with an aspect of the present disclosure, a method of optimizing a manufacturing process using spatial information for a tip portion of a razor blade comprises the steps of: measuring, using an atomic force microscope including a probe having a high aspect ratio of a length to a half side angle and a probe tip with a radius less than a radius of an ultimate tip of the tip portion of the razor blade, the spatial information by traversing the probe across the tip portion of the razor blade; analyzing, by one or more processors, the spatial information as measured by the atomic force microscope, to determine one or more blade characteristics; and using the blade characteristics to adjust the manufacturing process to improve a design of the razor blade.
The radius of the probe tip can be less than or equal to ⅓ the radius of the ultimate tip of the razor blade.
The probe can be traversed across the tip portion of the razor blade in a direction orthogonal to a longitudinal axis of the ultimate tip of the razor blade.
Measuring can include traversing the probe from the ultimate tip to 4 micrometers on each side of the ultimate tip.
The method can comprise positioning the probe at a first longitudinal position along the razor blade, where the step of measuring includes measuring first positional data with the probe at the first longitudinal position and approaching the razor blade from a first direction and measuring second positional data with the probe at the first longitudinal position and approaching the razor blade from a second direction, opposite the first direction.
Analyzing can include generating a two-dimensional representation of the tip portion of the razor blade at the first longitudinal position based on an average of the first positional data and the second positional data.
The method can comprise positioning the probe at multiple longitudinal positions along the razor blade, where the step of measuring includes measuring first positional data with the probe at each longitudinal position approaching the razor blade from a first direction and measuring second positional data with the probe at each longitudinal position approaching the razor blade from a second direction, opposite the first direction. Each longitudinal position can be at least 30 nanometers from adjacent longitudinal positions and analyzing can include generating a three-dimensional representation of the tip portion of the razor blade based on the first positional data and the second positional data measured at the multiple longitudinal positions and/or generating a Finite Element Analytical model of the tip portion of the razor blade and modeling an interaction of the Finite Element Analytical model against skin.
Analyzing can include determining at least one of: a radius of the ultimate tip, a departure angle, a tip-to-bevel transition, a tip width, a cross-sectional area, or a tip volume.
The radius of the probe tip can range up to 7 nanometers.
The aspect ratio can be at least 1 micron per degree or about 1.5 microns per degree.
The manufacturing process can be a sharpening process, a coating process, an electrochemical process, or any combination thereof. If a sharpening process, the adjustment to the sharpening process can include at least one of: changing a pitch of a grinding wheel, creating a new grinding wheel, or changing a configuration of a grinding machine. If a coating process, the adjustment to the coating process can include changing a configuration of a coating machine. The coating machine could be configured to coat at least a portion of the razor blade.
In accordance with another aspect of the present disclosure, a method of optimizing a blade array of a razor cartridge using spatial information for a tip portion of a razor blade comprises the steps of: measuring, using an atomic force microscope including a probe having a high aspect ratio of a length to a half side angle and a probe tip with a radius less than a radius of an ultimate tip of the razor blade, the spatial information by traversing the probe across the tip portion of the razor blade; analyzing, by one or more processors, the spatial information as measured by the atomic force microscope, to determine one or more blade characteristics; and using the blade characteristics to adjust a design characteristic of the blade array to improve a design of the razor cartridge.
The radius of the probe tip can be less than or equal to ⅓ the radius of the ultimate tip of the razor blade.
The probe can be traversed across the tip portion of the razor blade in a direction orthogonal to a longitudinal axis of the ultimate tip of the razor blade.
Measuring can include traversing the probe from the ultimate tip to 4 micrometers on each side of the ultimate tip.
The method can include the step of positioning the probe at a first longitudinal position along the razor blade and measuring can include measuring first positional data with the probe at the first longitudinal position and approaching the razor blade from a first direction and measuring second positional data with the probe at the first longitudinal position and approaching the razor blade from a second direction, opposite the first direction.
Analyzing can include generating a two-dimensional representation of the tip portion of the razor blade at the first longitudinal position based on an average of the first positional data and the second positional data.
The method can include positioning the probe at multiple longitudinal positions along the razor blade and measuring can include measuring first positional data with the probe at each longitudinal position approaching the razor blade from a first direction and measuring second positional data with the probe at each longitudinal position approaching the razor blade from a second direction, opposite the first direction. Each longitudinal position can be at least 30 nanometers from adjacent longitudinal positions and analyzing can include generating a three-dimensional representation of the tip portion of the razor blade based on the first positional data and the second positional data measured at the multiple longitudinal positions and/or generating a Finite Element Analytical model of the tip portion of the razor blade and modeling an interaction of the Finite Element Analytical model against skin.
Analyzing can include determining at least one of: a radius of the ultimate tip, a departure angle, a tip-to-bevel transition, a tip width, a cross-sectional area, or a tip volume.
The radius of the probe tip can range up to 7 nanometers.
The high aspect ratio can be at least 1 micron per degree or about 1.5 microns per degree.
The design characteristic of the blade array can be an arrangement of the blade array in the razor cartridge, a sharper tip location, a surface roughness, or a damage assessment.
While the specification concludes with claims particularly pointing out and distinctly claiming the subject matter that is regarded as forming the present invention, it is believed that the invention will be better understood from the following description, which is taken in conjunction with the accompanying drawings in which like designations are used to designate substantially identical elements, and in which:
The example methods described herein use the measurements of an ultimate tip of a razor blade by an AFM, and spatial information determined based on these measurements, to optimize manufacturing processes for the razor blade and/or optimize a blade array of a razor cartridge. The AFM can utilize a high aspect ratio cantilevered probe (~7 nm probe) that collects information from the ultimate tip of the razor blade, which can be used to determine the geometry of the ultimate tip while minimizing damage or artifacts from constant contact. A razor blade can be presented with a longitudinal axis of the razor blade orthogonal to a first direction of AFM probe travel. A complementary reverse second direction of AFM probe travel can also be employed to produce an additional scan to minimize method artifacts and identify abnormalities from the blade edge substrate. As a result of these scans, spatial information can be determined to reveal information from the peak of the tip down to about 4 micrometers. To further improve consistency, the ultimate tip of the razor blade can be scanned at multiple locations along the length or longitudinal axis of the razor blade. The spatial information determined from the scan can be analyzed via viable software-based scripts capable of further revealing a quantitative measure of the geometry of the ultimate tip by fitting the spatial information into a polynomial curve. Measurement obtained via an AFM can provide insights into various edge features from substrates in various states of manufacture, including as-sharpened, sputtered, and sintered conditions, benefitting both hair and skin interactions of the razor blade. In addition, another application of this measurement is the evaluation of post-shave razor blade characteristics, such as wear and damage.
Referring to
Referring to
Tip portion 135′ of the asymmetric razor blade 125′ in
While the razor blades in the schematic illustrations of an atomic force microscope below are shown and discussed with respect to symmetric razor blade 25, it should be appreciated that asymmetric razor blades 125 and 125′, or any other example of an asymmetric razor blade, may also be used.
With reference to the example razor blade 25 shown in
The spatial information about razor blade 25 may be obtained for all or part of tip portion 35 of razor blade 25. For example, spatial information may be obtained for part of the tip portion 35, e.g., from ultimate tip 45 to 4 micrometers on each side of ultimate tip 45. In other examples, spatial information may be obtained for an entirety of the tip portion 35, e.g., from ultimate tip 45 back to where first and second flanks 36a, 36b join body portion 30.
