Abstract:
A device for the removal of unwanted excess skin from an area of the human body to be treated in which a carrier encases a planing blade. The blade body is formed from a blank and co planer uniform opposed cutting edges protrude upwardly in a uniform transition beyond the plane of the blank in order to contact the skin to be removed while the device is moved to and fro across the area of the skin to be treated.

Description:
The present invention relates generally to devices for removal of dead skin, callouses and other unsightly buildup of excess skin on the feet, elbows and other areas of the human body and, more particularly, to a manually operated device which painlessly removes such unsightly skin without damaging or unnecessarily abrading good skin. 
     CROSS-REFERENCE TO RELATED APPLICATIONS 
     Not applicable. 
     STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT 
     Not applicable 
     INCORPORATION-BY-REFERENCE OF MATERIAL SUBMITTED ON A COMPACT DISC 
     Not applicable. 
     REFERENCE TO A “MICROFICHE APPENDIX” 
     Not applicable. 
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     A callous is typically a buildup of a thickened outer layer of skin. Corns have an inner core which penetrates the epidermis. Both tend to develop from some irritant, and, while callouses are typically not painful, corns may well be painful and both conditions are unsightly and often uncomfortable. 
     Concern for corns, callouses and other skin buildups dates back to at least 2400 B.C., as evidenced by reliefs and other evidence found at, and in, the Tomb of the Physician in ancient Egypt. Hippocrates expressed the need for care of such problems in pre biblical times in Greece. 
     Today, skin care generally, and the removal of corns, callouses, and other unsightly skin buildups, has become a billion dollar business, according to the American Academy of Dermatology. 
     The number and type of products for removal of dead skin is voluminous, ranging from abrasives such as sandpaper, rasps and emery boards, which simply abrade the skin, to blade type devices such as razors, knives and scrapers, which are prominent in the art, and which actually cut away unwanted skin, to pierced metal devices. 
     In the pierced metal devices, holes are punched into a metal sheet, causing a series of raised, essentially conical, bumps, in which the continuous edge about the opening is the result of the tearing of the metal by the punch, but because of its macroscopic size, serves to remove unwanted skin by abrading or scraping it off. 
     There are also myriad, often perfumed, chemicals available to consumers, which chemically soften and dissolve such buildups of unwanted and unsightly skin. 
     All of these products, whether used for cosmetic or medical purposes, are susceptible to excesses which can result in damage to viable growing tissue. 
     2. Description of Related Art 
     At least some of the various forms of devices for the removal of unwanted skin have been patented, although many simply come to the market in neat and attractive packaging. One of the earlier patents related to the use of a blade for the trimming and removal of corns and callouses was issued to Jackson as U.S. Pat. No. 1,714,371. Jackson&#39;s device resembles the venerable safety razor and professes to eliminate deep cuts. 
     Several other blade type devices have achieved patent status, among them Potvin U.S. Pat. No. 2,612,683 in which the head is formed with a recess, which receives a flat blade used to trim away excess dead skin. Potvin also issued U.S. Pat. No. 2,573,487 in which the blade is recessed behind a head  4 . 
     Other blade type callous removers include Pracht U.S. Pat. No. 3,636,625, and Gilhaus et. al U.S. Pat. No. 3,797,505. 
     The art is replete with sand papers and emery boards, all in common usage. Many are encased in an attractive and decorative handle, primarily for sales purposes. Others are powered, whether by battery or other electrical means. 
     At least one such file has been patented as a nail file, i.e., Haga U.S. Pat. No. 4,422,465. While not specifically designed as a device for removing excess skin, it nonetheless seemingly has that capacity, and it is formed by a photochemical etching process, although the process differs in significant ways from that employed by the present invention. 
     BRIEF SUMMARY OF THE INVENTION 
     Notwithstanding the expansive variety of manually manipulated products for the removal of unsightly accumulation of skin in the form of callouses, corns, and the like, the consumer continues to seek out a product which is affordable, yet very safe in its use, and easily cleaned and stored until next used. Such is the micro slicing product of the present invention. 
     Coincident with the foregoing, it is an objective of the present invention to provide the consumer with a skin care product which is trustworthy and very simple to use, while providing significantly improved skin removal. 
     It is another objective of the present invention to provide a skin care device which channels away, removed epidermal remnants, dirt and bacteria that have been excised from an area of the body being treated, so that there will be no clogging or impairment of the ability of the cutting edge to achieve full contact with the area to be treated and, further, will not deposit grit, or the like, while providing exceptional cleaning characteristics. 
