Shaving system

Abstract: The invention relates to a wet-shaving system comprising a blade member and an external skin engaging member (64) adjacent said blade member, said skin engaging member comprising an elongated sheath having a skin engaging surface (74) extending along an outer surface thereof, said sheath comprising a water-soluble shaving aid, and a rigid core (70) extending actually throughout said sheath, said core comprising a water-insoluble polymer.

Description: This invention relates to a wet shaving system of the type disclosed in US-A-5.113.585 to Rogers et al. The present invention resides broadly in providing the skin engaging cap and/or guard surfaces with configurations which reduce frictional drag of the razor across the skin. In shaving systems of the wet shave type, factors such as the frictional drag of the razor across the skin, the force needed to sever hairs, and irritation of pre-existing skin damage can create a degree of shaving discomfort. Discomfort, and other problems accompanying wet shaving systems, can be alleviated by the application of shaving aids to the skin. Shaving aids may be applied prior to, during, or after shaving. A number of problems accompany the use of pre- and post-applied shaving aids. Pre-applied shaving aids can evaporate or can be carried away from the site of application by repeated strokes of the razor. Post-applied shaving aids are not present on the skin during shaving and thus their application may be too late to prevent an unwanted affect. Both pre-applied and post-applied shaving aids add additional steps to the shaving process. Proposals have been made to incorporate a shaving aid e.g., lubricant, whisker softener, razor cleanser, medicinal agent, cosmetic agent or combination thereof, into a razor, e.g., by depositing a shaving aid in a recess on the razor, by incorporating a shaving aid directly into one or more molded polymeric components of the razor, by adhesively securing a shaving aid composite to the razor, and by use of a mechanical connection between a shaving aid composite and the razor as is the case of the devices disclosed in US-A-4 562 644 and US-A-4 875 287. A water-soluble shaving aid, e.g. polyethylene oxide, has been mixed with non-water-soluble material, e.g., a polystyrene polymer, to form an insoluble polymer/soluble shaving aid composite. The composite has been mounted on razor and shaving cartridge structures, adjacent the shaving edge or edges, of single or multiple blade shaving system. Upon exposure to water, the water-soluble shaving aid leaches from the composite onto the skin. Extruded composites with relatively large amounts of shaving agent material (up to 80% by weight) and relatively low amounts of water insoluble matrix material (as little as 20% by weight) are relatively weak and have a tendency towards mechanical failure, both in assembly and in use. Increase in mechanical strength can be obtained with increased amounts of the matrix material. However, such increase reduces the releasability of the shaving material. In accordance with one aspect of the invention, there is provided a shaving unit that comprises at least one blade and a skin engaging member that has a surface for engaging the user's skin adjacent the blade edge. The shaving unit may be of a disposable cartridge type adapted for coupling to and uncoupling from a razor handle or may be integral with a handle so that the complete razor is discarded as a unit when the blade or blades become dulled. The blade edge (or edges) cooperate with skin-engaging surfaces to define structure having a desired geometry. The skin engaging member is comprised of an elongated sheath made of a mixture of water insoluble matrix material and an effective amount of shaving aid material and a rigid core material extending axially throughout said sheath. The axial position of the core need not be through the central axis. It is desired to provide a skin engaging member with improved mechanical strength. Also desired is to provide a skin engaging member with improved shaving aid material release characteristics. Further, it is desired to provide a wear indicating skin engaging member. These problems are solved by a skin engaging member with the features of claim 1. FIG. 1 is a perspective view of a razor unit in accordance with the invention; FIG. 2 is a sectional view taken along the line 2-2 of FIG. 1; FIG. 3 is a perspective view of another razor unit in accordance with the invention; FIG. 4 is an enlarged perspective view of a skin engaging member of the present invention; FIG. 5 is sectional view taken along the line 3-3 of FIG. 4; FIG. 6-7 are sectional views in accordance with FIG. 5 wherein alternate core geometry's are depicted; FIG. 8 is yet another cross-sectional depiction; FIG. 9 is a schematic cross-section diagram of an extrusion die suitable for manufacturing the skin