Abstract:
By providing a substantially continuous, arcuately curved, helical-shaped, spring-like coil or ribbon as the cutting element and securely mounting and retaining the coil/ribbon in a holding member, a substantially improved, highly effective, and long-lasting cutting blade assembly is realized. Furthermore, the cutting blade assembly of this invention is substantially less expensive to manufacture, assemble, and employ in a shaver when compared to prior art constructions. In the preferred construction, an elongated coil holding bar is employed for securely holding and retaining the entire length of the helical-shaped, spring-like coil/ribbon, imparting the required rigidity for enabling the elongated coil/ribbon to function in the desired manner. Furthermore, in the preferred configuration, the elongated bar incorporates a plurality of radially extending panel members mounted to a central hub, with the panel members being constructed for enabling the elongated, helically shaped coil/ribbon to be quickly and easily mounted thereon.

Description:
RELATED APPLICATIONS  
       [0001]     This application is related to U.S. Provisional Patent Application Ser. No. 60/553,245, filed Mar. 15, 2004, entitled Improved Cutting System Construction for Electric Dry Foil Shavers.  
     
    
     TECHNICAL FIELD  
       [0002]     This invention relates to electric dry shavers and, more particularly, to improved cutting systems for shavers employing aperture foils.  
       BACKGROUND ART  
       [0003]     Over the last many years, both men and women have been increasingly drawn to the advantages provided by electric dry shavers. In general, the consuming public has found that the use of razors or other systems is extremely inconvenient for removing or shaving short hair or stubble, as is commonly found in men&#39;s beards and women&#39;s legs. In addition, with the ever increasing time constraints and commitments individuals typically encounter, a fast and effective shaving system is most desirable.  
         [0004]     The discomfort as well as the time consumed in using shaving cream, soaps, and gels in order to provide a medium for which a razor can be used, requires more time and inconvenience than most individuals are willing or capable of incurring. Furthermore, the cost of maintaining a sufficient supply of these products creates an additional burden. Consequently, electric dry shavers have become increasingly popular, as well as battery-operated electric dry shavers which can withstand exposure to moisture, thereby enabling individuals to simultaneously shower as well as shave either beards or legs.  
         [0005]     As the popularity of electric dry shavers increased, various product designs and alternate constructions proliferated, in an attempt to improve and enhance the comfort and cutting efficiency of such shavers. However, in spite of these product changes, difficulties have continued to exist in providing optimal results with optimum comfort.  
         [0006]     One particular configuration has been found to be extremely efficacious in achieving high quality shaving results, as well as being extremely comfortable to use. This configuration comprises various models of electric dry shavers incorporating a movable cutting blade which cooperates with a thin, flexible mesh screen or apertured foil.  
         [0007]     In operation, the cutting blades are rapidly and continuously reciprocatingly moved against one side of the mesh screen or apertured foil, causing the cutting blades to repeatedly cross a plurality of apertures and provide a virtually continuous cutting action in each aperture. Then, by slidingly guiding the other side of the mesh screen or apertured foil over the skin surface to be shaved, the individual hair shafts enter the holes formed in the screen or foil and are cut by the movement of the cutting blades.  
         [0008]     Although this dry shaving cutting system has proven to be extremely effective, as compared to other dry shaving products, particular areas of difficulty continue to exist. One such area is found in the expense and difficulty which has continued to exist in manufacturing the cutting blades and the cutting blade assembly.  
         [0009]     Typically, the cutting blade assembly employed in most foil shavers comprises a plurality of separate, substantially flat, circular shape cutting elements which are affixed in juxtaposed, spaced, parallel relationship to each other, mounted on an elongated support rod. By placing the elongated support rod and cutting blade assembly in a holding member, which is mounted in the shaver for longitudinal movement along the axis of the elongated rod, the cutting blades are able to reciprocate on the inside surface of the apertured foil or mesh screen for providing the desired cutting action.  
