RAZOR COMPONENT AND LUBRICATING STRIP

Abstract: A razor component (R) and lubricating strip (20). The strip (20) comprises a shave-aiding agent and between about 0.10 to about 10% by weight of a water soluble cosmetically acceptable plasticizer for the shave-aiding agent. This reduces the injection molding temperature of the strip (20), so that the strip (20) can be molded on the component (R) after the component (R) has been molded.

Description: This invention relates to a razor component and a lubricating strip. More particularly the invention relates to a razor cap and a lubricating strip. US-A-4,170,821 describes a razor cartridge having a cap with a lubricating composition. It also describes the incorporation of this composition in a water insoluble microporous substrate. Commercially available razors of this type namely Gillette ATRA PLUS and Schick ULTREX PLUS provide the combination of a lubricating strip and razor cap, the strip being subsequently affixed to the razor cap. This strip acts as a shaving aid and contains a shave-aiding agent in the form of polyethylene oxide having a molecular weight between 100,000 and 6,000,000. The shave-aiding agent is retained by a retaining structure in the form of a microporous substrate which is typically polystyrene. The shave-aiding agent is released from the substrate by leaching. The process for manufacturing a razor having such a lubricating strip employs first, injection molding of the cap and then the separate attachment of the strip. The strip is attached either by the use of acrylate adhesives or by mechanical means. When an adhesive is utilized, the combination of the strip and cap must be properly positioned after the adhesive is applied and then clamped for a period of time to allow the initial adhesive bonding to occur. This process has the disadvantage of the extra cost associated with the use of the adhesive as well as the separate steps utilized to mate and cure the adhesive. A mechanical attachment means usually involves a slot defining a recess in the top surface of the cap generally extending longitudinally along the cap length, and a positioning means either at the end of the recess or at the bottom of the recess or in both places. The strip (which is separately manufactured and which is either extruded or injection molded) is cut, positioned and retained usually by means of tabs or the like which can be bent over a portion of the strip to retain it. Ideally, the steps relating to the marriage of the separately formed strip and cap would be avoided if the strip could be molded in the same machine after molding of the cap had been completed. While the mixture of polyethylene oxide and polystyrene can be rendered plastic and deformable, attempts to sequentially mold the polystyrene/polyethylene combination have run into some substantial difficulties. One of the problems inherent in attempting to injection mold a polyethylene oxide compound is that high molecular weight polyethylene oxides are preferred for this particular application because they have the desired rate of water solubility. Lower molecular weight polyethylene oxide compounds, i.e., those near the bottom of the range disclosed in US-A-4,170,821 tend to rapidly leach out of the polystyrene open-celled matrix or honey-comb structure and may be essentially "used up" before the number of shaves comtemplated by the particular blade assembly is completed. The preferred high molecular weight polyethylene oxide is, unfortunately, highly susceptible to chain scission which reduces its molecular weight and consequently its efficacy as a shave-aiding agent. In the thermoplastic state, high molecular weight polyethylene oxide has an extremely high melt viscosity. Therefore, in order to sequentially mold the lubricating strip onto the razor cap, it is necessary to use very high injection molding temperatures to achieve the necessary melt flow to successfully complete the injection molding of the strip. This combination of high temperature and shear exposure accelerates the degradation of the polyethylene oxide via chain scisson. This problem could be substantially reduced if the temperatures used for injection molding were substantially reduced. Another problem associated with the use of very high injection molding temperatures in the sequential molding process is the potential thermal distortion of the previously molded cap during the sequential molding of the lubricating strip. For these reasons, and the obvious energy savings, it is highly desirable to be able to substantially reduce the injection molding temperatures used to form the lubricating strip. In US-A-4,381,293 there is disclosed a razor component having a lubricating strip comprising a shave-aiding agent and up to about 20% by weight of propylene glycol or glycerol. The propylene glycol or glycerol acts as a moisturizer during shaving. In GB-A-2,024,082 there is disclosed a razor having an insert which comprises polystyrene and polyethylene oxide. According to one aspect of the present invention there is provided a razor component having a lubricating strip said strip being characterised by being injection molded onto the razor component (R) and comprising a mixture of polystyrene, polyethylene oxide and between about 0.1% to about 10% by weight of a water soluble cosmetically acceptable plasticizer for polyethylene oxide said plasticizer being incompatible with polystyrene. Desirably said polystyrene comprises general purpose