engaging member of FIG. 4. The shaving unit 10 shown in FIGS. 1 and 2 includes base or platform member 12 molded of high impact polystyrene that includes integral coupling groove structure 14 for attachment to a razor handle and guard structure 16 that defines a transversely extending forward skin engaging surface 18. On the upper surface of platform 12 are disposed steel leading blade 20 having a sharpened edge 22, steel following blade 24 having sharpened edge 26, and aluminum spacer member 28 that maintains blades 20 and 24 in spaced relation. Cap member 30 is molded of high impact polystyrene and has body portion 32 that defines skin engaging surface 34 that extends transversely between forwardly projecting end walls 36 and has a front edge 38 that is disposed rearwardly of blade edge 26. Integral rivet portions 40 extend downwardly from transversely extending body portion 32 and pass through holes in blades 20 and 24, spacer 28, and platform 12 to secure cap 30, blades 20, 24 and spacer 28 on platform 12. Adhesively affixed to skin engaging surface 34 is skin engaging member 42. The shaving unit 50 shown in FIG. 3 is of the type shown in Jacobson U.S. Patent 4,586,255 and includes body 52 with front portion 54 and-rear portion 56. Resiliently secured in body 52 are guard member 58, leading blade unit 60 and trailing blade unit 62. A shaving aid composite in the form of elongated insert member 64 is frictionally locked in opening 66 of rear portion 56. FIG's. 4-9 generally depict variations on the present invention. As used herein, the term "core" refers to an internal portion of a skin engaging member as examines at the cross section. The core typically runs throughout the skin engaging member along an axis. The axis need not be the central axis. The FIG's. designate the core as 70. Embodiments of the present invention have at least one core element. As used herein, the term "sheath" refers to an outer coating layer(s) over the core material 13. The FIG's. designate sheaths as 72. Referring now to the drawings, and in particular to FIG. 4, there is shown an elongated skin engaging member 64. The member 64 has a skin engaging surface 74 and an elongated insert element 76. The insert member 76 is designed to frictionally lock in an opening as shown in FIG. 3. The skin engaging member further comprises a rigid core material 70 which is surrounded by a sheath material made of a mixture of water insoluble matrix material and an effective amount of shaving aid material. The sheath material includes from 5% to 30% by weight preferably from 5% to about 15% of the water insoluble matrix material and from 70% to 95% by weight of the shaving aid preferably from about 85% to 95% material. Suitable water insoluble matrix materials include for example, nylon, ethylene-vinyl acetate copolymer, polyethylene, polypropylene, polystyrene, polyacetyl and combinations. Suitable shaving aid materials include, for example, polyethylene oxide, polyvinyl pyrrolidone, polyacrylamide, hydroxypropyl cellulose, polyvinyl imidazoline, polyethylene glycol, polyvinyl alcohol, methylcellulose, starch, water soluble vinyl polymers (Carbopol® brand sold by B.F. Goodrich), polyhydroxyethylmethacrylate, silicone copolymers, sucrose stearate, vitamin E, panthenol, aloe, essential oils such as menthol and combinations. The sheath may include additional components such as: plastisizers, such as polyethylene glycol; beard softeners; additional lubricants, such as silicone oil, Teflon® polytetrafluoroethylene powders (manufactured by DuPont), and waxes; shaving aids, such as menthol, eugenol, eucalyptol, safrol and methyl salicylate; fillers, such as calcium carbonate, mica and fibers; tackifiers such as Hercules Regalrez 1094 and 1126; fragrances; antipruritic/counterirritant materials; antimicrobial/keratolytic materials such as Resorcinol, anti-inflammatory agents such as Candilla wax and glycyrrhetinic acid; astringents such as zinc sulfate; surfactants such as pluronic and iconol materials; compatibilizers such as styrene-b-EO copolymers; and, blowing agents such as Uniroyal Celogen Aznp 130. These additives may leach from the surface to provide improved shaving. These components could be dispersed throughout the sheath or alternatively, a second, outer sheath containing the additional element could be extruded or merely coated over the primary sheath. The present skin engaging member is produced by a coextrusion process whereby a rigid core material displaces a portion of the sheath material. The nature and relative portions of the sheath and core polymeric materials being such that the akin engaging member has adequate mechanical strength, both as initially produced and after a significant amount of water soluble material has been leached out, the quantity of the water-soluble material being sufficient to provide effective shaving assistance, such as