         [0010]     Although this construction has become extremely popular and is widely used, the cost of manufacturing each of the plurality of independent cutting blade elements and affixing each of the cutting blade elements to the elongated rod has proven to be an extremely time-consuming and costly component to manufacture and assemble. However, although this problem has existed for many years, prior art constructions have been incapable of achieving an alternate construction which is capable of providing all of the qualities and performance characteristics inherent in this prior art construction.  
         [0011]     In addition, in order to assure long term, continuous and effective operation, each cutting blade is constructed with sharp edges in order to provide the desired cutting action as the blade reciprocatingly moves in contact with the mesh screen or apertured foil. However, due to the continuous, reciprocating movement, the edges of the cutting blades become worn, thereby losing their cutting efficiency. As a result, replacement of the entire cutting blade assembly is needed, thereby requiring the consumer to incur additional expenses.  
         [0012]     Therefore, it is a principal object of the present invention to provide an enhanced cutting system for electric dry shavers wherein the cutting blade assembly is constructed in a substantially more efficient and effective manner.  
         [0013]     Another object to the present invention is to provide an enhanced cutting blade system for electric dry shavers having the characteristic features described above which is highly effective in providing the desired reciprocating inter-engagement with any mesh screen or apertured foil.  
         [0014]     Another object of the present invention is to provide an enhanced cutting blade system for electric dry shavers having the characteristic features described above which is capable of being assembled quickly and easily, with a minimum of labor being required.  
         [0015]     Another object of the present invention is to provide an enhanced cutting blade system for electric dry shavers having the characteristic features described above which is capable of virtually eliminating any areas which remain unshaven after use.  
         [0016]     Another object of the present invention is to provide an enhanced cutting blade system for electric dry shavers having the characteristic features described above wherein the cutting blade element remains sharp, even after long term use.  
         [0017]     Other and more specific objects will in part be obvious and will in part appear hereinafter.  
       SUMMARY OF THE INVENTION  
       [0018]     By employing the present invention, all of the difficulties and drawbacks found with the prior art constructions are completely eliminated and a substantially improved, highly effective, and long-lasting cutting blade assembly is realized. Furthermore, the present invention provides a cutting blade assembly which is substantially less expensive to manufacture, assemble, and employ in a shaver when compared to prior art constructions.  
         [0019]     In accordance with the present invention, a unique highly effective, and low-cost cutting blade assembly is attained by employing a substantially continuous, arcuately curved, helical-shaped, spring-like coil or ribbon as the cutting element which is securely mounted and supportingly retained in a holding member. In the preferred construction, an elongated coil holding bar is employed for securely holding and retaining the entire length of the helical-shaped, spring-like coil/ribbon, imparting the required rigidity for enabling the elongated coil/ribbon to function in the desired manner.  
         [0020]     In the preferred configuration, the elongated bar incorporates a plurality of radially extending panel members mounted to a central hub, with the panel members being constructed for enabling the elongated, helically shaped coil/ribbon to be quickly and easily mounted thereon. In this way, the cutting blade component is quickly and easily fully assembled and mounted to the shaver in cooperating engagement with the apertured foil or mesh screen thereof.  
         [0021]     In this regard, in the preferred construction, the helically shaped coil/ribbon and holding bar assembly is constructed for being securely retained in a blade assembly support member. Typically, the blade assembly support member is constructed for cooperative engagement with the reciprocating drive system of the shaver, as well as for positioning and maintaining the blade assembly in cooperative engagement with the mesh screen or apertured foil.  
         [0022]     By employing the construction detailed above, a highly efficient and effective cutting blade assembly is realized which is capable of providing long term, highly effective and efficient cutting capabilities in any desired apertured foil or mesh screen shaver. In addition, the cutting blade assembly is constructed and fully assembled quickly and easily, without requiring numerous small components and tedious, costly assembly time. Consequently, an easily produced, low-cost, cutting blade assembly is achieved without in any way compromising the desired efficacy and efficiency.  
         [0023]     A further feature preferably incorporated into the cutting blade assembly of this invention is the construction of the helically shaped coil/ribbon with an outer edge which is constructed for optimizing cutting efficiency. In this regard, in one embodiment, the outer edge of the helically shaped coil/ribbon is constructed with sharp edges for providing the desired cutting efficacy.  
         [0024]     In the preferred embodiment, however, the outer edge of the helical shaped coil/ribbon is constructed with inwardly sloping or slanted side edges, providing an outer edge which essentially tapers downwardly as one moves from the outer edge inwardly. In this way, as the outer edge of the helical shaped coil/ribbon wears due to frictional engagement with the aperture foil or mesh screen, the cutting angle formed between the side edge and the terminating outer surface of the helical shaped coil/ribbon remains at a sharp angle, thereby assuring long term, continuous cutting effectiveness.  
         [0025]     The invention accordingly comprises an article of manufacture possessing the features, properties, and relation of elements which will be exemplified in the article hereinafter described, and the scope of the invention will be indicated in the claims.  
     
    
     THE DRAWINGS  
       [0026]     For a fuller understanding of the nature and objects of the invention, reference should be had to the following detailed description taken in connection with the accompanying drawings, in which:  
         [0027]      FIG. 1  is an exploded perspective view of the cutting blade and support assembly of the present invention;  
         [0028]      FIG. 2  is a perspective view of the fully assembled cutting blade assembly and support system of the present invention;  
         [0029]      FIG. 3  is a top plan view of the cutting blade assembly and support system of  FIG. 2 ;  
         [0030]      FIG. 4  is a side elevation view of the cutting blade assembly and support system of  FIG. 2 ;  
         [0031]      FIG. 5  is an end view of the cutting blade assembly and support system of  FIG. 4 ;  
         [0032]      FIG. 6  is a cross-sectional end view of the cutting blade assembly and support system taken along the line  6 - 6  of  FIG. 4 ; and  
         [0033]      FIG. 7  is a greatly enlarged, cross-sectional, side elevation view, partially broken away, depicting convolutions of the helically shaped coil/ribbon member securely mounted within notches formed in the coil holding bar, both of which are components of the cutting blade assembly of the present invention.  
         [0034]      FIG. 8  is an exploded perspective view, partially broken away, of the cutting blade assembly and support system of the present invention.  
     
    
     DETAILED DESCRIPTION  
       [0035]     By referring to  FIGS. 1-8 , along with the following detailed disclosure, the construction of the preferred embodiment of cutting blade assembly and support system  20  of the present invention can best be understood. However, is also to be understood that alternate constructions or variations of this invention can be made without departing from the scope of this invention. Consequently, the following disclosure, along with  FIGS. 1-8 , are provided for exemplary purposes only and are not intended as a limitation of the present invention.  
         [0036]     In a typical construction, cutting blade assembly and support system  20  of the present invention is employed in an electric shaver which incorporates an apertured foil or mesh screen in order to achieve the desired cutting action. In this regard, as shown in  FIG. 8 , a generally conventional electric shaver  50  is shown, for exemplary purposes only, comprising housing  51  to which guard/cover support base  52  is removable and mounted. In addition, two separate and independent cutting blade assemblies and support systems  20  of the present invention are mounted to drive assembly  53 , which is constructed for causing cutting blade assemblies and support systems  20  to reciprocatingly move along the central axis thereof in an oscillating, side to side manner.  
         [0037]     Furthermore, cutting blade assemblies and support systems  20  are cooperatively associated with apertured foils or mesh screens  54  in order to achieve the desired cutting action. As is well known in the art, each cutting blade assembly and support system  20  is maintained in biasing engagement with one surface of one mesh screen or apertured foil  54 , thereby causing each cutting blade assembly and support system  20  to reciprocatingly move in contact with one surface of the mesh screen or apertured foil  54 . This oscillating, side to side movement enables the hairs entering through the apertures of the mesh screen or apertured foil  54  to be cut, achieving the desired close, comfortable shave.  
         [0038]     In order to attain the desired movement of each cutting blade assembly and support system  20 , a motor is contained in housing  51  of shaver  50 , which is interconnected with drive assembly  53  in a manner which causes each cutting blade assembly and support system  22  to move in the desired side to side, reciprocating manner. In this way, whenever the motor is activated by the user, the desired cutting action is realized.  