     It is a further objective of the present invention to provide a manually manipulable device for the removal of unsightly skin buildup, the cutting surface of which is formed, at least in part, by a photochemical etching process, as distinguished, e.g., from a metal piercing process, to provide a sharper, more durable, cutting or planing surface, which leaves the surface being treated relatively smooth, rather than the roughened surface to be expected from use of existing files or emery boards and, generally, by metal piercing methods of formation. 
     It is yet another, and still further, objective of the present invention to provide a device as described which is capable of at least bi_directional, and in other embodiments, multi-directional, operation. 
     The foregoing objects and advantages of the present invention, in addition to others not specifically articulated, will occur to those skilled in the art when the following Detailed Description of a Preferred Embodiment is read in conjunction with the accompanying drawings, wherein: 
    
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS 
         FIG. 1  is a perspective view of one embodiment of the present invention illustrating a palm controlled carrier device as viewed from above; 
         FIG. 2  is an additional perspective view of the embodiment of  FIG. 1 , as viewed from beneath the device, and further illustrating a cap which protects the cutting edges of the device from dirt, lint and the like when not in use; 
         FIG. 3  is a top plan view of the palm held device of  FIG. 1 , illustrating a pattern of cutting teeth formed on a blade body secured in the carrier of  FIG. 1 ; 
         FIG. 4  is a view, in perspective, of a carrier device which shows the blade body in place, and includes an elongated handle; 
         FIG. 5  is a top plan view of the carrier device of  FIG. 4 ; 
         FIG. 6  is top plan view of a blade body constructed in accordance with the present invention; 
         FIG. 7  is a perspective view of the blade body of  FIG. 6  as seen from the underside thereof; 
         FIG. 8  is an enlarged, fragmented top plan view of a portion of the cutter blade of  FIG. 6 , illustrating the raised cutting surfaces of that cutter blade; 
         FIG. 9  is a side elevation of the tooth configuration of the plane cutter of  FIG. 8  taken along lines  9 - 9  of  FIG. 8 ; 
         FIG. 10  illustrates an alternative to the structure; and, 
         FIG. 11  is a partial sectional view of the plane body taken along lines  11 - 11  of  FIG. 6 . 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     With reference now to the drawings, and initially to  FIGS. 1 and 9 , a blade type device for the manual removal of unwanted and unsightly skin, constructed in accordance with the present invention, is depicted at  20 . The device  20  comprises a carrier  22  which supports a blade body  24 . 
     In the  FIG. 1  embodiment, the carrier  22  is adapted to be held in the palm of one&#39;s hand, such that the blade body faces away from the palm and is movable against and across the area to be treated while in that position. 
     The carrier, in its illustrated form, is of an upstanding shell having a generally oval shape as viewed in  FIGS. 1 and 3 , for example. It will be appreciated that some variation in the specific shape is within the contemplation of the invention so long as it conforms to the purposes attributable to it. 
     The shell has an upper ridge  26 , and a lower ridge  28 , with a center section  31 . The center section has a generally concave side wall which enhances one&#39;s ability to grip the device. The carrier, for economy and simplicity&#39;s sake, is preferably made of a moldable material, such as any number of well known plastic materials, although it will become apparent that any number of formable materials, including wood and certain metals, could be effectively used. 
     In keeping with the safety aspects of the invention, and referring to  FIG. 2 , an auxiliary cap  33  may be provided. The cap  33  fits about and snaps into place about the lower ridge  28  of the carrier  22 . The free surface  35  of the cap may have an abrasive coating thereon to serve as a buffer to smooth any skin which may have been roughened during the skin removal process. 
     In order to maximize the efficiency of the device while achieving optimum safety and smoothness as the dead skin is removed from the area to be treated, the blade body  24 , includes a tooth configuration which provides, in accordance with the invention, a bi-directional planing action when moved to and fro across the user&#39;s unsightly build up of skin to be treated. 
     Referring to  FIGS. 6 and 7 , the blade body  24  is formed from a blank  25  of deformable material and is shaped to fit in a carrier, such as carrier  22 . As shown, it is of a generally oval configuration with a uniform array of teeth  73  formed thereon. 
     The skin care device  20  of the present invention is so designed as to lend itself to a highly efficient manufacturing process in which the blade body  24 , and the carrier  22  therefor, may be formed into a fully integrated unit. More specifically, the blade body  24  is ideally suited to be formed by a photochemical etching process and, in particular, a single sided etching process such as that disclosed and taught in Sturtevant U.S. Pat. No. 5,100,506, which process provides an exceptionally uniform sharp edge. It will be understood, however, that other methods of manufacture, consistent with the objectives to be achieved, are within the contemplation of the invention. 