lubrication, for the entire expected life of the blade or blades. The function of the core material is not only to provide additional rigidity but to displace trapped shaving aid material. In conventional skin engaging members, such as those described in U.S. Pat. Nos. 5,063,667; 5,095,619; and 5,113,585, a significant amount of shaving aid material is trapped within the insoluble matrix. By displacing it closer to the skin engaging surface 74, diffusional paths are reduced and more efficient delivery is achieved. Furthermore, the core material provides additional mechanical strength for the attaching mechanism, if used. The core material must have sufficient mechanical strength and rigidity to provide adequate mechanical strength to the entire skin engaging member, both as initially produced and after a significant amount of water insoluble material has been leached out of the sheath. Preferably, the core material can be made from a non-water soluble plastic resin or a blend consisting of at least about 50% of non-water soluble plastic resin to prevent the core from disintegrating. Water-soluble resins for use in such blends include polyethylene oxide, polyvinyl pyrrolidone; polyacrylamide, hydroxypropyl cellulose, polyvinyl imidazoline, polyethylene glycol, polyvinyl alcohol, methylcellulose, starch, water-soluble vinyl polymers (Carbopol® brand sold by B.F. Goodrich), polyhydroxyethyl methacrylate, and combinations thereof. Core material suitable for use in the present invention include polystyrene, high impact polystyrene, polypropylene, filled polypropylene, nylon, and blends such as 70% nylon/30% polyethylene oxide, 60% polystyrene/40% polyethylene oxide. Optionally, the core material can include additives such as lubricants foaming agents, microspheres, baby powders, fillers such as CaCO 3 , colorants such as TiO 2 silicone copolymers, sucrose stearate, vitamin E, panthenol, aloe, essential oils, e.g. menthol, and combinations thereof. In an embodiment of the present invention a wear indicating effect is produced when the sheath material and the core material are made of disparately colored materials (e.g. white colored sheath and blue colored core). Upon use, the sheath material over the skin engaging surface is typically worn off through use. With sufficient use, a second colored region represented by the core is exposed, thus, providing the user with and indication that the shaving unit and/or skin engaging surface have reached their effective life. In a preferred embodiment, the sheath material consists of polyethylene oxide/polystyrene mixture which is white in color and the core consists of nylon and/or styrene which has been colored with a FD&C #2 dye. Other suitable dyes or pigments include FD&C Red No. 40, Erythrosine (FD&C Red No. 3), Brilliant Blue FCF (FD&C Blue No. 1), Indigotine (FD&C Blue No. 2), Tartozine (FD&C Yellow No. 5), Sunset Yellow FCF (FD&C Yellow No. 6) and Fast Green FCF (FD&C Green No. 3) and Titanium Dioxide. Figure 5 depicts a cross section of an alternate skin engaging member. The core material 70, follows the genaral contours of the surface defined by the outside of the sheath material. Figure 6 depicts a slight variation on that theme where a thicker sheath layer is provided along the skin engaging surface 74. Still further, Figure 7 provides a cross-section wherein a very high degree of sheath material is present along the skin engaging surface. Finally, Figure 8 depicts the skin engaging member depicted in Figures 1 and 2. It is interesting to note that the core in this case provides mechanical strength to the unit yet is not vital to the mechanical locking of the unit. The skin engaging member of Figures 1 and 2 are affixed by adhesive. According to the present invention, the skin engaging members may be a affixed by adhesive such as Loctite Super Bonder 499, mechanical locking mechanism, thermal welds. Figure 9 is a schematic cross section diagram of an extrusion die suitable for manufacturing the skin engaging member of the present invention. Core material 80 is fed into the intrusion die 81 by an extrusion screw, hot melt or other suitable means. In the core inlet port 82 the tight core orifice 83 encounters the sheath material 84 wherein the core becomes encapsulated by the sheath material when viewed in a transverse cross section to the flow of the die material. The encapsulated core then proceeds to the die outlet 55 wherein the continuous skin engaging members can be cured and/or drawn down to provide the appropriate dimensions. Also, it should be noted that the core material could consist of solid plastic material which is fed in through a conventional die to produce an encapsulated skin engaging member. For general discussion of coextrusion technology see Levi, Plastics Extrusion Technology Handbook , Industrial Press Inc., pages 168-188(1981), incorporated herein by reference. After