The present invention relates generally to cutting blade assemblies for electric shavers, and more particularly to cutting blades for such assemblies which are more readily coated with a coating material.
Electric shavers are commonly used to shave facial and body hair. Many people prefer electric shavers to razors because the cutting blades of electric shavers do not contact the skin, thereby reducing the risk of nicks, cuts and other skin irritations. One conventional type of electric shaver type is commonly referred to as a foil shaver (
Cutting blade assemblies are typically constructed by mounting multiple cutting blades in parallel, spaced relationship with each other on a common support shaft as shown in
It is also known to coat part or all of a cutting blade used in foils shavers with a suitable coating compound, such as a titanium compound, a nickel compound or the like to increase the strength and wear resistance of the blades. In one process, the cutting blade assembly, i.e., with individual cutting blades mounted on a common support shaft in spaced relationship with each other, are subjected to a conventional coating process such as a physical vapor deposition process (PVD) to coat the opposite faces of each cutting blade. However, such a process coats a relatively small number of blades.
It would be desirable to coat the blades prior to assembling the cutting blade assembly. For example, a substantial number of cutting blades are currently loaded onto a wire or thin rod as shown in
There is a need, therefore, for cutting blades that more readily remain separated from each other during coating prior to assembly of the cutting blade assembly.
In general, a cutting blade assembly for an electric foil shaver according to one embodiment of the present invention comprises a first cutting blade having a generally planar first face, a generally planar second face opposite the first face, and a peripheral cutting edge. The first cutting blade has at least one bump disposed on the first face. A second cutting blade has a generally planar first face, a generally planar second face opposite the first face, and a peripheral cutting edge. The first and second cutting blades are arranged in the cutting blade assembly in generally parallel relationship with each other and with the first face of the first cutting blade facing one of the first face and the second face of the second cutting blade.
In one embodiment of a cutting blade for an electric shaver cutting blade assembly that includes multiple cutting blades, the cutting blade has a generally planar first face, a generally planar second face opposite the first face, and a peripheral cutting edge. The cutting blade further has at least one bump on its first face.
A process according to one embodiment of the present invention for coating cutting blades for a cutting blade assembly generally comprises arranging first and second discrete cutting blades on a support member in generally parallel relationship with each other, with each of the first and second cutting blades having a first face and a second face opposite the first face. The arranging step generally comprises arranging the discrete first and second cutting blades relative to each other on the support member such that an outer edge margin of the first face of the first cutting blade is in spaced relationship with a corresponding outer edge margin of the second face of the second cutting blade. The cutting blades are subjected to a coating process to coat the outer edge margins of the first and second faces of each of the first and second cutting blades while the cutting blades remain on the support member. The cutting blades are subsequently removed from the support member and mounted on a cutting blade assembly support in spaced relationship with each other.
Corresponding reference characters indicate corresponding parts throughout the drawings.
Referring now to the drawings and in particular to
A pair of apertured foils 24 (also often referred to as mesh screens) are mounted on the guard/cover support base 22 to extend side-to-side in parallel relationship with each other in accordance with the cutting blade assemblies 28. The cutting blade assemblies 28 are suitably biased into contacting, hair cutting relationship with the inner surfaces of the respective apertured foils 24. The apertured foils 24 and cutting blade assemblies 28 are also constructed and arranged to permit flexing movement relative to the housing 21 during use, while the cutting blade assemblies remain in contact with the apertured foils.
Activation of an on/off switch 25 (
With particular reference now to
Each cutting blade 130 has a generally planar first face 132, a generally planar second face 134 opposite the first face, and a peripheral cutting edge 136. A segment 138 of the peripheral cutting edge 136 of each cutting blade 130 suitably has a contour that generally accords with the contour of the inner surface of the apertured foil 24 to provide a generally flush contact therebetween. In the illustrated embodiment, each cutting blade 130 is generally circular, or disk-shaped, so that an arcuate segment 138 of the peripheral cutting edge 136 of each blade has a contour that matches the contour of the inner surface of the foil 24 regardless of the angular orientation at which the blade is mounted on the support shaft 131. It is understood, however, that the cutting blades 130 need not be circular, such that only a defined segment of the peripheral cutting edge 136 of each cutting blade has the desired contour that accords with the contour of the apertured foil 24. The segment 138 of peripheral cutting edge 136 that contacts the inner surface of the apertured foil 24 broadly defines a cutting edge for cutting hairs that extend through the apertures of the foil.
An opening 139 (
With reference to
In one particularly suitable embodiment, the bumps 142 are formed by stamping dimples 144 into the second face 134 of the cutting blade 130 such that each bump is formed by a corresponding dimple. Alternatively, the bumps 142 may be formed on the first face 132 of the cutting blade 130 other than by stamping dimples 134 into the second face 134, and the dimples may be omitted altogether, without departing from the scope of this invention.