         [0039]     The oscillating, side to side movement as well as the overall construction and operation of shavers employing cutting blade assemblies and apertured foils/mesh screens are more fully exemplified in prior art patents, such as U.S. Pat. Nos. 5,185,926 and 6,601,302. For purposes of disclosure, the information contained in these patents regarding the drive systems and the manner in which the cutting blade assemblies and support systems are mounted and driven in combination with the aperture foils and mesh screens is incorporated herein by reference.  
         [0040]     As shown in  FIGS. 1-6 , the preferred embodiment of cutting blade assembly and support system  20  preferably comprises helically shaped, spring-like coil or ribbon member  21 , elongated coil holding bar  22 , and support carrier  23 . As depicted, helically shaped, spring-like coil/ribbon member  21  comprises a generally continuous, arcuately curved, elongated length formed by a plurality of arcuately curved convolutions  24 . In addition, each arcuately curved convolution  24  comprises a substantially identical diameter as each adjacent convolution, with convolutions  24  formed along a single, common, elongated central axis.  
         [0041]     In addition, each arcuately curved convolution  24  of helically shaped, spring-like coil/ribbon member  21  comprises a substantially flat, outer surface  25 . Furthermore, each convolution  24  also comprises side surfaces  26  and  27  extending from outer surface  25 , with cutting edge  28  formed at the juncture between side surface  26  and outer surface  25  and cutting edge  29  formed at the juncture between side surface  27  and outer surface  25 .  
         [0042]     As is evident from the foregoing detailed discussion, by employing this construction, the formation of single, continuous, elongated, helically shaped, spring-like ribbon/coil member  21  simultaneously creates all of the plurality of cutting edges required for cooperative engagement with an apertured foil or mesh screen. As a result, by employing the present invention, the simple formation of elongated, continuous, helically shaped coil/ribbon member  21  eliminates the need for a separate and independent cutting blade to be formed and individually mounted to an elongated support rod. In this way, substantially improved and enhanced manufacturing and production capabilities are realized, with an entire cutting blade assembly being achieved at a substantially reduced cost.  
         [0043]     In order to impart sufficient rigidity to elongated, continuous, helically shaped, spring-like ribbon/coil member  21  for enabling coil/ribbon member  21  to be reciprocatingly moved along the inside surface of a cooperating mesh screen or apertured foil, cutting blade assembly and support system  20  preferably comprises coil holding bar  22 . In its preferred construction, coil holding bar  22  comprises a longitudinally extending, centrally disposed, elongated mounting post  31 , with a plurality of support panels  32  radially extending outwardly from post  31 .  
         [0044]     As depicted, coil holding bar  22  preferably comprises four separate and independent support panels  32 , each of which are mounted to post  31  for radially extending outwardly therefrom at substantially equivalent spaced arcuate distances. As a result, each support panel  32  is positioned substantially 90° from each adjacent panel  32 .  
         [0045]     In addition, each panel  32  incorporates a plurality of notches  33  formed along the outer edge thereof and extending substantially the entire length of panel  32 . As best seen in  FIGS. 3-7 , notches  33  provide receiving zones within which elongated, helically shaped, spring-like coil/ribbon member  21  is mounted and securely retained on coil holding bar  22 .  
         [0046]     By employing this construction, it has been found that helically shaped, spring-like, coil/ribbon member  21  is quickly and easily securely mounted in locked engagement with coil holding bar  22  by threadily advancing helically shaped coil/ribbon member  21  onto holding bar  22 . This engagement is most easily and conveniently achieved by continuously rotating coil/ribbon member  21  onto coil holding bar  22  for causing convolutions  24  to continuously advance through notches  33  of support panels  32  in response to the rotation of coil/ribbon  21 . Once coil/ribbon member  21  is advanced into complete engagement with coil holding bar  22 , rotation of coil/ribbon member  21  is stopped and a securely retained, rigid construction is achieved wherein each convolution  24  of coil/ribbon member  20  is secured in notches  33  of support panels  32 , and fixedly retained in position for cooperative, sliding, hair-cutting contact with any desired aperture foil or mesh screen.  