polystyrene. In a preferred embodiment the strip comprises, by weight, about 55% to about 85% polyethylene oxide, about 35% to about 15% polystyrene, and about 0.1% to about 10% plasticizer. The plasticizer may be one or more of propylene glycol, polyethylene glycol, polypropylene glycol, glycerol, alkyl phenol ethoxylate and water. The plasticizer is preferably octyl phenol ethoxylate containing nine moles of ethylene oxide. According to a further aspect of the invention there is provided a method for sequentially injection molding a lubricating strip and at least a plastic razor component with orifices for anchoring said strip in a position extending longitudinally across the component, said method being characterised by: molding at least said component with orifices spaced along a recessed area extending longitudinally across the component; and injecting a mixture comprising at least a shave-aiding agent and from about 0.1% to about 10% by weight of the mixture of a water soluble cosmetically acceptable plasticizer, at temperatures sufficient to produce flowability of the shave-aiding agent without substantially reducing its molecular weight during the time of injection, said mixture forming said strip and flowing into said orifices to anchor said strip to said component. Desirably the mixture further includes an insoluble plastics material, and the shave-aiding agent preferably comprises polyethylene oxide. Preferably the insoluble plastics material is polystyrene, preferably particulate polystyrene. According to another aspect of the invention there is provided a razor component and a lubricating strip disposed on an upper surface of the component, characterised in that said strip includes anchoring means for anchoring the strip by injection moulding to the component, and said anchoring means comprises a plurality of anchoring formations extending into the component. Preferably each anchoring formation has a free end which includes a portion disposed at an angle to, and/or of greater thickness than, the rest of the formation. In the preferred construction each anchoring formation comprises a downwardly directed substantially T-shaped formation, the top of the T is substantially parallel to the strip and abuts a portion of the component substantially parallel to the top of the upper surface of the component, and the leg of the T extends through the component between the upper surface and said portion. The strip may be molded in place after a moulding operation forming the component. Typically the razor component is a razor cap. The insoluble plastics structure can act as a retaining structure for the shave-aiding agent. In particular, the retaining structure may be microporous, with the shave-aidig agent disposed therein. The shave-aiding may be leachable. As explained above, the invention is particularly useful for high molecular weight shave-aiding agents. The present invention enables the lubricating strip to be molded in situ on the razor cap, after the cap has been previously injection molded. The lubricating strip acts as a shaving aid which facilitates the act of shaving. Reference is now made the the accompanying drawings, in which: Figure 1 is a plan view of a razor cap and lubricating strip according to the invention; Figure 2 is a cross sectional view taken along lines 2-2 of Figure 1; Figure 3 is a view of a lubricating strip according to the invention. As can be seen from Figure 1, a razor cap R of a razor is provided with handle 17 connected to the razor cap R by neck 16. For clarity the precise means of connection is not shown. Also the razor blade or blades are not shown. A lubricating strip 20 is disposed along a longitudinal line in a recessed area 18 on the cap R. The strip 20 is retained in place and anchored through T-shaped anchoring means in the form of anchoring formations 22, 23, 24 and 25 which extend into cooperating formations 12, 13, 14 and 15 respectively on the cap R. As can be seen by reference to Figure 3, a typical anchoring formation 22 may be generally T-shaped and contains a neck portion 22″ and a wider portion 22′. The anchoring formations 22 to 25 may extend under a bottom surface of the cap R and flow along to define a mold area within the cap R, or may be positioned within a hollow receiving portion within the thickness of the cap R itself as shown in Figure 2. The anchors 22 to 25 serve to maintain the strip 20 in its position on the cap R within the recess 18. Figure 3 shows the strip 20 as it would appear if separate from the cap R. As can be seen therein, the series of T-shaped anchoring formations 22, 23, 24, and 25 are designed to mate with formation 12, 13, 14, and 15 respectively (which are in the form of slots or orifices). The formations 22 to 25 are designed so that the neck portion of the T represented by 22″, 23″, 24″, and 25″ are positioned within the slots and the strip 20 is retained by the spread out anchor portions 22′, 23′, 24′, and 25′ shaped as the cross bar portion of the T. The particular configuration of the anchoring formations 22 to 25 may be varied; for example, any anchoring formation can be used in which the bottom portion (represented in the drawings by numerals 22′, 23′, 24′, and 25′) is wider than the respective mating formation 12, 13, 14, and 15 through which the strip 20 is anchored. The number of the formations 22 to 25 is not critical except, with regard to their location, it is preferred that they be positioned essentially