Shaving razors and shaving cartridges

A shaving cartridge includes a housing having a top surface, a bottom surface, a front edge, a rear edge, and a pair of side edges extending between the front edge and the rear edge. The housing includes at least one blade having a cutting edge and being disposed between the front edge and the rear edge, and a pair of retainers each having a top portion, a bottom portion, and a portion connecting the top portion to the bottom portion. The retainers extend along the pair of side edges between the front edge of the housing and the rear edge of the housing.

BACKGROUND

Field of the Disclosure

The following description relates to shaving razors and shaving cartridges. A shaving razor or shaving cartridge may include one or more blades and one or more retainers for retaining elements of the shaving razor or shaving cartridge. For example, a pair of c-shaped retainers extending along a pair of side edges of the shaving cartridge retains the blades in position within the housing.

Description of Related Art

Typically, a conventional razor head includes one or more razor blades secured to a razor head housing. A number of different securing mechanisms are typically used for securing razor blades. Such conventional mechanisms include clip retaining elements that wrap around the front and rear edges of a razor head housing and clip retaining elements that extend through one or more pairs of apertures adjacent to the front and rear ends of the housing.

FIGS. 11A-11Bare diagrams illustrating a prior art shaving cartridge. Referring toFIGS. 11A-11B, a conventional razor cartridge10includes a pair of clips15that extend through apertures formed on both ends of the razor cartridge. The clips15extend over the razor blades from a front edge of the housing adjacent to a guard bar to a rear edge of the housing adjacent to the cap.

During the manufacturing process, clips15typically encounter buckling as a result of the force that is applied in bending the legs of the clips15. As a result of the bending force exerted on the clips15, the clips15have a tendency to buckle upwards. Therefore, the blade exposures are unstable throughout the razor cartridge10and may vary significantly from the intended blade exposure values.

Also, during the manufacturing of the razor cartridge10, one or more legs of the clips15may fail to be bent. That is, after manufacturing of the razor cartridge10is completed, additional attention and labor may be required to ensure that all the clips are properly secured, and all the clip legs are properly bent beneath the housing of the razor cartridge10. Where a clip leg is not secured, additional steps are required to bend the clip leg beneath the housing.

Further, manufacturing of the razor cartridge10is a multi-step process that typically includes providing clips15having specific dimensions and materials that may need to be manufactured and supplied by a third-party vendor, positioning the clips15at the proper position, placing the clip legs through one or more pairs of apertures or wrapping the clip legs around the housing, and bending the clip legs after securing the clips15to the one or more pairs of apertures. This manufacturing process is timely and costly, and typically requires multiple steps and a third-party manufacturer and vendor.

Additionally, the clips15provide a variable retaining force throughout the length of the clips15. For example, the clips15are secured to the razor cartridge10at only the front and rear ends thereof, thus, the retaining forces throughout the length of the clips15is variable.

SUMMARY OF THE DISCLOSURE

According to aspects of the disclosure, a shaving cartridge may include a housing having a top surface, a bottom surface, a front edge, a rear edge, and a pair of side edges extending between the front edge and the rear edge; the housing may have at least one blade disposed between the front edge and the rear edge; the at least one blade may include a cutting edge; and a pair of substantially c-shaped retainers may each include a top portion, a bottom portion, a substantially convex portion connecting the top portion to the bottom portion; the retainers may extend along the pair of side edges between the front edge of the housing and the rear edge of the housing; wherein the top portion of each of the retainers may be substantially planar and the bottom portion of each of the retainers may be curved.

According to another aspect, a shaving cartridge may include a housing having a top surface, a bottom surface, a front edge, a rear edge, and a pair of side edges extending between the front edge and the rear edge; the housing may have at least one blade disposed between the front edge and the rear edge; the at least one blade may include a cutting edge; a pair of substantially c-shaped retainers may each include a top portion, a bottom portion, a substantially convex portion connecting the top portion to the bottom portion, and an inner surface; the retainers may extend along the pair of side edges between the front edge of the housing and the rear edge of the housing; wherein the top portion of each of the retainers may be substantially planar and the bottom portion of each of the retainers may be curved, and a protrusion may be disposed on the inner surface.

