Patent Publication Number: US-2023139750-A1

Title: Shaving cartridges

Description:
CROSS REFERENCE TO RELATED APPLICATION(S) 
     This application is a National Stage Application of International Application No. PCT/EP2020/086686, filed on Dec. 17, 2020, now published as WO2021170280A1 and which claims benefit from European patent application EP20159535.2 filed on 26 Feb. 2020, the entire contents being incorporated herein by reference. 
    
    
     FIELD 
     The present disclosure relates generally to the field of skincare, and in particular to shaving. More specifically, the present disclosure relates to a cartridge of a handheld shaving device constructed of a rigid material and configured to allow movement razor blades. 
     BACKGROUND 
     A typical handheld shaving device may include a handle and a shaving cartridge (head). The shaving cartridge may include one or more razor blades (hereafter, “blades”) configured to pass along the skin of a user to shave and/or groom hair of the user. Many conventional shaving cartridges may be constructed of plastic due to ease, simplicity, and cost of manufacturing. However, the usage of suitable plastics to manufacture shaving cartridges may be harmful for the environment. Additionally, manufacturing a shaving cartridge which may accommodate and/or allow movement of blades may present difficulties, as dimensions for necessary structures of the shaving cartridge may typically be small, have complex geometrical shapes, and require precision to manufacture. 
     It is desirable to provide an improved cartridge for a handheld shaving device that fulfills one or more of the needs described above. 
     SUMMARY 
     According to aspects of the present disclosure, a cartridge for a shaving device having one or more blades for use on a surface comprises a base including a base first end and a base second end offset from an axis of the cartridge, the base being configured to carry a blade. A frame configured to cooperate with the base, the frame included at the base first end and the base second end, the frame defining an opening configured to expose the blade. The cartridge further includes one or more resilient elements configured to cooperate with a corresponding blade. The base, the resilient elements and the frame are each constructed of sheet metal. 
     According to aspects of the present disclosure, the resilient elements are arranged between the base first end and the base second end. 
     According to aspects of the present disclosure, the base and the resilient element may be formed from one piece of sheet metal. 
     According to aspects of the present disclosure, the base and the frame may be formed from one or two pieces of sheet metal. 
     According to aspects of the present disclosure, the resilient element may be capable of axial flexure. 
     According to aspects of the present disclosure, movement of the blade along the surface in a first direction relative to the axis may cause the resilient element to flex in a second direction relative to the axis. 
     According to aspects of the present disclosure, the resilient element may comprise a plurality of support fingers extending from a support root. 
     According to aspects of the present disclosure, the support root may extend from and along one or both of the base first end and base second end. 
     According to aspects of the present disclosure, the support root may extend axially between the base first end and the base second end, and the support fingers may extend towards one or both of the base first end and the base second end. 
     According to aspects of the present disclosure, a blade-receiving void may be defined within each support finger. 
     According to aspects of the present disclosure, the base may include a first plane and a second plane offset from the first plane in a direction transverse to the axis, and the resilient element may extend from the first plane to the second plane. 
     According to aspects of the present disclosure, the resilient element may include a proximal section and a distal section, and the distal section may be planar with respect to the first and second planes. 
     According to aspects of the present disclosure, the distal section of the resilient element may be configured to support a terminal portion of the blade and the proximal section may be configured to support a core portion of the blade. 
     According to aspects of the present disclosure, the frame may include one or more engagement elements configured to secure the base at the base first end and the base second end. 
     According to aspects of the present disclosure, a method of allowing movement of blades within a housing of a shaving device may comprise the cartridge according to any aspect described above. 
     In the manner described and according to aspects illustrated herein, the metal resilient element provided on the cartridge may allow for movement of blades while also reducing cost and complexity of manufacturing. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       Aspects of embodiments of a cartridge will be described with reference to the drawings, where like numerals reflect like elements: 
         FIG.  1    is a front perspective view of a cartridge according to aspects of the disclosure; 
         FIG.  2    is a front perspective view of a blade for use within the cartridge of  FIG.  1    according to aspects of the disclosure; 
         FIG.  3    is a front perspective view of a base of the cartridge of  FIG.  1    according to aspects of the disclosure; 
         FIG.  4    is a front perspective cross-sectional view of the base of  FIG.  3   , taken along line IV of  FIG.  3   ; 
         FIG.  5    is a front perspective view of a frame of the cartridge of  FIG.  1    according to aspects of the disclosure; 
         FIG.  6    is front view of the cartridge of  FIG.  1   ; 
         FIG.  7    is a front perspective view of the cartridge of  FIG.  1   , shown without blades; 
         FIG.  8    is a front perspective view of the cartridge of  FIG.  7   ; 
         FIG.  9    is a front perspective view of the cartridge of  FIG.  7    with emphasis on a pair of fasteners according to aspects of the disclosure; 
         FIG.  10    is a front perspective view of an alternative embodiment of a cartridge in an unformed state according to aspects of the disclosure; 
         FIG.  11    is a front perspective view of the cartridge of  FIG.  10    in a formed state; 
         FIG.  12    is a bottom cross-sectional view of the cartridge of  FIG.  11   , taken along line XII of  FIG.  11   ; 
         FIG.  13    is a partial bottom perspective cross-sectional view of the cartridge of  FIG.  11   , taken along line XIII of  FIG.  11   ; 
         FIG.  14    is a front perspective view of the cartridge of  FIG.  11   , shown with blades; 
         FIG.  15    is a side perspective cross-sectional view of the cartridge of  FIG.  11   , taken along line XV of  FIG.  11   ; and 
         FIG.  16    is a side perspective cross-sectional view of the cartridge of  FIG.  11   , taken along line XVI of  FIG.  11   . 
     
    
    
     DETAILED DESCRIPTION 
     Embodiments of a cartridge according to aspects of the disclosure will now be described with reference to  FIGS.  1 - 16   , wherein like numerals represent like parts, and will generally be referred to by the reference numerals  10  and  100 . Although the cartridge  10 ,  100  is described with reference to specific examples, it should be understood that modifications and changes may be made to these examples without going beyond the general scope as defined by the claims. In particular, individual characteristics of the various embodiments shown and/or mentioned herein may be combined in additional embodiments. Consequently, the description and the drawings should be considered in a sense that is illustrative rather than restrictive. The Figures, which are not necessarily to scale, depict illustrative aspects and are not intended to limit the scope of the disclosure. The illustrative aspects depicted are intended only as exemplary. 
     The term “exemplary” is used in the sense of “example,” rather than “ideal.” While aspects of the disclosure are amenable to various modifications and alternative forms, specifics thereof have been shown by way of example in the drawings and will be described in detail. It should be understood, however, that the intention is not to limit aspects of the disclosure to the particular embodiment(s) described. On the contrary, the intention of this disclosure is to cover all modifications, equivalents, and alternatives falling within the scope of the disclosure. 
     Various materials, methods of construction and methods of fastening will be discussed in the context of the disclosed embodiment(s). Those skilled in the art will recognize known substitutes for the materials, construction methods, and fastening methods, all of which are contemplated as compatible with the disclosed embodiment(s) and are intended to be encompassed by the appended claims. 
     As used in this disclosure and the appended claims, the singular forms “a,” “an,” and “the” include plural referents unless the content clearly dictates otherwise. As used in this disclosure and the appended claims, the term “or” is generally employed in its sense including “and/or” unless the content clearly dictates otherwise. 
     Throughout the description, including the claims, the terms “comprising a,” “including a,” and “having a” should be understood as being synonymous with “comprising one or more,” “including one or more,” and “having one or more” unless otherwise stated. In addition, any range set forth in the description, including the claims should be understood as including its end value(s) unless otherwise stated. Specific values for described elements should be understood to be within accepted manufacturing or industry tolerances known to one of skill in the art, and any use of the terms “substantially,” “approximately,” and “generally” should be understood to mean falling within such accepted tolerances. 
     When an element or feature is referred to herein as being “on,” “engaged to,” “connected to,” or “coupled to” another element or feature, it may be directly on, engaged, connected, or coupled to the other element or feature, or intervening elements or features may be present. In contrast, when an element or feature is referred to as being “directly on,” “directly engaged to,” “directly connected to,” or “directly coupled to” another element or feature, there may be no intervening elements or features present. Other words used to describe the relationship between elements or features should be interpreted in a like fashion (e.g., “between” versus “directly between,” “adjacent” versus “directly adjacent,” etc.). 
     Spatially relative terms, such as “top,” “bottom,” “middle,” “inner,” “outer,” “beneath,” “below,” “lower,” “above,” “upper,” and the like, may be used herein for ease of description to describe one element or feature&#39;s relationship to another element(s) or feature(s) as illustrated in the drawings. Spatially relative terms may be intended to encompass different orientations of a device in use or operation in addition to the orientation depicted in the drawings. For example, if the device in the drawings is turned over, elements described as “below” or “beneath” other elements or features would then be oriented “above” the other elements or features. Thus, the example term “below” can encompass both an orientation of above and below. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly. 
     Although the terms “first,” “second,” etc. may be used herein to describe various elements, components, regions, layers, sections, and/or parameters, these elements, components, regions, layers, sections, and/or parameters should not be limited by these terms. These terms are only used to distinguish one element, component, region, layer, or section from another region, layer, or section. Thus, a first element, component, region, layer, or section discussed herein could be termed a second element, component, region, layer, or section without departing from the teachings of the present disclosure. 
     As shown in  FIGS.  1 - 6   , the cartridge  10  may be configured to allow movement of a blade  12  within a housing  14  constructed of a rigid material. In embodiments, the blade  12  may have a pair of terminal portions  16  and a core portion  18  extending between the terminal portions  16  (see  FIG.  2   ). The cartridge  10  may be configured for use as a head/cartridge  10  on a handheld shaving device  100  for shaving and/or grooming hair of a user. To this end, the cartridge  10  may be configured for movement along a surface, such as the skin of the user, in a plurality of directions. However, for the purposes of illustrating usage of the cartridge  10  herein, the directions of use of the cartridge  10  along the surface will be referred to as a first direction and a second direction different from the first direction. Therefore, it should be understood that any reference to the first direction and the second direction does not limit any aspect of the cartridge  10  to only two directions. Referring to  FIGS.  1 ,  3 , and  5 - 6   , the cartridge  10  may include a housing  14  configured to receive one or more blades  12 . In embodiments, the housing  14  is configured to receive a plurality of blades  12 . The housing  14  may include a base  20  and a frame  60  centered on an axis AL extending through the cartridge  10 . In embodiments, the base  20  and the frame  60  may be constructed from two pieces of sheet metal. The usage of sheet metal, and/or the minimal amount of sheet metal/components used, may allow for increased cost efficiency, increased simplicity of the manufacturing process, and increased sustainability. Additionally, the modularity of the base  20  and the frame  60  described herein may allow for increased interchangeability of the base  20  with alternative configurations of the frame  60 . Further, the modularity may allow for enhanced ease of manufacture and increased quality control. 
     As shown in  FIGS.  3 - 4   , the base of the cartridge  10  may include a base first end  22  and a base second end  24  extending about the axis A L . In embodiments, the base  20  may be constructed of stainless steel, which is heat-treated after sheet metal forming, however, a person having ordinary skill in the art would appreciate that other metals may be suitable for the cartridge  10 . The base first end  22  and the base second end  24  may extend parallel to the axis A L . The base first end  22  and/or the base second end  24  may each include one or more attachment elements  26  configured to hold and position a blade  12  and/or an extension thereof. In embodiments, the base first end  22  and the base second end  24  may include a plurality of opposing pairs of attachment elements  26 . Each attachment element  26  may include an attachment surface  28  (see  FIG.  4   ) configured to engage the terminal portions  16  of the blade  12 , such that the blade  12  extends from one attachment element  26  to a corresponding attachment element  26  in a given pair of opposing attachment elements  26 . A support or resilient element  30  is provided to cooperate with a corresponding blade  12 . The resilient element  30  is arranged between the base first end  22  and the base second end  24  to cooperate with the corresponding blade  12  between the base first end  22  and the base second end  24 . It should be understood that the term “cooperate” as used herein may be defined as “function with,” “work jointly with,” and/or “provide support for.” In embodiments, cooperation between the support  30  and the blade  12  may mean that the support  30  may be configured to allow movement of the blade  12  and ensure correct placement of the blade  12  within the cartridge  10 . Each of the attachment element  26  and the support  30  may be configured to be large in size and without complex geometry in order to simplify manufacturing of the cartridge  10 . The support  30  may be elastically deformable to allow for axial movement of the blade  12 . In embodiments, the support  30  may have a spring force of between 10±5 (gr) and 10±5 (gr). In embodiments, the support  30  may have a spring force of 30±5 (gr). In embodiments, the support  30  may have a thickness of between 0.05 (mm) and 3.50 (mm). In embodiments, the support  30  may have a thickness of 0.20 (mm). 
     Referring to  FIGS.  3 - 4   , in embodiments, the support  30  may comprise a plurality of opposing pairs of supports (support fingers)  32  that are arranged between the base first end  22  and the base second end  24 . Each support finger  32  may extend from a support root  34 , which may extend from and along the base first end  22  and the base second end  24 . Each support finger  32  may extend inwardly from a proximal section  32   a  of the support finger  32  connected to the support root  34  on the base first end  22  and the base second end  24 . Each support finger  32  may extend toward the axis A L  to a distal section  32   b  of the support finger  32 . Additionally or alternatively, one or more central support roots  36  (see  FIGS.  7 - 8   ) may extend axially between the base first end  22  and the base second end  24  along the axis A L  and/or offset from the axis A L . Each support finger  32  extending from the central support root  36  may extend inwardly toward the axis A L , or away from the axis A L  and toward one of the base first end  22  or the base second end  24 . The support fingers  32  may be arranged in series such that a slot  38  is defined between each adjacent support finger  32 . Each slot  38  may have a width of between 0.10 (mm) and 1 (mm). In embodiments, the width of the slot may be 0.50 (mm). Each slot  38  may extend from the base first end  22  to the base second end  24 . Each slot  38  may be configured to receive a corresponding blade  12  and allow room for flexure of each support finger  32 . Each corresponding blade  12  may extend throughout the slot  38  so that the terminal portions  16  of the blade  12  are engaged by corresponding attachment surfaces  28  of the attachment elements  26 . Each blade  12  is supported axially by the support fingers  32  defining the corresponding slot  38 , which each blade  12  extends through. 
     In embodiments, the support fingers  32  may be capable of axial flexure to allow for axial movement of the blades  12  during use of the cartridge  10  along a surface. As a user pushes the cartridge  10  on or along the surface and applies a force in a first direction, the surface may exert a reaction force on the blades  12  in a second direction. The reaction force on the blades  12  in the second direction may cause the blades  12  to transmit the reaction force to the support fingers  32 , which causes the support fingers  32  to flex in the second direction in response to the reaction force exerted on the blades  12 . Therefore, movement of the cartridge  10  in a first direction or a second direction along the surface causes the blades  12 , and thus the support fingers  32 , to move and/or flex in the first direction or the second direction. 
     In embodiments, the blade  12  may include a blade support  19  and be mounted at a position on top or below the corresponding support finger  32  (see  FIG.  15   ). At either position, the support finger  32  may contact the blade support  19  and elastically bias the blade  12  and blade support  19  towards a rest position within the slot  38 . Alternatively, the blade support  19  may be an integrally formed component having a bent portion (see  FIG.  15   ). In this case, the support finger  32  may contact the bent portion during use and bias the blade  12  and the bent portion towards the rest position. 
     Referring to  FIGS.  3 - 4   , the base  20  may be oriented in a first plane P 1  and a second plane P 2 . The second plane P 2  may be offset from the first plane P 1  in a direction transverse to the axis A L . The support root  34  and/or central support root  36  may be located within the first plane P 1  of the base  20 . The proximal section  32   a  of each support finger  32  may extend from the support root  34  and/or central support root  36  within the first plane P 1  to the distal section  32   b  at a position within the second plane P 2 . The distal section  32   b  of each support finger  32  may be substantially planar with respect to the second plane P 2 . To extend from the first plane P 1  to the second plane P 2 , each support finger  32  may include a slope  40  leading to the distal section  32   b  and a bend  42  positioned between the slope  40  and the distal section  32   b . With respect to the distal section  32   b , the slope  40  and the bend  42  may be considered to be part of the proximal section  32   a . As the blade flexes, the bend  42  may establish a point of contact between the blade  12  and the support finger  32  so that the support finger  32  may support the core portion  18  of the blade  12  at the point of contact as the blade  12  flexes. As such, the positioning of each support finger  32  within both of the first plane P 1  and the second plane P 2  may allow each support finger  32  to have more than one point of contact with the corresponding blade  12  when supporting the blade  12  during use. In particular, a given blade  12  may be supported by one or more of a corresponding attachment element  26  at each of the first base end  22  and the second base end  24 , a corresponding bend  42  of a support finger  32  extending from the support root  34  at the base first end  22  and the base second end  24 , and/or a corresponding bend  42  of a support finger  32  extending from a central support root  36 . 
     As shown in  FIG.  5 - 6   , the frame  60  may be configured to cooperate with the base  20 . The frame  60  may include a frame first end  62  and a frame second end  64  complementary to the base first end  22  and the base second end  24 , respectively. In embodiments, the frame  60  is constructed of aluminum to enhance anti-corrosion, however, a person having ordinary skill in the art would appreciate that other metals may be suitable for the cartridge  10 . The frame  60  may include a first side  66  defining a first opening  68  extending between the frame first end  62  and the frame second end  64  for receiving the base  20 . The first opening  68  may allow exposure of the blades  12  carried by the base  20 . The frame  60  may include a second side  70  opposing the first side  66  and defining a second opening  72  extending between the frame first end  62  and the frame second end  64 . The second opening  72  may also allow for exposure of the blades  12  carried by the base  20  as well as drainage of fluid out of the base  20  during use. It is contemplated that the base first end  62  and the base second end  64  may each include drainage holes  44  (see  FIGS.  3 - 4   ) to further facilitate drainage of fluid from the base  20 . The first opening  66  may lead to a cavity  74  defined by a sidewall  76  extending between the first side  66  and the second side  70  of the frame  60 . The base  20  may be received in the cavity  74  and securely surrounded by the sidewall  76 . The cavity  74  and sidewall  76  may have a depth D 1  which corresponds to a depth D 2  (see  FIG.  4   ) of the base  20 . The depth D 1  corresponding to the depth D 2  may ensure a secure fit of the frame  60  over the base  20 . The frame  60  may include a first protective bar  78  and a second protective bar  80  extending between the frame first end  62  and the frame second end  64 . The first protective bar  78  and second protective bar  80  may provide a safety boundary between the base  20  and a surface on which the cartridge  10  is used. The frame  60  may include a first engagement element (retainer)  82  extending from the frame first end  62  and a second engagement element (retainer)  84  extending from the frame second end  64  for securing the base  20  and the blades  12  within the frame  60 . In embodiments, each engagement element  82 ,  84  may be a flap extending away from the second side  70  of the frame  60  and past the first side  66  of the frame  60 . Each engagement element  82 ,  84  may be configured to bend and fold over the first side  66  of the frame  60  and the base first end  22  and base second end  24  to hold the base  20  within the frame  60 . The engagement element  82 ,  84  may also be configured to secure the blade  12  within the base  20 . As shown in  FIG.  9   , additionally or alternatively, a fastener (clip)  86  may extend around each of the frame first end  62  and frame second end  64  and the base first end  22  and the base second end  24 . The fastener  86  may hold the base  20  within the frame  60  and/or hold each of the engagement elements  82 ,  84  in a folded configuration over the first side  66  of the frame  60  and the base first end  22  and base second end  24 . 
     As shown in  FIGS.  10 - 16   , an alternative embodiment of the cartridge  10  is shown and referred to by reference numeral  100 . With respect to the cartridge  100 , structures and/or relationships that may be the same or similar to the structures and/or relationships of the cartridge  10  may utilize the same or similar name and corresponding reference numeral as the structures and/or relationships of the cartridge  10 . The cartridge  100  is discussed herein with reference to the aspects that may differ from the cartridge  10 . It is contemplated that the same or similar structures and/or relationships of the alternative embodiment may function the same or similarly to the same or similar structures and/or relationships of the cartridge  10 . Additionally, it is contemplated that aspects of the cartridge  100  may be combinable with aspects of the cartridge  10  described above. Referring to  FIGS.  10 - 11   , a base  120 , resilient elements  130  and a frame  160  of the cartridge  100  may be formed of one piece of sheet metal. Therefore, the cartridge  100  is capable of transitioning from a flat, unformed state (see  FIG.  10   ) to an integral, multi-dimensional, formed state (see  FIG.  11   ). The frame  160  may be connected to the base  120  rather than defining an opening  68  for receiving the base  120 . 
     As such, the frame  160  may surround the base as an extension of the base  120 . The frame  160  may fold inwardly and be mechanically formed around the base  120 . 
     Referring to  FIGS.  10 - 11   , the base  120  may include a first central support root  136  and a second central support root  136 . The first central support root  136  may include a plurality of support fingers  132  extending towards a base first end  122  and the second central support root  136  may include a plurality of support fingers  132  extending towards a base second end  124  to define the resilient element  130  configured to cooperate with a corresponding blade, which is arranged between the base first end  122  and the base second end  124 . Additionally or alternatively, the support fingers  132  may extend inwardly from a support root  34 , which may extend from and along the base first end  122  and the base second end  124 . Additionally or alternatively, the base first end  122  and  124  may be formed and/or function similarly to the first and second engagement elements  82 ,  84 . Referring to  FIG.  13   , each support finger  132  may extend from a proximal section  132   a  connected to the first central support root  136  or the second central support root  136 . Each support finger  132  may extend away from an axis A L  toward one of the base first ends  122  or the base second end  124  to a planar distal section  132   b . In embodiments, each support finger  132  extending from the first central support root  136  extends towards the base first end  122  and each support finger  132  extending from the second central support root  136  extends towards the base second end  124 . Referring to  FIGS.  12 - 13   , each support finger  132  may include a slope  140  throughout the proximal section  132   a  and a bend  142  positioned between the slope  140  and the distal section  132   b . 
     Each support finger  132  may include a rounded end  146  at the distal section  132   b . The rounded end  146  may reduce the complexity of the geometry of the support fingers  132  to simplify the manufacturing process. Each support finger  132  may define a void (blade-receiving void)  148  extending from the corresponding first or second central support root  136  and/or the proximal section  132   a  to the rounded end  146  and/or the distal section  132   b . The void  148  may be configured to receive a corresponding blade  12 . In embodiments, the planar distal section  132   b  of each support finger may have a length between 1 (mm) and 10 (mm). In embodiments, the planar distal section  132   b  of each support finger may have a length between 3 (mm) and 6 (mm). In use, the distal section  132   b  and/or rounded end  146  of each support finger may support the terminal portion  16  of the corresponding blades  12  and the proximal section  132   a  and/or the bend  142  of each support finger  132  may support the core portion  18  of the blades  12 . Axial flexure of the support fingers  132  may allow for support and/or movement of the blades  12  in the manner described with respect to the cartridge  10 . 
     Although the present disclosure herein has been described with reference to particular embodiments, it is to be understood that these embodiments are merely illustrative of the principles and applications of the present disclosure. 
     It is intended that the specification and examples be considered as exemplary only, with a true scope of the disclosure being indicated by the following claims. 
     Additionally, all of the disclosed features of an apparatus may be transposed, alone or in combination, to a method and vice versa.