Generally, spatial information can be considered two-dimensional or three-dimensional topography, which can be characterized as a collection of points defined by their coordinate locations, relative to each other or to a datum. One example of spatial information that may be obtained is shown in
A method 300 for optimizing a manufacturing process using spatial information, such as that discussed above, for tip portion 35 of razor blade 25 is illustrated in the flow diagram of
At step 305, AFM 200 with probe 205 is used to measure spatial information for tip portion 35 of razor blade 25 by traversing probe 205 across tip portion 35 of razor blade 25, preferably by traversing probe 205 across tip portion 35 in a direction orthogonal to a longitudinal axis 50 of ultimate tip 45 of razor blade 25 and from ultimate tip 45 to 4 micrometers on each side of ultimate tip 45 (e.g., from 0.5 micrometers to 4 micrometers). As best shown in
At step 310, one or more processors are used to analyze the spatial information as measured by AFM 200 (e.g., using software-based scripts) to determine one or more characteristics of blade 25. For example, the spatial information can be used to determine a variety of information regarding tip portion 35 of razor blade 25, such as radius R1 of ultimate tip 45, convexity of the blade bevel in the ultimate tip region, departure angle 55, tip-to-bevel transition 60, tip width (e.g., T1-T3), sputtering conditions and deposition materials, sputtered tip shapes, cross-sectional area, tip volume, etc. A two-dimensional representation of tip portion 35 of razor blade 25 (see, e.g.,
At step 315, the blade characteristics are used to adjust the manufacturing process to improve a design of razor blade 25. In one example, the manufacturing process could be a sharpening process and adjustment of the sharpening process could include changing a pitch of a grinding wheel, creating a new grinding wheel through varied formulations, or changing one or more configurations of a grinding machine. U.S. Pat. No. 4,918,617, assigned to the Assignee hereof and incorporated herein in its entirety, describes various possible grinding wheel configurations. In another example, the manufacturing process could be a coating process, such as for hard coating or lubricous coating at least a portion of razor blade 25 using a coating machine. Examples of hard coating processes for razor blades are described in U.S. Pat. No. 6,684,513 and an example of Teflon coating for razor blades can be found in U.S. Pat. No. 3,071,856, both of which are incorporated by reference herein. In this example, adjustment of the coating process could include changing a configuration of the coating machine to accommodate different types of coatings and to deposit optimal coating. In addition to a sharpening process and/or coating process, the manufacturing process could be an electrochemical process, or any combination of manufacturing processes. An example of an electrochemical process is described in U.S. Pat. No. 5,983,756, which is incorporated herein by reference.
A method 400 for optimizing blade array 20 of razor cartridge 15 using spatial information, such as that discussed above, for tip portion 35 of razor blade 25 is illustrated in the flow diagram of
At step 405, AFM 200 with probe 205 is used to measure spatial information for tip portion 35 of razor blade 25 by traversing probe 205 across tip portion 35 of razor blade 25, preferably by traversing probe 205 across tip portion 35 in a direction orthogonal to a longitudinal axis 50 of ultimate tip 45 of razor blade 25 and from ultimate tip 45 to 4 micrometers (e.g., from 0.5 micrometers to 4 micrometers) on each side of ultimate tip 45. As best shown in
At step 410, one or more processors are used to analyze the spatial information as measured by AFM 200 (e.g., using software-based scripts) to determine one or more characteristics of blade 25. For example, the spatial information can be used to determine a variety of information regarding tip portion 35 of razor blade 25, such as radius R1 of ultimate tip 45, departure angle 55, tip-to-bevel transition 60, tip width (e.g., T1-T3), cross-sectional area, tip volume, etc. A two-dimensional representation of tip portion 35 of razor blade 25 (see, e.g.,
At step 415, the blade characteristics are used to adjust a design characteristic of blade array 20 to improve a design of razor cartridge 15. In one non-limiting example, the design characteristic could be an arrangement of blade array 20 in razor cartridge 15, such as the distance between blades, or an arrangement of razor blades 25 within blade array. The design characteristic could also be providing an area in the cartridge where a blade having a sharper tip is located. In another non-limiting example, the design characteristic could be a surface roughness. In yet another non-limiting example, the design characteristic could be a damage assessment. The profile, type of blade steel, or type of coating(s) of the razor blade may be needed to be changed if the surface is deemed too rough or if after a damage assessment, the coatings are deemed too fragile. Some examples of the adjustment of some of these design characteristics to improve the design of the razor cartridge are described in U.S. Pat. No. 7,882,640 and U.S. Pat. Publication No. 2007/0227008, which are incorporated herein by reference.
A. A method of optimizing a manufacturing process using spatial information for a tip portion of a razor blade, comprising the steps of: i. measuring, using an atomic force microscope including a probe having a high aspect ratio of a length to a half side angle and a probe tip with a radius less than a radius of an ultimate tip of the tip portion of the razor blade, the spatial information by traversing the probe across the tip portion of the razor blade; ii. analyzing, by one or more processors, the spatial information as measured by the atomic force microscope, to determine one or more blade characteristics; and iii. using the blade characteristics to adjust the manufacturing process to improve a design of the razor blade.
B. A method of optimizing a blade array of a razor cartridge using spatial information for a tip portion of a razor blade, comprising the steps of: i. measuring, using an atomic force microscope including a probe having a high aspect ratio of a length to a half side angle and a probe tip with a radius less than a radius of an ultimate tip of the razor blade, the spatial information by traversing the probe across the tip portion of the razor blade; ii. analyzing, by one or more processors, the spatial information as measured by the atomic force microscope, to determine one or more blade characteristics; and iii. using the blade characteristics to adjust a design characteristic of the blade array to improve a design of the razor cartridge.
C. The method of any one of paragraphs A-B, wherein the radius of the probe tip is less than or equal to ⅓ the radius of the ultimate tip of the razor blade.
D. The method of any one of paragraphs A-C, wherein the probe is traversed across the tip portion of the razor blade in a direction orthogonal to a longitudinal axis of the ultimate tip of the razor blade.
E. The method of any one of paragraphs A-D, wherein the step of measuring comprises traversing the probe between the ultimate tip to 4 micrometers on each side of the ultimate tip.
F. The method of any one of paragraphs A-E, comprising the step of positioning the probe at a first longitudinal position along the razor blade; wherein the step of measuring includes measuring first positional data with the probe at the first longitudinal position and approaching the razor blade from a first direction and measuring second positional data with the probe at the first longitudinal position and approaching the razor blade from a second direction, opposite the first direction.
G. The method of paragraph F, wherein the step of analyzing comprises generating a two-dimensional representation of the tip portion of the razor blade at the first longitudinal position based on an average of the first positional data and the second positional data.
H. The method of any one of paragraphs A-G, comprising the step of positioning the probe at multiple longitudinal positions along the razor blade; wherein the step of measuring includes measuring first positional data with the probe at each longitudinal position approaching the razor blade from a first direction and measuring second positional data with the probe at each longitudinal position approaching the razor blade from a second direction, opposite the first direction.
I. The method of paragraph H, wherein each longitudinal position is at least 30 nanometers from adjacent longitudinal positions.
J. The method of paragraph H, wherein the step of analyzing comprises generating a three-dimensional representation of the tip portion of the razor blade based on the first positional data and the second positional data measured at the multiple longitudinal positions.
K. The method of paragraph J, wherein the step of analyzing comprises generating a Finite Element Analytical model of the tip portion of the razor blade and modeling an interaction of the Finite Element Analytical model against skin.
L. The method of claim 1, wherein the step of analyzing comprises determining at least one of: a radius of the ultimate tip, a departure angle, a tip-to-bevel transition, a tip width, a cross-sectional area, or a tip volume.
M. The method of any one of paragraphs A-L, wherein the radius of the probe tip ranges up to 7 nanometers.
N. The method of any one of paragraphs A-M, wherein the aspect ratio is at least 1 micron per degree.
O. The method of any one of paragraphs A-M, wherein the aspect ratio is about 1.5 microns per degree.
P. The method of any one of paragraphs A or C-O, wherein the manufacturing process is a sharpening process, a coating process, an electrochemical process, or any combination thereof.
Q. The method of paragraph P, wherein the adjustment to the sharpening process comprises at least one of: changing a pitch of a grinding wheel, creating a new grinding wheel, or changing a configuration of a grinding machine.
R. The method of paragraph P, wherein the adjustment to the coating process comprises changing a configuration of a coating machine.
S. The method of paragraph R, wherein the coating machine is configured to coat at least a portion of the razor blade.
T. The method of any one of claims B-O, wherein the design characteristic of the blade array is an arrangement of the blade array in the razor cartridge, a sharper tip location, a surface roughness, or a damage assessment.
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 “40 mm” is intended to mean “about 40 mm”.
Every document cited herein, including any cross referenced or related patent or application and any patent application or patent to which this application claims priority or benefit thereof, is hereby incorporated herein by reference in its entirety unless expressly excluded or otherwise limited. The citation of any document is not an admission that it is prior art with respect to any invention disclosed or claimed herein or that it alone, or in any combination with any other reference or references, teaches, suggests or discloses any such invention. Further, to the extent that any meaning or definition of a term in this document conflicts with any meaning or definition of the same term in a document incorporated by reference, the meaning or definition assigned to that term in this document shall govern.
While particular embodiments of the present invention have been illustrated and described, it would be obvious to those skilled in the art that various other changes and modifications can be made without departing from the spirit and scope of the invention. It is therefore intended to cover in the appended claims all such changes and modifications that are within the scope of this invention.
The present application is related to co-pending application serial numbers (63/326,215, 63/326,219, 63/326,222) filed on the same date and by the same Assignee as the present application, which are not admitted to being prior art with respect to the present invention by their mention in the cross-reference section. These co-pending applications are incorporated herein by reference in their entireties.
| Number | Date | Country | |
|---|---|---|---|
| 63326210 | Mar 2022 | US |