According to yet another aspect, a shaving cartridge may include a housing having a top surface, a bottom surface, a front edge, a rear edge, and a pair of side edges extending between the front edge and the rear edge; the housing may include at least one blade disposed between the front edge and the rear edge; the at least one blade may include a cutting edge; a pair of substantially c-shaped retainers may each include a top portion, a bottom portion, a substantially convex portion connecting the top portion to the bottom portion, an inner surface, a front edge, and a rear edge; the retainers may extend along the pair of side edges between the front edge of the housing and the rear edge of the housing; wherein the top portion of each of the retainers may be substantially planar and the bottom portion of each of the retainers may be curved, a protrusion may be disposed on the inner surface, and a recess may be disposed on the top portion of each of the retainers and may extend from the front edge of the retainer to the rear edge of the retainer.

According to further aspects, a shaving cartridge may include a housing having a top surface, a bottom surface, a front edge, a rear edge, and a pair of side edges extending between the front edge and the rear edge; the housing may include at least one blade disposed between the front edge and the rear edge; the at least one blade may include a cutting edge; and a pair of substantially c-shaped retainers may each include a top portion, a bottom portion, a substantially convex portion connecting the top surface to the bottom surface; the retainers may extend along the pair of side edges between the front edge of the housing and the rear edge of the housing, wherein each of the retainers may be preloaded thereby securing the retainer to the housing.

According to various aspects of the disclosure, one and/or the other of the following features may be incorporated in the shaving cartridge alone or in mutual combination:the cartridge may further include a protrusion;the top portion of each of the retainers may include a free end and the protrusion may be positioned about 1 mm to about 3 mm from the free end;each of the retainers may include a front edge and a rear edge, and the protrusion may extend from the front edge to the rear edge;the protrusion may include a triangular, oblong, square, rectangular, circular or semi-circular shape;the cartridge may further include a recess disposed on the top portion;the recess may include a triangular, oblong, square, rectangular, circular or semi-circular shape;the cartridge may further include a pair of housing recesses extending along the pair of side edges for receiving the pair of substantially c-shaped retainers;the cartridge may further include a corresponding surface formed on each housing recess for receiving the protrusion;the protrusion and the corresponding surface may have the same shape, and may include a triangular, oblong, square, rectangular, circular or semi-circular shape;

The present disclosure may also concern a shaver or a shaving razor including a handle and a shaving cartridge according to any of the preceding aspects, wherein the shaving cartridge may be connected to the handle.

DETAILED DESCRIPTION

It is to be understood that the present disclosure is not limited in its application to the details of construction and to the aspects of the components set forth in the following description or illustrated in the drawings. The figures and written description are provided to teach any person skilled in the art to make and use the disclosure for which patent protection is sought. The disclosure is capable of other aspects and of being practiced and carried out in various ways. Persons of skill in the art will also appreciate that the development of an actual commercial embodiment incorporating aspects of the present disclosures will require numerous implementations and decisions to achieve the ultimate goal of the developer for the commercial embodiment. While these efforts may be complex and time-consuming, these efforts nevertheless would be a routine undertaking for those of skill in the art having the benefit of this disclosure.

In addition, it is to be understood that the phraseology and terminology employed herein are for the purpose of description and should not be regarded as limiting. For example, the use of a singular term, such as, “a” is not intended as limiting of the number of items. Also the use of relational terms, such as but not limited to, “top,” “bottom,” “left,” “right,” “upper,” “lower,” “down,” “up,” “side,” are used in the description for clarity in specific reference to the figures and are not intended to limit the scope of the disclosure or the appended claims. Further, it should be understood that any one of the features of the disclosure may be used separately or in combination with other features. Other systems, methods, features, and advantages of the disclosure will be or become apparent to one with skill in the art upon examination of the figures and the detailed description. It is intended that all such additional systems, methods, features, and advantages be included within this description, be within the scope of the present disclosure, and be protected by the accompanying claims.

Further, the term “substantially” as used in the description and the appended claims should be understood to include an exact or a similar but not exact configuration. For example, substantially c-shaped means having an exact c-shape or a similar but not exact c-shape. Also, a substantially planar surface means having an exact planar surface or a similar but not exact planar surface. Also, the term “about” or “approximately” as used in the description and the appended claims should be understood to include the recited values or a value that is three times greater or one third of the recited values. For example, about 3 mm includes all values from 1 mm (millimeters) to 9 mm, and approximately 50 degrees includes all values from 16.6 degrees to 150 degrees.