symmetrically about the transverse centre of the razor cap R to maintain resistance to torque forces which may be applied to the strip 20 during shaving. It will be appreciated that the strip 20 can be molded to other parts of the razor structure than the cap. The method according to the present invention resides in the sequential molding of the razor cap R and, subsequently, the lubricating strip 20 positioned in appropriately predesigned areas on the top of the cap R. As can be seen by reference to the drawings, particularly Figures 1 and 2, the cap R is formed with a receiving area (in the form of the recess 18) by injection molding,and subsequently a mixture of polystyrene and polyethylene oxide along with suitable amounts of acceptable plasticizers present from about 0.1 to about 10% by weight of the mixture is prepared as a fluid for a second stage injection molding operation. The receiving cavity for this second stage is formed in part by the injection molded cap R. The use of a plasticizer in the polystyrene-polyethylene oxide mixture brings about the desired reduction in injection molding temperatures and the previously described performance and processing benefits derived therefrom. The plasticizer should be water soluble and compatible with polyethylene oxide and also cosmetically acceptable. By "cosmetically acceptable" it is meant that the use of the plasticizer in the indicated amounts of 0.1 to 10% by weight of the mixture will not generally produce irritation to the skin of the majority of the users of the shaving implement. The plasticizer should also be substantially incompatible with polystyrene. If the plasticizer is imprisoned in the polystyrene matrix it has no effect on the polyethylene oxide. Of course, plasticizers which are compatible with polyethylene oxide and polystyrene, which are also cosmetically acceptable, could be used if present in relatively high levels but obviously this is undesirable because high levels of plasticizer could adversely affect both the polyethylene oxide and the polystyrene. The use of the plasticizers allows the utilization of substantially lower temperatures during the time of processing to produce a flowability of the polyethylene oxide without substantially reducing its molecular weight and performance in the lubricating strip 20. Preferred plasticizers are polyethylene glycol particularly with molecular weight between 400 and 20,000, water soluble polypropylene glycol particularly with molecular weight between 400 and 4,000, water soluble copolymers of ethylene and propylene oxide, water soluble alkyl phenol ethoxylates, glycerine, sorbitol and water. Particularly preferred plasticizers are propylene glycol and octyl phenol ethoxylate with 9 moles of ethylene oxide. This latter plasticizer is commercially available under the trade name Triton X-100 from Rohm and Haas Company, Philadelphia, PA. It is also possible to use water as a plasticizer although the use of water requires a change in certain of the process parameters. With regard to each specific plasticizer flowability at a given temperature increases with the amount of plasticizer added as will be shown in the examples set forth below. Example 1 A series of runs were made in which the level of high molecular weight polyethylene oxide, polystyrene and propylene glycol was varied within the ranges in table 1 set forth below. A small amount of 3,5,-di tertbutyl-p-cresol, commonly known as butylated hydroxy toluene or BHT, was added to the composition as an oxidation inhibitor for the compostion. In order to determine the effect of plasticizers on the injection molding temperatures required to successfully sequentially mold the lubricating strip 20 onto at least the cap R, the runs were conducted on a commercial injection molding machine. Temperatures of the different sections of the machine were varied to determine the minimum temperatures for sequentially molding lubricating strips. The table 1 below shows the compositions of the strip 20 used in each run, and table 2 shows the minmum acceptable temperature necessary for successful sequential molding of the lubricating strip for each run. The tables show that the introduction of 5% plasticizer enabled a reduction in the minmum acceptable injection molding machine temperatures of 40°F (22°C) at the rear of the machine and 80°F (44°C) at the nozzle and sprue. Addition of 10% plasticizer enabled reduction in the minmum acceptable molding machine temperatures by 50°F (28°C) at the rear of the machine and 85-130°F (47-72°C) at the nozzle and sprue. Example 2 A two-minute water immersion laboratory test is used to evaluate the efficacy of inserts and assess their ability to release polyethylene oxide during shaving. A minimum of 70% water weight gain is required for an insert to be efficacious (perceived as providing significant lubrication to the shaver during the act of shaving). Water immersion values for each tested composition are as follows: The table shows when comparing Sample No 3 (no plasticizer) to No 6 (5% propylene glycol) that the plasticized compound is more efficacious (73% water absorption vs. 67%) and it can be molded at nozzle and sprue temperatures of 70°F (38°C) and 85°F (47°C), respectively, below the non-plasticized formulation. The introduction of 10% propylene glycol (compare compound 1 to compound 7) permits a reduction in nozzle and sprue temperatures of 80°F (44°C) and 130°F (72°C) respectively, while slightly increasing efficacy.