         [0047]     In completing the construction of the preferred embodiment of the present invention, cutting blade assembly and support system  20  preferably comprises carrier  23  which is constructed for securely holding and supportingly retaining helical, spring-like coil/ribbon member  21  and coil holding bar  22 . In its preferred construction, carrier  23  comprises an elongated support base  40  which incorporates a first pair of juxtaposed, spaced, facing, upstanding holding fingers  41 - 41  formed at one end of support base  40  and a second pair of juxtaposed, spaced, facing, upstanding holding fingers  42 - 42  formed at the opposed end of base  40 .  
         [0048]     In its preferred embodiment, upstanding holding fingers  41 - 41  and  42 - 42  are constructed for peripherally surrounding and securely engaging both, opposed, terminating ends of mounting post  31  of coil holding bar  22 . Although the terminating ends of mounting post  31  may comprise any desired configuration, the substantially rectangular shape depicted in  FIGS. 1-5  is preferred, with holding fingers  41 - 41  and  42 - 42  being constructed for enabling the rectangular shaped ends of mounting post  31  to be quickly and easily inserted therebetween for secure, retained, locked engagement therewith.  
         [0049]     By employing this construction, helical, spring-like, coil/ribbon member  21  and coil holding bar  22  are securely maintained in the precisely desired orientation and position for being reciprocatingly moved along the axis defined by holding bar  22 , thereby enabling helical, spring-like coil/ribbon member  21  to be capable of frictionally engaging with the inside surface of any desired apertured foil or mesh screen. In this way, the desired cutting action is achieved with the cutting edges of coil/ribbon member  21  being continuously maintained in the precisely desired frictional engagement with the apertured foil or mesh screen.  
         [0050]     Finally, by referring to  FIG. 7 , the preferred construction of helical, spring-like, coil/ribbon member  21  is clearly depicted. As shown, convolutions  24  of helical coil/ribbon member  21  are securely retained within notches  33  of support panels  32 . In addition, cutting edges  28  and  29  of each convolution  24  of helical coil/ribbon member  21  is clearly depicted, with cutting edges  28  being formed at the juncture between outside surface  25  and side surface  26 , with cutting edge  29  being formed at the juncture between outside surface  25  and side surface  27 .  
         [0051]     Furthermore, as clearly depicted in  FIG. 7 , side surfaces  26  and  27  of each convolution  24  of helical coil/ribbon member  21  are preferably constructed with an inwardly sloping construction, wherein each side surface tapers inwardly towards each other as one moves from outside surface  25  towards notches  33 . As detailed above, this construction enables cutting edges  28  and  29  of helical coil/ribbon member  21  to maintain a sharp cutting configuration, even after an extended, longer-term use. By employing sloping or tapering sidewalls  26  and  27 , cutting edges  28  and  29  formed with outside surface  25  are maintained sharp, even as outside surface  25  is worn due to frictional engagement with a desired apertured foil or mesh screen.  
         [0052]     As is evident from this construction, even though the frictional wear produced on surface  25  by frictional contact with any desired mesh screen or apertured foil causes the overall diameter of convolutions  24  to be reduced, the juncture angle between surface  25  and side surfaces  26  and  27  are maintained at an acute angle due to the slope of surfaces  26  and  27 . As a result, cutting edges  28  and  29  are maintained sharp due to this acute angle. In this way, long-term, continuous cutting efficiency is realized and an easily produced and assembled construction is achieved.  
         [0053]     It will thus be seen that the objects set forth above, among those made apparent from the preceding description, are efficiently attained and, since certain changes may be made in the above article without departing from the scope of the invention, it is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense.  
         [0054]     It is also to be understood that the following claims are intended to cover all of the generic and specific features of the invention herein described, and all statements of the scope of the invention which, as a matter of language, might be said to fall therebetween.