The bumps 142 of the cutting blade 130 as illustrated in
It is understood that the bumps 142 may instead be of another planar projection shape, such as circular, semicircular, polygonal, or irregular shape. It is also contemplated that the bumps 142 may extend laterally (e.g., radially in the illustrated embodiment) on the first face 132 of the cutting blade 130, or at a skewed angle. Further, one or more bumps 142 on the first face 132 of the cutting blade 130 may have one shape in planar projection while one or more other bumps on the same first face of the cutting blade may have another shape or shapes in planar projection. As illustrated in
In accordance with one embodiment of a process of the present invention, the cutting blades 130 are suitably subjected to a coating process subsequent to the bumps being formed but prior to mounting the cutting blades on the cutting blade assembly 128. In particular, the cutting blades are subjected to a coating process in which at least a portion of the first and second faces 132, 134, as well as the peripheral cutting edge 136, of each of the cutting blades are coated with a suitable coating to increase the strength and wear resistance thereof. As an example, the cutting blades 130 may be coated with a titanium nitride compound or other suitable coating composition or material. The coating may be suitably applied by a physical vapor deposition (PVD) process, and more particularly an arc evaporation PVD coating process, which is known to those skilled in the art and is not be further described herein except to the extent necessary to disclose the present invention.
In one particularly suitable embodiment, the first and second faces 132, 134 of each cutting blade 130 are coated only about an annular edge margin extending laterally inward along each respective face from the peripheral cutting edge 136 of the cutting blade. For example, the annular edge margin along which the coating 136a is applied to each face 132, 134 of the cutting blade may have a width of about 0.012 inches (about 0.30 mm) . It is understood, however, that a greater portion of each cutting blade face 132, 134 may be coated, including the entirety of each cutting blade face, without departing from the scope of this invention.
With reference now to
As between adjacent cutting blades 130, the bumps 142 formed on the first face 132 of one cutting blade contact the second face 134 of the adjacent cutting blade to space the adjacent cutting blades a distance substantially equal to the rise of the bumps. As used herein, the rise of the bumps 142 means the height of the apex of the bump relative to the plane of the first face 132 of the cutting blade 130. Accordingly, the bumps 142 equally space the cutting blades 130 from each other and retain the cutting blades on the wire 146 in spaced relationship with each other during coating (i.e., the bumps inhibit stacking together of the blades). As an example, the bumps 142 of the cutting blade 130 illustrated in
Where the bumps 142 are formed by stamping dimples 144 into the second face 134 of the cutting blade 130, there is some risk that the bumps on the first face 132 of one cutting blade may nest in the dimples on the second face of an adjacent cutting blade if the cutting blades are identical and are loaded onto the wire 146 at the same angular orientation. As used herein, the term angular orientation refers to the rotational position of the cutting blade 130 on the wire 145 (or cutting blade assembly 128), such as from 0 to 360 degrees, about the longitudinal axis X of the wire (or cutting blade assembly). Thus, in one embodiment (
The cutting blades 130, supported on the wire 146, are then simultaneously subjected to the coating process to coat at least a portion of each of the blades. Where only a portion of each face 132, 134 of each cutting blade 130 is intended to be coated, it is understood that the longitudinally outward facing faces of the two end blades of the multiple blades being coated may be coated entirely. Following coating of the cutting blades 130, the cutting blades are removed from the wire 146 and mounted on the support shaft 131 in the manner shown in
As mounted on the support shaft 131, the cutting blades 130 are suitably spaced from each other at a pitch such that the bumps 142 disposed on the first faces 132 of the cutting blades are spaced from (i.e., not in contact with) the second faces 134 of the adjacent cutting blades. In such an embodiment, the angular orientations of the cutting blades 130 in the cutting blade assembly 128 may be the same or different within the scope of this invention. Alternatively, the bumps 142 on the first faces 132 of the cutting blades 130 may contact the second faces 134 of the adjacent cutting blades, with each cutting blade suitably being at a different angular orientation than the adjacent cutting blade.
In an alternative embodiment illustrated in
As an example, the cutting blades 130, 230 illustrated in
As illustrated in
Following coating of the cutting blades 130, 230, the cutting blades are removed from the wire 246 and mounted on a support shaft 231 as shown in
The cutting blades (e.g., the blades 130 of the cutting assembly 128 of
Also, while the cutting blades 130, 230 illustrated and described herein each comprise a single peripheral cutting edge 136, 236 (e.g., such that two discrete cutting blade assemblies are required in the shaver 20 of
When introducing elements of the invention or the preferred embodiments thereof, the articles “a”, “an”, “the” and “said” are intended to mean that there are one or more of the elements. The terms “comprising”, “including”, and “having” are intended to mean that there may be additional elements other than the listed elements.
As various changes could be made in the above constructions, products, and methods without departing from the scope of the invention, it is intended that all matter contained in the above description and shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense.
This application claims priority to U.S. Provisional Patent Application Ser. No. 60/577,129 filed Jun. 4, 2004, the entire disclosure of which is incorporated herein by reference.
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