     A preferred manufacturing process involves the initial etching of a flat blank of material to form the outer profile of the blade body and the teeth within that profile. Referring to  FIGS. 6 and 7 , the periphery of the blade body  24  is formed with a series of tabs  53  which circumscribe the blade body. The blank so formed is then placed in a die, or mold, where the tabs  53  are bent, referring to  FIG. 6 , upon compression of the blank in the die and a moldable material, such as plastic, is injected, or otherwise introduced into the die. 
     In a preferred method of manufacture, the moldable material forms the carrier within the die about the blade body, simultaneously encapsulating the tabs in the moldable material, thereby securing the blade in the carrier. It is recognized that other manufacturing procedures may be used to create the device of the present invention without departure from the essential features thereof. The carrier comprises a continuous side wall completely circumscribing the blade body and projecting below the plane of the blank, fixedly and permanently holding the blade body in the carrier about a peripheral region of the blade body, with the carrier not protruding above the plane of the blank. 
     While the palm held carrier  20  is very useable for many people, there are instances, and locations, of unsightly skin buildup where such a carrier is less than helpful. For those folks, the invention contemplates the use of other carriers, e.g., the hand held carrier  60 , illustrated in  FIGS. 4 and 5 . 
     An ergonomically pleasant carrier  60  is formed with a head section  62 , which is formed, or otherwise provided, at the end of a handle section  64 . The head section  62  is oval in configuration and adapted to receive a blade body, e.g., the blade body  24 . The handle section  64  is gently curved away from the head section to the tip  66 , where an aperture is formed to permit storage of the device on a hook, or the like, as desired. The handle provides to the user an ability to reach to otherwise less accessible areas of the body in order to remove unwanted skin. 
     The present invention contemplates a blade body which is bi_directional in operation. Referring to  FIGS. 6 and 7 , such a blade body  71  is illustrated. The blade body  71  is conveniently formed from a blank having an oval shape, although clearly, if the carrier is adapted to receive another shape, it would be readily accomplished. Several rows of bi-directional teeth  73  are formed in transverse relation to the longitudinal axis of the blade, perhaps best illustrated in  FIG. 6 . 
     Considering now  FIGS. 8 through 11 , several amplified views of a bi-directional tooth of the present invention are illustrated in some detail. Each tooth  73  is provided with oppositely extending elements defining oppositely extending, preferably elements of substantially equal length, each of said elements termination in discreet opposed cutting edges  75  and  76 . Each of the edges, as illustrated, coplanar and raised by a predetermined small amount from the plane of the blank  78 , from which the cutting edges are formed in order that the cutting edges are exposed to the area of skin to be treated. The height, “H” of the cutting edges  75 ,  76  relative to the plane of the blank  78  is carefully controlled to a dimension of no more than 0.025″ in order to assure the user that only a very minimal amount of excess skin would be removed in a given stroke of the device. 
     As may be viewed in  FIG. 8 , the raised edges define, with the blank  25  from which the blade is formed, a channel indicated by arrows  87 . The channel provides for a controlled tunnel-like chute, beneath the cutting edge, through which material, in the nature of dead skin, is quickly funneled away from the area to be treated and through the openings  83 . 
     As previously alluded to, in forming the finished blade body covered by the present invention, a photo chemical etching process, such as that disclosed in the aforementioned Sturtevant et al. &#39;506 patent, is ideally suited to the manufacture of the blade body. By using such an etching process, each opening  83  is first formed in the blank  78 , and the profile of the blade is thus defined. 
     The resultant opening  83  is defined by peripheral edges. Opposed ones of the edges,  75 ,  76 , in the present scenario, resulting from the formation of that opening, are upset, by pressing them in a die, to move the edges by a height “H” above the plane of the blank  78 . 
     Furthermore, upsetting the edges  75  and  76  in a die provides a softer transition between an adjacent edge and the raised or upset edge. As a result, there is less likelihood that debris of any kind would hang up or accumulate in that area, thereby enhancing the integrity of the device. 
     In summary this novel device is provided for the gentle, yet safe, removal, by means of a to and fro planing action, of unwanted skin buildup in the nature of callouses and corns. The invention contemplates two convenient carrier styles which receive the blade body, providing the consumer with choices to fit his or her particular needs. 
     It will be apparent to those skilled in the art that minor variations in one or more of the elements of the invention are possible without departure from the invention, wherein it is claimed: