Abstract:
The present invention is a razor blade carrier having a base with at least two stepped protrusion extending outwardly therefrom. The stepped protrusion define at least two landing positions that support a portion of the razor blade. The landing surfaces of the stepped protrusions cooperate to define at least two razor blade locations. The razor blade carrier is used in a razor cartridge.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
   This application is a division of U.S. patent application Ser. No. 10/765,549, filed Jan. 27, 2004, the contents of which are incorporated herein in their entirety, and which application is entitled to the benefit of and incorporates by reference essential subject matter disclosed in Provisional Patent Application No. 60/442,990 filed on Jan. 28, 2003. 

   FIELD OF THE INVENTION 
   The invention relates generally to shaving implements for use on hirsute surfaces and more specifically to a device for supporting razor blades forming part of a razor cartridge. 
   BACKGROUND OF THE INVENTION 
   Modern safety razors typically include a razor cartridge that supports at least one razor blade for removing hair from hirsute surfaces during a shaving operation. These razor cartridges typically incorporate two or more razor blades to allow for greater hair removal in a single pass of the razor. 
   The positioning of multiple razor blades within a small, often disposable razor cartridge, can be complex. For example, to ensure an acceptably close shave and to minimize the potential for cutting, abrading, or nicking the skin, or uncomfortably pulling the hair during a shaving operation the orientation of the razor blades in a multi-blade razor cartridge important. A problem associated with prior art razor cartridges concerns the difficulties associated with establishing and maintaining a desired blade alignment and orientation. This is due in part to the fact that the razor cartridge consists of a multiplicity of parts including spacers. Each of these parts has associated with it an acceptable tolerance range. When assembled these tolerance ranges can sometimes become additive thereby resulting in a less than desirable alignment of the razor blades. In addition, due to the miniature nature of the parts that comprise the razor cartridge, difficulties in assembly can further misorient components. As a result of the multiple parts, manufacturing is expensive with quality control being problematic. 
   In addition, the multiple parts cause undesirable blockages within the razor cartridge. In a wet shaving operation wherein a shaving aid, such as a cream or gel is employed, debris, such as hair and shaving cream, may become lodged within the multi- blade razor cartridge between the razor blades. The debris is customarily removed from the multi-blade razor cartridge by flushing with water, however, blockages due to the positioning of features and components in the cartridge can make removal of the debris difficult or impossible. In extreme cases, blockages can cause a buildup of debris within the cartridge that alters the spacing between the blades or causes the development of surfaces that prevent the skin from properly engaging the blades leading to a shaving outcome that is less than optimum. 
   Based on the foregoing, it is an object of the present invention to improve upon or overcome the problems associated with prior art razors and cartridges. 
   SUMMARY OF THE INVENTION 
   The present invention is directed in one aspect to a razor blade platform that includes a base portion having at least two projections extending therefrom. Each projection defines at least a pair of approximately parallel spaced apart support surfaces. Each of the support surfaces on one of the projections is approximately laterally aligned with a corresponding support surface defined by the other projection and is adapted to carry a portion of a razor blade. 
   In an embodiment of the present invention, the razor blade platform includes a plurality of projections, a portion of which define slots that are open at one end with one of the above-described support surfaces partially defining each slot. A portion of a razor blade to be mounted onto the blade platform, is slidably received within each slot and engages an abutment surface forming part of the slot portion of a rear edge defined by each razor blade to be mounted to the blade thereby ensuring proper alignment of the razor blade relative to the blade platform. Preferably, the blade platform is formed from a single piece of polymeric material and defines at least one aperture extending therethrough to allow shaving debris to be washed from the blade platform. 
   The present invention also resides in a second aspect to a razor cartridge that includes a first cover that defines an opening and is adapted to overlie the above-described razor blade platform. The razor blade platform has at least two razor blades mounted thereon so that at least a portion of the cutting edges of the razor blades is positioned within the first cover opening and thereby exposed. A second cover is coupled to the first cover and together they cooperate to define an interior area in which the blade platform is located. 
   In one embodiment, a thin wire is wrapped around the razor cartridge and over the opening defined by the first cover. The wrapped wire extends across the opening transversely of the cutting edges to minimize the potential for skin to extrude between the razor blades during a shaving operation. In addition, the second cover preferably defines an aperture that cooperates with any apertures or passages in the blade platform to allow shaving debris to be washed from the razor cartridge. 
   The present invention resides in yet another aspect, in a method for loading razor blades into a blade platform for use in a razor cartridge. 
   Initially, a blade platform is provided that defines at least two support surfaces each adapted to carry a portion of a razor blade. A blade support is also provided and defines at least two mating support surfaces positioned to be approximately coincident with the support surfaces defined by the blade platform when the blade platform and the blade support are moved into proximity with one another. The blade support also includes means for releasably retaining at least two razor blades thereon. At least two razor blades are releasably mounted to the blade support which is then moved into proximity with the blade platform so that a portion of the razor blades engage the support surfaces defined by the blade platform. The razor blades are then adhered to the blade platform and at least one of the blade support and the blade platform is moved away from the other of the blade support and the blade platform so that the razor blades remain adhered to the blade platform. 
   In another embodiment of the method of the present invention, the razor blades are mounted onto a retainer so that they can be rotatably, or angularly, moved into position on the razor blade platform. 

   
     BRIEF DESCRIPTION OF THE DRAWINGS 
       FIG. 1  is an exploded perspective view illustrating a razor blade platform of the present invention along with razor blades and a wire wrap to be supported by the razor blade platform. 
       FIG. 2  is a cross sectional view of the razor blade platform of  FIG. 1  taken along line  2 - 2 . 
       FIG. 3  is a partial sectional view of an alternative embodiment of the razor blade platform of  FIG. 1  taken along line  2 - 2 . 
       FIG. 4  is a bottom view of a razor cartridge that employs the razor blade platform of  FIG. 1 . 
       FIG. 5  is a rear view of a razor cartridge employing the razor blade platform of  FIG. 1 . 
       FIG. 6  is a side view of a razor cartridge employing the razor blade platform of  FIG. 1 . 
       FIG. 7  is a front view of a razor cartridge employing the razor blade platform of  FIG. 1 . 
       FIG. 8  is a top view of a razor cartridge employing the razor blade platform of  FIG. 1 . 
       FIG. 9  is an exploded perspective view of a razor cartridge employing the razor blade platform of  FIG. 1 . 
       FIG. 10  schematically illustrates a method for mounting razor blades to a razor blade platform of the present invention. 
       FIG. 11  schematically illustrates another embodiment of a method for mounting razor blades to a razor blade platform of the present invention. 
   

   DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS 
   As shown in  FIG. 1 , a razor blade platform embodying the present invention and generally denoted by the reference number  10 , includes a base portion  12  having a plurality of projections  14  extending outwardly therefrom. Each projection  14  defines at least a pair of spaced apart, and in the illustrated embodiment, stepped, support surfaces  16 . Each projection  14  has four approximately parallel support surfaces  16 . Each support surface  16  on one of the projections  14  being approximately laterally aligned with a corresponding support surface on the next successive projection. Each of the support surfaces  16  is adapted to support a portion of a razor blade  18 , so that the razor blade extends across, and is carried by the approximately laterally aligned support surfaces. As shown in  FIG. 1 , the razor blade platform  10  is adapted to carry four razor blades  18 . However, the present invention is not limited in this regard as the razor blade platform  10  can be configure to carry more than, or less than four razor blades  18 . 
   In the preferred embodiment of the present invention, the razor blade platform  10  is formed from, or into a single piece of, preferably polymeric, material. The razor blade platform  10  can also be made by injection molding. However, the present invention is not limited in this regard as the razor blade platform can be made from different materials, such as metals or elastomers. 
   The base portion  12  has passages  20  therein to allow for the removal of debris, such as skin, hair, and shaving aid, that can become lodged between the razor blades  18  and/or between the razor blades  18  and the base portion  12  during a shaving operation. 
   There may be any number of support surfaces  16  on a projection  14 . These support surfaces  16  can be equally spaced or not. In some cases, some of the support surfaces  16  could be equally spaced and others not. In addition, the area defined by each of the support surfaces  16  may vary. The support surfaces  16  are not necessarily planar and may be undulating or have troughs, such an embodiment is illustrated in  FIG. 3 . 
   Referring to  FIG. 2 , a portion of the plurality of projections  14  include slots  22 , open at one end and defined in-part by one of the support surfaces  16 . As shown, an overhanging portion  24 , a surface of which defines a support surface  16  can also be established with a surface  26  generally opposite the support surface  16  acting to define in-part one of the slots  22 . Depending upon the design of a shaving implement employing the razor blade platform  10 , the overhang portion  24  can include a distal end  28  positioned such that skin does not extrude too far into an interstitial space  30  between the razor blades  18  during a shaving operation. The distal end  28  could also have, if desired, a chamfer  32  creating a larger opening  34  into the slot  22 . 
   In addition to the above-described support surfaces  16 , the projections  14  also define abutment surfaces  36  that provide for alignment of the razor blades  18  when positioned on the razor blade platform  10 . Accordingly, when a razor blade  18  is mounted onto the razor blade platform  10 , a surface  38  of the razor blade generally opposite the cutting edge  40 , defined by the razor blade  18 , engages the abutment surface  36 , thereby aligning the razor blade relative to the razor blade platform  10 . 
   Still referring to  FIG. 2 , the slot  22  can be of any shape. Depending upon the shape, the slot  22  could frictionally retain the razor blade  18  against the support surface  16 . An alternative slot design is shown in  FIG. 3 . In this design, the overhang portion  24  has an undersurface  42  that is angled relative to the support surface  16  over which the overhang portion  24  projects such that the razor blade  18  is not held against the support surface  16  by the overhang portion  24 . 
   Referring back to  FIG. 1 , a razor blade  18  is preferably attached to each laterally aligned support surface  16  of the razor blade platform  10 . The support surfaces  16  provide the contour, if any, to the razor blade  18 . In the preferred embodiment, the support surfaces  16  define a contour that is generally planar, but this should not be a limitation of the invention as any contour could be defined such as a fair curve but the contour could be unfair if desired. Attachment of the razor blade  18  to a support surface  16  can be by any 
   Multiple configurations of the projection  14  are possible. In the embodiment depicted in  FIG. 1 , two configurations of the projections  14  are shown wherein some of the projections  14  define slots  22  while others do not. While a particular number of slotted and unslotted projections has been shown, the present invention is not limited in this regard as any number of projections and combinations of slotted and unslotted projections can be employed without departing from the broader aspects of the present invention. 
   A protective covering  44 , shown in the illustrated embodiment as a thin length of wire is wrapped around the razor blade platform  10  and extends over the cutting edges  40  of the razor blades  18  mounted thereon. The wire  44  is provided to prevent a user&#39;s skin from excessively extruding between the razor blades  18 . In order to properly orient the wire  44 , relative to the razor blade platform  10 , the wire  44 , is positioned in slots  46  located in the base portion  12 . However, the present invention is not limited in this regard as the wire  44  can be simply wrapped around the razor blade platform  10 . Preferably, the wire  44  is metal, however other materials, such as, but not limited to, polymeric strands can be substituted without departing from the broader aspects of the present invention. 
   As shown in  FIGS. 4 through 9 , the razor blade platform  10  is integrated into a razor cartridge, generally designated by the reference number  48 . The razor cartridge  48  has a first cover  50  that securely mates with a second cover  52 . The first and second covers,  50  and  52  respectively, cooperate to define an interior area  54  into which the razor blade platform  10  is located. The first cover  50  has an opening  56  positioned relative to the razor blade platform  10  so that at least a portion of the cutting edges  46  of the razor blades  18  mounted on the razor blade platform  10  are exposed. In addition, the second cover  52  includes at least one opening  58  that cooperates with the passages  20  to allow debris accumulated during a shaving operation to be washed through the passages  20  and the opening  58  in the second cover  52 . 
   The first cover  50  has protrusions  60  that extend outwardly from an interior surface  62 . The protrusions  60  rest on one of the razor blades  18 . The first cover  50  includes a leading edge  64  that defines recesses  66  that are aligned with the slots  46  on the razor blade platform  10 . As stated above, the wire  44  engages the slots  46  as it is wrapped around the razor blade platform  10  and the razor blades  18  mounted thereon. The recesses  66  are sized based upon the size of the protective covering  44  such that there is a smooth transition for the skin from the leading edge  64  onto the protective covering  44 . 
   The first cover  50  also includes a lubricious strip of material  68 , preferably impregnated with a shaving aid. The lubricious strip  68  is positioned within a pocket  70  defined by the first cover  50  such that during a shaving operation, the user&#39;s skin engages the lubricious strip  68  prior to the skin engaging the cutting edge  40  of the razor blades  18 . A second lubricious strip  72 , also preferably impregnated with a shaving aid is located on an outer surface  74  of the first cover  50 . Extending outwardly from an inner surface  76  of the second cover  52  is a tab  78  positioned to engage a slot  80  in the razor cartridge  48  defined by lobes  82  on the base portion  12  of the razor blade platform  10 . The tabs  78  and slot  80  prevent longitudinal movement of the razor blade platform  10  relative to the first and second covers  50  and  52 , respectively. 
   The razor blade platform  10  is mounted on the second cover  52  by placing opposed extensions  84  onto opposed bearing surfaces  86 . In this embodiment, the extensions  84  are curved to match the contour of the bearing surfaces  86 . This permits the razor blade platform  10  to roll in the second cover  52 . A flange  88  on each distal end  90  of the extensions  84  further limit longitudinal movement of the razor blade platform  10 . 
   The first cover  50  mates with the second cover  52  positioning the razor blade platform  10  within the razor cartridge  48 . The first cover  50  has apertures  92  that are sized to permit the first cover to be positionable over the extensions  84 . When assembled, the flanges  88  are located adjacent opposed outer surfaces  94  of the razor cartridge. A spring  96  is positioned in the interior area of the razor cartridge  48  between the second cover  52  and razor blade platform  10  to normally bias the razor blade platform  10  toward the first cover  50  and assist in positioning at least a portion of the cutting edges  40  within the opening  56 . 
   The present invention also resides in a method for mounting the above-described razor blades  18  to the razor blade platform  10 . As shown in  FIG. 10 , in an embodiment of the method, the razor blades  18  are mounted onto a blade support  98  defining support surfaces  100  oriented so as to be approximately coincident with the support surfaces  16  of the razor blade platform  10 , when the blade support  98  and the razor blade platform  10  are brought into proximity with one another. The blade support  98  defines slots  102  adapted to releasable receive and retain at least a portion of the cutting edges  40  defined by the razor blades  18 . Adhesive  104  is then applied to an outwardly facing surface  106  of each razor blade  18  releasably retained by the blade support  98 . The adhesive  104  is applied on areal portions of each razor blade  18  that will engage the support surfaces  16  defined by the projection  14 . The blade support  98  and the razor blade platform  10  are then brought into proximity with one another so that the outwardly facing surfaces  106  of the razor blades  18  engage the support surfaces  16  of the blade support  98 . The adhesive  104  is then allowed to cure so that when the blade support  98  is moved away from the razor blade platform  10 , the razor blades  18  release from the blade support  98  and remain bonded to the razor blade platform  10 . While slots  102  on the blade support  98  have been shown and described as the mechanism by which the cutting edges  40  if the razor blade  18  are retained, the present invention is not limited in this regard as other manners of releasably retaining the razor blades  18  on the blade support  98  can be employed. For example, suction or clamps can be employed without departing from the broader aspects of the present invention. 
   In another method as shown schematically in  FIG. 11 , the razor blades  18  are each mounted to a retainer  108  and rotatably brought into engagement with the razor blade platform  10 . 
   Although the present invention has been described in considerable detail with reference to certain preferred versions thereof, other versions are possible. Therefore, the spirit and scope of the invention should not be limited to the description of the preferred versions contained herein.