the continuous skin engaging members are produced, the strand is sent for further processing where it is typically drawn down to the correct size and cut to length suitable for implant into the body of a razor blade cartridge. This cutting can be achieved by knife edge cutting, lasers or water lasers. The skin engaging surfaces of the present invention typically are rectangular in shape with a width of from about 1,27 mm (0.05 inches)to about 2,54 mm (0.1 inches) and a length of about 30 mm (1.2 inches). Applicant considers embodiments within the scope of the claims to be part of the present invention. For example, non-rectangular skin engaging surface areas may be utilized (such as ovals) and non-flat surface patterns could be utilized. These and other equivalent embodiments are also contemplated by the present invention. The present invention and the manner of making and using the same should be evident from the following examples: EXAMPLES The following samples were coextruded with a cross-section as in FIG. 5. Example 5 is not within the scope of the claims. Example 12 The following procedure can be used to produce a skin engaging member of the type depicted in Figure 4. The extrusion equipment includes two single-screw extruders, a die cross-head, a cooling channel, and a puller. The strip extruded from the extruders is pulled through a cooling tunnel by a Farris puller (a take-off machine) at a speed of approximately 10 feet per minute with minimum tension on the strip. The strip is air-cooled by blowing dry compressed air into the tunnel at approximately 10 CFM. The extrudate is kept in a cool, dry room. The core blend (70% Zytel 330 brand amorphous nylon/blue pigment, 30% ethylene oxide/styrene blend 60/40 is extruded through the first 3/4" Haake extruder (barrel pressure of approx. 29,6·10 6 Pa (4,343 psi), and temperature of 180°C.). The sheath blend (80% polyethylene oxide/styrene 60/40, 14% polystyrene/white color, 3% PEG, and 3% PVA 2025) is extruded through the second 3/4" Haake extruder (barrel pressure of approx. 42,2·10 6 Pa (6,131 psi) and temperature of 180°C.). The two materials are then joined and are fed through a cross-head at a temperature of 180°C., die temperature of 180°C., and die pressure of approx. 24,8·10 6 Pa (3,600 psi) to form a continuous lubricating strip. The line speed is approximately 5 mm/s (10 FPM).

Claims: A wet shaving system comprising a blade member and an external skin engaging member adjacent said blade member, said external skin engaging member comprising a water soluble shaving aid and a water insoluble matrix, characterized in that the skin engaging member comprises an elongated sheath (72) having a skin engaging surface extending along an outer surface thereof, said sheath (72) comprising a mixture including by weight 5% to 30% of said water insoluble matrix and 70% to 95% of said water soluble shaving aid and a rigid core (70) extending axially throughout said sheath, said core comprising a water insoluble polymer. The wet shaving system of any of the preceding claims, wherein said core comprises at least 50% water insoluble polymer. The wet shaving system of any of claims 1 or 2, wherein said sheath comprises 5% to 15% of said water insoluble matrix. The wet shaving system of any of the preceding claims, wherein said sheath comprises 85% to 95% of said water soluble shaving aid. The wet shaving system of any of claims 2 to 4, wherein said core additionally comprises a water soluble polymer. The wet shaving system of any of the preceding claims, wherein said shaving aid comprises polyethylene oxide, polyvinyl pyrrolidone, polyacrylamide, hydroxypropyl cellulose, polyvinyl imidazoline, polyethylene glycol, polyvinyl alcohol, methyl cellulose, starch, water soluble vinyl polymers, polyhydroxyethylmethacrylate, silicone copolymers, sucrose stearate, vitamin E, panthenol, aloe, essential oils or combinations thereof. The wet shaving system of claim 6, wherein said water soluble shaving aid comprises polyethylene oxide. The wet shaving system of claim 7, wherein said sheath comprises from 65% to 82% of said polyethylene oxide. The wet shaving system of any of the preceding claims, wherein said water insoluble polymer comprises polystyrene, high impact polystyrene, polypropylene, filled polypropylene, or nylon. The wet shaving system of any of the preceding claims, wherein said water insoluble matrix comprises nylon, ethylene vinyl acetate, polyethylene, polypropylene, polystyrene or polyacetal. The wet shaving system of any of the preceding claims, wherein said sheath and said core are coextruded. The wet shaving system of any of the preceding claims, wherein said sheath and said core are disparately colored.

Inventors: TSENG MINGCHIH M, TSENG, MINGCHIH M.
Applicants: GILLETTE CO, THE GILLETTE COMPANY
Application year: 1995
Main classification: B26B21
IPC codes: B26B21