Claims: 1. A razor component (R) having a lubricating strip (20) said strip (20) being characterised by being injection molded onto the razor component (R) and comprising a mixture of polystyrene, polyethylene oxide and between about 0.1% to about 10% by weight of a water soluble cosmetically acceptable plasticizer for polyethylene oxide said plasticizer being incompatible with polystyrene. 2. A razor component (R) according to Claim 1, characterised in that said polystyrene is general purpose polystyrene. 3. A razor component (R) according to Claim 1 or 2, characterised in that the strip (20) comprises, by weight, about 55% to about 85% polyethylene oxide, about 35% to about 15% polystyrene, and about 0.1% to about 10% plasticizer. 4. A razor component (R) according to Claim 2 or 3, characterised in that the plasticizer is one or more of propylene glycol, polyethylene glycol, polypropylene glycol, glycerol, alkyl phenol ethoxylate and water. 5. A razor component (R) according to any of Claims 1 to 4, characterised in that the plasticizer is octyl phenol ethoxylate containing nine moles of ethylene oxide. 6. A method for sequentially injection molding a lubricating strip (20) and at least a plastic razor component (R) with orifices (12,13,14,15) for anchoring said strip (20) in a position extending longitudinally across the component (R), said method being characterised by: molding at least said component with orifices (12,13,14,15) spaced along a recessed area (18) extending longitudinally across the component; and injecting a mixture comprising at least a shave-aiding agent and from about 0.1% to about 10% by weight of the mixture of a water soluble cosmetically acceptable plasticizer, at temperatures sufficient to produce flowability of the shave-aiding agent without substantially reducing its molecular weight during the time of injection, said mixture forming said strip (20) and flowing into said orifices (12,13,14,15) to anchor said strip (20) to said component (R). 7. A method according to Claim 6, characterised in that the mixture further includes an insoluble plastics material, and the shave-aiding agent comprises polyethylene oxide. 8. A method according to Claim 7, characterised in that the insoluble plastics material is polystyrene, preferably particulate polystyrene. 9. A razor component (R) and a lubricating strip (20) disposed on an upper surface of the component (R), characterised in that said strip (20) includes anchoring means (22,23,24,25) for anchoring the strip (20) by injection moulding to the component (R), and said anchoring means (22,23,24,25) comprises a plurality of anchoring formations extending into the component (R). 10. A razor component (R) according to Claim 9, characterised in that each anchoring formation (22,23,24,25) has a free end (22′,23′,24′,25′)which includes a portion disposed at an angle to, and/or of greater thickness than, the rest of the formation. 11. A razor component (R) according to Claim 9 or 10, characterised in that each anchoring formation (22,23,24,25) comprises a downwardly directed substantially T-shaped formation, the top (22′,23′,24′,25′) of the T is substantially parallel to the strip (20) and abuts a portion of the component substantially parallel to the top of the upper surface of the component, and the leg (22′,23′,24′,25) of the T extends through the component between the upper surface and said portion. 12. A razor component (R) according to Claim 9, 10 or 11, characterised in that the strip (20) is molded in place after a molding operation forming the component (R).

Inventors: BRAUN, DAVID B., MOTTA, VINCENT C., VREELAND, WILLIAM E.
Applicants: WARNER-LAMBERT COMPANY
Application year: 1988
Main classification: B26B21
IPC codes: B26B21