It will be appreciated by those skilled in the art that changes could be made to the embodiments described above without departing from the broadened aspects of the concepts thereof. It is understood, therefore, that the disclosure, is not limited to the particular embodiments disclosed herein, but is intended to cover modifications within the spirit and scope of present aspects of the disclosure as defined by the appended claims.

An aspect of the shaving cartridge100, as shown inFIG. 1, may include a housing having a front edge101, a rear edge103, a pair of side edges105,107, a top surface109, and a bottom surface111. The pair of side edges105,107extends between the front edge101of the housing and the rear edge103of the housing. The shaving cartridge100may include a guard bar113adjacent to the front edge101of the housing and a cap115adjacent to the rear edge103of the housing. One or more blades117may be positioned between the guard bar113and the cap115and may be retained in position within the housing using one or more retainers200. According to some aspects, the shaving cartridge100may include, for example, five blades117that are retained in position within the housing using a pair of retainers200. While five blades117are noted, the disclosure is not limited to five blades, and any number of blades may be used.

Referring toFIGS. 2-3, the retainers200may be spaced apart and positioned on opposite sides of the housing. The retainers200extend along the side edges105,107of the housing and may include a top portion201that extends above the top surface109of the housing and above one or more blades117to retain the position of the blades117within the housing.

According to some aspects, retainers200may extend along a length L on the side edges105,107about, for example, 8.5 mm. It should be appreciated; however, that according to other aspects, the retainers200may extend along a shorter or longer portion of the side edges105,107. For example, a pair of retainers200may each extend along the entire length, a shorter portion, or a longer portion of the side edges105,107. The extension of length L of the retainers200may facilitate securing the guard bar113, cap115, or according to some aspects, a trimmer assembly. While a pair of retainers200is illustrated, any number of retainers200may be used with the shaving cartridge100. For example, according to some aspects, the shaving cartridge100may include a single retainer, four retainers, or any number of retainers may be used to retain the position of the blades117within the housing.

Referring toFIG. 4, the retainer200may be a substantially c-shaped retainer and may include the top portion201, a bottom portion203, and a substantially convex portion205connecting the top portion201to the bottom portion203. The retainer200may define an interior space that is adapted to receive a portion of the housing. When viewed from the interior space, the retainer200may have a globally concave shape. When viewed from outside, i.e. from a user point of view, when the retainer is mounted on the housing, the retainer200may have a globally convex shape. More particularly, the retainer200may include a convex portion205including a substantially convex shape viewed from a user point of view. Additionally, the retainer200may include a first end face211on the top portion201that is facing towards the blades117and a second end face213on the bottom portion203that is facing towards the blades117. The retainer200may include an inner surface217that extends throughout the internal surface of the top portion201, bottom portion203, and convex portion205of the retainer200, and may be in contact with the housing of the shaving cartridge100. Similarly, the retainer200may include an outer surface215that extends throughout the external surface of the top portion201, bottom portion203, and convex portion205of the retainer200. Referring back toFIG. 2, each retainer200may include a front edge221that is adjacent to the guard bar113and a rear edge219that is adjacent to the cap115.

The top portion201of the retainer200may be substantially planar and may facilitate securing the blades117to the housing. For example, the inner surface217of the top portion201of the retainer200may be in direct contact with the edges of the blades117to maintain the position of the blades117and to maintain the blade exposure of each of the blades117with respect to a contact plane. The contact plane may refer to a plane that is formed on the surface of the guard bar113and the cap115.

The bottom portion203may be curved for securing the retainer200to the underside of the housing. The substantially convex portion205connects the top portion201to the bottom portion203and includes a curvature. According to some aspects, for example, the curvature of the convex portion205may include a plurality of radii and may include one or more straight portions throughout its length. However, according to other aspects, the convex portion may include a single radius of curvature and the retainer200may form a semi-circular shape.

Still referring toFIG. 4, the retainer200may include a recess209that is formed on the outer surface215of the top portion201of the retainer200. According to some aspects, the retainer200may include a protrusion207that extends from the inner surface217of the top portion201of the retainer200. The protrusion207may be configured to be received by a corresponding surface152on the housing that will be further described below in reference toFIGS. 5-8. The protrusion207may further secure the retainer200to the housing of the cartridge100.

The recess209may further support the planar stiffness of the top portion201, and the protrusion207may facilitate anchoring the retainer200in a fixed position.

According to some aspects, the retainer200may be manufactured, for example, by forming the protrusion207and the recess209from a punch and die. The die, in the shape of the protrusion207, may be positioned, with adequate offset needs for stamping, on the inner surface217of the retainer200. The punching of the outer surface215of the top portion201creates the recess209on the outer surface215of the top portion201and transfers the material of the retainer200into the shape of the protrusion207. The protrusion207may thus extend from the inner surface217of the top portion201, taking the shape of the die, as illustrated inFIG. 4.

According to some aspects, the retainer200may have a height e from the uppermost part of the top portion201to the lowermost part of the bottom portion203that may be, for example, about 5.4 mm. The retainer200may have a distance b from the innermost part of the first end face211that is closest to the center of the housing to the tip of the protrusion207that may be, for example, about 2.2 mm. However, other aspects may include a distance b that may be, for example, in the range from about 1 mm to about 3 mm. In other words, the retainer200, and more particularly the top portion201of the retainer200may include a free end located at the innermost part of the first end face211that is closest to the center of the housing, and the distance between the free end and the tip of the protrusion207may range from, for example, about 1 mm to about 3 mm. The retainer200may include a distance f from the innermost part of the first face end211that is closest to the center of the housing to the outermost part of the retainer200that is farthest from the center of the housing. The distance f may be, for example, about 4 mm but according to some aspects, may range from about 3 mm to about 5 mm. The retainer200may further include an angle a between the horizontal line that is tangent to the lowermost point of the bottom portion203and the line x that is tangent to the innermost point on the inner surface of the bottom portion203prior to a change in the radius of curvature of the bottom portion may be, for example, approximately 22 degrees. According to some aspects, the angle a may be a positive angle that can range from, for example, about 0 to about 60 degrees. The value of the angle applied will drive the amount of locking interaction that is needed for a specific head design. The thickness of the retainer200may range throughout the length of the retainer200with the greatest thickness h being, for example, approximately 0.5 mm.

Still referring toFIG. 4, the protrusion207may have a triangular shape, and the angle c between the left side of the protrusion207and the vertical line that is passing through the tip of the protrusion may be, for example, about 55 degrees. The angle d between the outer side of the protrusion207and the vertical line that is passing through the tip of the protrusion may be, for example, about 5 degrees. The protrusion207may include a depth i from the uppermost part of the top portion201that may be, for example, about 0.75 mm. The recess209may have a semi-circular shape and a depth g of the recess209, from the uppermost part of the top portion201, may be for example about 0.25 mm.

It should be appreciated by one of ordinary skill in the art that the dimensions and shapes are only examples according to aspects of the disclosure. Any number of other dimensions and shapes may be used for the retainer200, the protrusion207, and the recess209. For example, while the shapes of the protrusion207and the recess209are triangular and semi-circular, respectively, the shapes of the protrusion207and recess209may include triangular, oblong, square, rectangular, circular, semi-circular, elliptical, or other related shapes.

Referring toFIG. 5, the shaving cartridge100is shown with the retainers200, the cap115, and the blades117being removed. The shaving cartridge100may include one or more springs119for supporting the blades117and providing independently movable blades117within the housing. The shaving cartridge100includes a pair of recesses150for receiving the pair of retainers200, each recess150having a corresponding surface152for receiving the protrusion207of the retainer200. According to some aspects, the recesses150may extend along the same length L as the retainers200of about 8.5 mm; however, it should be appreciated that a variety of different lengths may be used. In addition, the recess150may have a different length than the retainer200.

Referring toFIGS. 6-7, as with the retainers200described above, the recesses150are formed along a portion of the side edges105,107of the housing. The recesses150may also be formed along the entire side edges105,107of the housing or along smaller portions of the side edges105,107. Further, the corresponding surface152for receiving the protrusion207of the retainer200may be formed on the upper surface of the recess150. According to some aspects, the corresponding surface152may be a triangular recess that is formed on the upper surface of the recess150. According to other aspects, the corresponding surface152may include a mating surface that is not a recess, or a mating surface that is a recess and has a different shape that corresponds to the shape of the protrusion207. The springs119that are used for supporting the blades117may extend from the side of the housing in the region of the recess150.

Referring toFIG. 8, the corresponding surfaces152may have a similar shape as the protrusions207. According to some aspects, each corresponding surface152may have a triangular shape, and the angle c between the left side of the corresponding surface152and the vertical line that is passing through the tip of the corresponding surface152may be for example, about 55 degrees. The angle d between the outer side of the corresponding surface152and the vertical line that is passing through the tip of the corresponding surface152may be for example, about 5 degrees.

According to further aspects, the wall of the housing at the position of the recess150may include a substantially flat surface154corresponding to the substantially convex portion205of the retainer200. As a result, an air-gap may exist between the inner surface217of the retainer200and the parting line area. The flat surface154is due to the parting line and the need to avoid creating a fulcrum effect with the retainer200. For example, the use of a curved surface in direct contact with the substantially convex portion205at the recess150, rather than the substantially flat surface154, may create a fulcrum surface that may push the retainer200away from the recess150and interfere with the secure attachment of the bottom portion203with the underside of the housing. Consequently, the recess150may include a flat surface154for optimal alignment between the retainer200and the housing of the razor cartridge100; however, the razor cartridge100may not be not limited to including the substantially flat surface154. The razor cartridge100may include an entirely curved wall at the recess150, or one or more flat surfaces154corresponding to the substantially convex portion205, top portion201, or bottom portion203. An air gap and flat surface154may also be applied anywhere that a parting line is designed to ensure the best retainer alignment to the housing.

According to some aspects, the corresponding surface152may have a depth j that extends from the top surface of the recess150that may be, for example, approximately 0.4 mm. The distance k from the end of the corresponding surface152to the end of the recess150may be, for example, approximately 1.3 mm. The distance m between the end of the recess150and the side edge105of the housing where the recess is not formed may be, for example, approximately 0.5 mm. The height n of the recess from the uppermost portion to the lowermost portion may be, for example, approximately 4.4 mm, and the height o of the side edge105of the housing where the recess is not formed may be, for example, approximately 5.5 mm. Additionally, the radius of curvature r at the bottom tip of the corresponding surface152may be, for example, approximately 0.1 mm, and the radius of curvature q at the upper tip of the corresponding surface152may be, for example, approximately 0.15 mm. It should be appreciated by one of ordinary skill in the art that these dimensions and shapes are only an example of certain aspects of the disclosure; however, any number of other dimensions and shapes may be used for the recess150and the corresponding surface152.

Referring toFIG. 9, the retainer200may be a substantially c-shaped retainer and may include a top portion201, a bottom portion203, and a substantially convex portion205connecting the top portion201to the bottom portion203. In addition, the retainer200may include a first end face211on the top portion201, a second face213on the bottom portion203, an inner surface217, and an outer surface215. The retainer200is shown in a configuration prior to being installed on the razor cartridge100where the bottom portion203′ is closer to the top portion201as compared to the position of the bottom portion203after the retainer200is installed on the razor cartridge100. That is, the retainer200, according to some aspects may be a preloaded retainer.

As used in this disclosure, the term preloaded hereinafter means having a different configuration in response to being installed in the razor cartridge100. According to some aspects, prior to being installed in the razor cartridge100, the retainer200may have a smaller configuration where the distance p′ from the lowermost part of the top portion201adjacent to the first end face211to the uppermost part of the bottom portion203′ adjacent to the second end face213′ may be, for example, approximately 3.8 mm. In response to being installed in the razor cartridge100, the bottom portion203moves downwardly and the distance p from the lowermost part of the top portion201adjacent to the first end face211to the uppermost part of the bottom portion203adjacent to the second end face213may be, for example, approximately 4.2 mm. According to further aspects, there may be an increase of approximately 10 percent, for example, in the distance from the top portion201to the bottom portion203in response to the retainer200being installed in the razor cartridge100. It should be appreciated by one of ordinary skill in the art that these dimensions and ratios are only an example of certain aspects of the disclosure, and a variety of other dimensions and ratios may be used.

According to further aspects, several functional advantages exist for providing a shaving cartridge100with a preloaded retainer200having a planar top portion201and having a bottom curved portion203. The planar top portion201may act as a blade edge reference that may be in direct contact with the blade edges for securing the blades117to the razor cartridge100. The curved bottom portion203may more tightly secure the retainer200to the razor cartridge100, and the preloaded retainer200may allow for an even more secure attachment between the retainer200and the razor cartridge100. Because the retainer200may expand from the original, at-rest configuration in response to being installed in the razor cartridge100, a spring force may be formed as a result of being stretched beyond the at-rest position to further secure the retainer200to the razor cartridge100.

Referring toFIG. 10, the retainer200may include a recess209that is formed on the top portion201, and a protrusion207that extends downwardly from the top portion201. The retainer200may include a front edge221that is adjacent to the guard bar113when the retainer200is secured to the razor cartridge100, and a rear edge219that is adjacent to the cap115when the retainer200is secured to the razor cartridge100. The recess209and the protrusion207may extend along the entire top portion201of the retainer200, from the rear edge219to the front edge221. However, the recess209and the protrusion207may extend along only a portion of the retainer200, and more than one recess209and protrusion207may be formed in different patterns along the top portion201of the retainer200. Similarly, one or more recesses209or protrusions207may be formed on the bottom portion203.

According to further aspects, the retaining load may be applied equally along the entire length of the retainer200since the profile of the retainer200is the same along its entire length.

According to other aspects, bowing that is typically exhibited, may no longer be an issue with the manufacture of the shaving cartridge100with retainers200, as is in comparison with conventional razor heads having the clip design. Accordingly, a more stable blade edge exposure may be attained when using the retainer200. For example, in a conventional razor head designed to have blade exposures in line with the contact plane, the conventional razor head typically includes blade exposures ranging from 0-0.1 mm above the contact plane. This results from a bowing effect of the clip retaining elements in conventional razor heads. On the other hand, a similarly designed razor cartridge100using the retainer200may include actual blade exposures ranging from, for example, 0-0.06 mm, according to some aspects. That is, a razor cartridge100using the retainer200may exhibit up to 40 percent improved stability in blade edge exposure.

According to further aspects, assembly quality may be improved because there are no possibilities of a clip leg being left unbent under the housing to fix and secure in place. Typically, during the manufacture of a conventional razor head including one or more clip elements for securing blades to a razor head, one or more of the clip elements will remain unbent under the housing and will require further labor to fix and secure the clips in place. In using the razor cartridge100and the retainer200, this manufacturing defect is avoided, and the shaving cartridge assembly quality is improved.

According to other aspects, efficiency of the manufacturing process may be significantly improved, and manufacturing costs may be reduced. In manufacturing a conventional razor head including one or more clip elements, at least a three-step process is employed. First, the clip elements are positioned with respect to the housing; second, the clip elements are placed within one or more apertures within the housing; third, the legs of the clip elements are bent and wrapped beneath the housing. Alternatively, according to aspects of the manufacture of the razor cartridge100and the retainer200, the retainer200may be provided and directly fitted to the housing in a single-step process. Additionally, the materials and dimensions of a conventional clip element typically requires a third-party manufacturer to provide the clip elements. Alternatively, the larger dimensions and shape of the retainer200, in accordance with the detailed disclosure, provides for significantly reduced manufacturing costs.

One of skill in the art will recognize that the described examples are not limited to any particular size. Further, one of skill in the art will recognize that the components of the retainer200are not limited to any type of material. According to some aspects, the retainer200may be formed of a metal material but may also be formed of a variety of different materials including plastic. One skilled in the art will further recognize that diameters, types and thicknesses of materials may be considered when taking into consideration design and stability parameters. Additionally, and according to some aspects, any number of manufacturing techniques may be used such as the molding, machining or casting of any component.

It will be appreciated by those skilled in the art that changes could be made to aspects of the disclosure as described above without departing from the broad inventive concept thereof. It is understood, therefore, that the concepts detailed herein is not limited to the particular embodiments disclosed and is intended to cover modifications within the spirit and scope of the present disclosure.