Patent Description:
The shaving razor category has many different razor configurations, including razors that are "system" razors that have handles with replaceable cartridges, and disposable razors where the handle and cartridge are used together and thrown out after a time. Razors vary based on many attributes such as number of blades, cartridge shape, chemistry features on the cartridge and so forth.

In some shaving systems, the blades are resiliently mounted with respect to the cartridge housing and deflect under the force of skin contact during shaving. Connection of the cartridge to the handle may provide a pivotal mounting of the cartridge with respect to the handle (i.e., a front-to-back pivoting motion) so that the cartridge angle adjusts to follow the contours of the surface being shaved. In such systems, the cartridge may be biased toward an at-rest or home position by the action of a spring-biased plunger (a cam follower) carried on the handle against a cam surface on the cartridge housing.

Many razor handles are made from two separate components comprising, for example, a thermoplastic polymer, that are joined together via ultrasonic welding, adhesive, and/or other suitable methods. These razor handles are subjected to a variety of forces including impact and bending forces, such as during shaving and cartridge replacement when one end of the handle is held rigid and the other end is placed under a load. Over time, these forces may damage the handle and cause the two pieces to begin separating, cracking, etc..

Patent document <CIT> describes a shaving razor handle comprising an elongated hand gripping structure including a metal frame joined to a lower gripping pad. One end of the frame defines a recess for mounting a cartridge connecting subassembly.

Thus, there is a need for a two-piece razor handle with improved bending strength, and preferably with a rotatable portion, that is simpler, cost-effective, reliable, durable, easier and/or faster to manufacture, and easier and/or faster to assemble with more precision.

According to the present invention, there is provided a shaving razor handle in accordance with claim <NUM>. The shaving razor handle comprises: a body defined by a top shell joined to a bottom shell, the body comprising an open end, in which one of the top shell or the bottom shell comprises a substantially continuous band of material that forms the open end of the body, wherein the shaving razor handle further comprises a handle-engaging assembly received in the open end of the body, and wherein one or more components of the handle-engaging assembly extend past a joint between the top shell and the bottom shell in a direction toward a second end of the body.

In accordance with another aspect of the present disclosure, which is not part of the current invention, a shaving razor handle is provided that comprises: a body defined by a top shell joined to a bottom shell, the body comprising an open end, in which one of the top shell or the bottom shell comprises a substantially continuous band of material that forms the open end of the body; and a forward assembly coupled to the body, in which at least a portion of the forward assembly rotates relative to the body.

In accordance with one or more embodiments, an inner edge of the one of the top shell or the bottom shell comprises: a substantially linear portion extending substantially parallel to a longitudinal axis of the body; and a curved portion extending between the substantially linear portion and the substantially continuous band of material.

While the specification concludes with claims particularly pointing out and distinctly claiming the subject matter which is regarded as forming the present invention, it is believed that the invention will be better understood from the following description which is taken in conjunction with the accompanying drawings in which like designations are used to designate substantially identical elements, and in which:.

With reference to <FIG> and <FIG>, a razor system <NUM> comprises a handle <NUM> and a cartridge <NUM>, which may be replaceable. The cartridge <NUM> comprises a cartridge housing <NUM>, which carries a plurality of blades <NUM>, a guard structure <NUM>, and a cap structure <NUM>. The cartridge <NUM> may also comprise an interconnect member <NUM> on which the cartridge housing <NUM> is pivotally mounted. The interconnect member <NUM> includes a base <NUM>, which is releasably received by a cartridge-connecting assembly <NUM> of the handle <NUM> and two arms <NUM> that pivotally support the cartridge housing <NUM>. The cartridge housing <NUM> pivots about an axis A (see <FIG>) relative to the interconnect member <NUM> in a direction indicated by arrow B in <FIG>. The cartridge housing <NUM> comprises a cam surface <NUM> that is acted upon by a spring-biased plunger <NUM> of the cartridge-connecting assembly <NUM>. When the base <NUM> is connected to the handle <NUM>, the plunger <NUM> passes through an opening (not shown) formed in the base <NUM> and engages the cam surface <NUM> on the cartridge housing <NUM> to bias the cartridge housing <NUM> to a rest or home position shown in <FIG> and <FIG>. The cartridge-connecting assembly <NUM> further comprises an eject assembly comprising a housing <NUM>, a button <NUM>, and eject fingers <NUM>, one of which is shown in <FIG>, wherein the fingers <NUM> are fixedly coupled to the button <NUM> and mounted in the housing <NUM>. The button <NUM> is received in a slot in a connecting portion <NUM> of the handle <NUM>. When the button <NUM> is pushed toward the cartridge housing <NUM>, the eject fingers <NUM> extend out from the housing <NUM> and eject the cartridge <NUM>. As illustrated in <FIG> and <FIG>, the cartridge-connecting assembly <NUM> may comprise a conventional GILLETTE MACH3® docking interface. In other examples, the handle <NUM> may be provided with other docking interfaces, such as a GILLETTE FUSION® interface.

As shown in <FIG>, the handle <NUM> comprises a body <NUM> comprising a top shell <NUM> joined to a bottom shell <NUM>, which may together define an elongated gripping structure. The body <NUM> comprises a first end 40A (also referred to herein as an open end) and a second end 40B opposite the first end 40A. While the first end 40A defines an open end and the second end 40B defines a closed end in the illustrated embodiment, in other examples (not shown), both ends 40A, 40B may be open. In some examples, the body <NUM> may be substantially straight, as shown in <FIG> and 5A (see also <FIG>). In other examples (not shown), one or more sections of the body <NUM> may be offset or curved relative to one or more other sections and/or to a major longitudinal axis A<NUM> of the body <NUM> (see <FIG>). The body <NUM> may be substantially hollow and may receive a metal weight or rod <NUM>, as described in more detail below. The metal rod <NUM> may comprise, for example, stainless steel with zinc plating.

As described herein in more detail, a forward assembly <NUM> may be coupled to the body <NUM>, as shown in <FIG> and <FIG>, in which the forward assembly <NUM> may comprise a handle-engaging assembly <NUM> and a head assembly <NUM>. The handle-engaging assembly <NUM> may be coupled to, and is received in, the open end 40A of the body <NUM> and may comprise a shaft <NUM>, a spring <NUM>, and an optional cover <NUM>. The head assembly <NUM> may be coupled to the handle-engaging assembly <NUM>. In particular, the head assembly <NUM> may comprise the connecting portion <NUM> and the cartridge-connecting assembly <NUM>, in which the connecting portion <NUM> may be fixedly coupled at a forward end 64A to the cartridge-connecting assembly <NUM>, e.g., via pins (not shown), and at a rear end 64B to the handle-engaging assembly <NUM>. The forward end 64A of the connecting portion <NUM> may comprise a cavity <NUM> that receives the cartridge-connecting assembly <NUM>. When present, the cover <NUM> may be positioned between the body <NUM> and the head assembly <NUM>. In some examples, at least a portion of the forward assembly <NUM> may rotate relative to the body <NUM>, as described herein in detail.

With reference to <FIG>, and <FIG>, the top shell and bottom shell <NUM>, <NUM> may be joined at one or more points along their respective inner edges <NUM>, <NUM>, as shown in <FIG>, and <FIG>, in which the inner edges <NUM>, <NUM> define a mating surface or interface along which the top and bottom shells <NUM>, <NUM> are joined to each other. The top and bottom shells <NUM>, <NUM> may be joined using one or more of ultrasonic welding, adhesive, and a snap or friction fit. The inner edges <NUM>, <NUM> of the top and bottom shells <NUM>, <NUM> may be substantially planar, and in some examples, the top and/or and bottom shell <NUM>, <NUM> may comprise a welding feature (not shown) extending around at least a portion of the respective inner edge <NUM>, <NUM> that helps to join the top and bottom shells <NUM>, <NUM>. The welding feature may comprise a rib extending outward from one or both of the inner edges <NUM>, <NUM>. The rib may be sacrificed during the ultrasonic welding process and helps to join the inner edges <NUM>, <NUM> together.

The top and bottom shells <NUM>, <NUM> may be formed, for example, by molding and may comprise two or more layers and/or types of material. As shown in <FIG>, <FIG>, and <FIG>, the top shell <NUM> may comprise an inner layer <NUM> that may comprise, for example, polycarbonate/polyethylene terephthalate (PC/PET), and an outer layer <NUM> that may comprise, for example, acrylonitrile butadiene styrene (ABS). The outer layer <NUM> may receive a metallic outer coating, e.g., chrome, via a conventional electroplating process. The top shell <NUM> may further comprise a plurality of upper gripping pads <NUM>. The bottom shell <NUM> may comprise an inner layer <NUM> that may comprise PC/PET, and an outer layer <NUM> that forms a lower gripping pad. In the assembled handle <NUM>, the upper gripping pads <NUM> and the outer layer <NUM> of the bottom shell <NUM> provide a hand-gripping structure and may comprise an elastomeric polymeric outer gripping layer (e.g., thermoplastic elastomer) and a nonelastomeric polymeric support layer (e.g., of polypropylene or ABS). The inner layers <NUM>, <NUM> of the top and bottom shells <NUM>, <NUM> may preferably comprise one or more materials that are durable and suitable for ultrasonic welding and/or adhesive. While the material(s) that make up the inner layers <NUM> are generally able to withstand the chemicals associated with the chrome plating, they may be unsuitable for chrome plating as they may not be good conductors of electrons. The outer layer <NUM> of the top shell <NUM> may comprise one or more materials that are suitable for chrome plating, e.g., have good electrical conductive properties. It is further contemplated that each of the top and bottom shells <NUM>, <NUM> may comprise only a single layer and/or type of material. In these examples, the single layer of material that defines the top and bottom shells <NUM>, <NUM> would generally be thicker, as compared to the layers <NUM>, <NUM> and <NUM>, <NUM> of the (multilayer) top and bottom shells <NUM>, <NUM>, to provide the required strength and durability. In all examples, the top and bottom shells <NUM>, <NUM> may be made by one-shot molding, two-shot molding, etc..

The inner edge <NUM> of the top shell <NUM> may be defined by edge portions of both the inner and outer layers <NUM> and <NUM>. Further, the inner edge <NUM> of the bottom shell <NUM> may be formed by edge portions of both the inner layer <NUM> and the outer layer <NUM>. In the illustrated example, the edge portion of the inner layer <NUM> forming part of the inner edge <NUM> of the top shell <NUM> is ultrasonically welded to the edge portion of the inner layer <NUM> forming part of the inner edge <NUM> of the bottom shell <NUM>. In other examples, the top and bottom shells <NUM>, <NUM> may be joined by ultrasonically welding and/or adhering the edge portion of the outer layer <NUM> forming part of the inner edge <NUM> of the top shell <NUM> to the edge portion of the outer layer <NUM> forming part of the inner edge <NUM> of the bottom shell <NUM>.

One or more structures may be formed in or on a respective interior surface 42A, 44A of the top and bottom shells <NUM>, <NUM>, e.g., during the molding process. These one or more structures may, for example, help to align the top and bottom shells <NUM>, <NUM> with respect to each other during assembly; hold the top and bottom shells <NUM>, <NUM> together; position the metal rod <NUM>; and engage one or more other components of the handle <NUM>, as described in detail below. With reference to <FIG> and <FIG>, the bottom shell <NUM> may comprise a first protrusion <NUM> and a pair of second protrusions <NUM> extending outward from the interior surface 44A of the bottom shell <NUM>. The first protrusion <NUM> is received in a corresponding recess <NUM> formed in the inner edge <NUM> of the top shell <NUM>, e.g., by a friction fit. The pair of second protrusions <NUM> are received in a corresponding pair of sockets <NUM> formed in the interior surface 42A of the top shell <NUM>, e.g., by a friction fit. The bottom shell <NUM> may also comprise a projection <NUM> that extends outward from the interior surface 44A and fits over a corresponding structure <NUM> formed on the interior surface 42A of the top shell <NUM>, e.g., by a friction fit or ultrasonic welding. The top and bottom shells <NUM>, <NUM> may further comprise one or more additional structures (not separately labeled) that assist in aligning the top and bottom shells <NUM>, <NUM> during assembly and/or holding the top and bottom shells <NUM>, <NUM> together.

As shown in <FIG>, <FIG>, and <FIG>, the top and bottom shells <NUM>, <NUM> may define a cavity <NUM> with one or more structures that receive and position the metal rod <NUM> within the cavity <NUM>. For example, the bottom shell <NUM> may comprise cradle structure <NUM> that receives and supports the metal rod <NUM>, and the top shell <NUM> may comprise an elongated projection <NUM> extending outward from the interior surface 42A along at least a portion of the cavity <NUM> that aligns the metal rod <NUM> and holds it in place in the cradle structure <NUM> when the handle <NUM> is assembled. A forward end 46A of the metal rod <NUM> may rest against a shoulder <NUM> formed in the top shell <NUM>, and a rear end 46B of the metal rod <NUM> may rest against the U-shaped projection <NUM> formed in the bottom shell <NUM>.

One of the top shell <NUM> or the bottom shell <NUM> comprises a structure that forms or defines the open end 40A of the body <NUM>. With reference to <FIG>, <FIG>, <FIG>, and <FIG>, in some examples, the top shell <NUM> may comprise a substantially continuous band of material <NUM> that solely forms or defines the open end 40A of the body <NUM> in the assembled handle <NUM>. Hence, in this example, the open end 40A of the body <NUM> is formed solely within the top shell <NUM>.

In the embodiment illustrated in <FIG>, the inner edge <NUM> of the top shell <NUM> may comprise first and second substantially linear portions 94A, 94B that extend substantially parallel to the major longitudinal axis A<NUM> of the body <NUM>; first and second connecting portions 96A, 96B that extend between respective ones of the first and second substantially linear portions 94A, 94B and the substantially continuous band of material <NUM>; and an intermediate portion <NUM> that extends between and connects the first connecting portion 96A with the second connecting portion 96B, in which the intermediate portion <NUM>, in the illustrated embodiment, comprises at least a portion of the continuous band of material <NUM>. More specifically, in the embodiment illustrated in <FIG>, the intermediate portion <NUM> of the inner edge <NUM> is defined by a portion 43A of the inner layer <NUM> of the top shell <NUM>, which portion 43A forms part of the continuous band of material <NUM> and defines the recess <NUM> and a pair of generally planar sections 143A on opposing sides of the recess <NUM>. The intermediate portion <NUM> of the inner edge <NUM> may also be defined by an adjacent portion of the outer layer <NUM> of the top shell <NUM>. As best seen in <FIG>, in some examples, the first and second connecting portions 96A, 96B may be curved or arched. In other examples (not shown), the first and second connecting portions 96A, 96B may be substantially linear and may extend at an angle between the first and second substantially linear portions 94A, 94B and the intermediate portion <NUM>. In further examples (not shown), one or more sections of the portions 94A, 94B may be non-linear, e.g., comprising a curve or other shape. In yet further examples (not shown), one or more sections of the inner layer <NUM> may comprise a different shape, as compared to the corresponding section(s) of the outer layer <NUM>.

As shown in <FIG>, the inner edge <NUM> of the bottom shell <NUM> may comprise third and fourth substantially linear portions 102A, 102B that extend substantially parallel to one another; third and fourth connecting portions 104A, 104B, and an intermediate portion <NUM>, in which the intermediate portion <NUM> connects the third connecting portion 104A with the fourth connecting portion 104B.

After the bottom shell <NUM> is assembled to the top shell <NUM>, the inner edges <NUM> and <NUM> are located adjacent to one another. More specifically, the first and second substantially linear portions 94A, 94B of the top shell <NUM> are adjacent to the third and fourth linear portions 102A, 102B of the bottom shell <NUM>; the first and second connecting portions 96A, 96B of the top shell <NUM> are adjacent to the third and fourth connecting portions 104A, 104B of the bottom shell <NUM>; and the intermediate portion <NUM> of the top shell <NUM> is adjacent to the intermediate portion <NUM> of the bottom shell <NUM>. As noted above, the edges <NUM> and <NUM> may be joined using one or more of ultrasonic welding, adhesive, and a snap or friction fit. In all examples, the inner edge <NUM> of the bottom shell <NUM> may comprise a shape that corresponds to adjacent portions of the inner edge <NUM> of the top shell <NUM>. For example, when the connecting portions 96A, 96B of the top shell <NUM> extend at an angle and/or the portions 94A, 94B of the top shell <NUM> comprise a non-linear shape as described above, the corresponding portions 102A, 102B, 104A, 104B of the bottom shell <NUM> may comprise a corresponding shape.

In the illustrated embodiment, the substantially continuous band of material <NUM> is defined by the top shell <NUM>, which may comprise the inner layer <NUM> and the outer layer <NUM>, as shown, or may comprise a single layer (not shown). The substantially continuous band of material <NUM> may comprise a substantially annular shape that may be defined between a forward edge 90B, which may comprise a point on the substantially continuous band of material <NUM> that is furthest from the second end 40B of the body <NUM>, and a rear edge 90C, as shown in <FIG> and <FIG>. In some particular examples, the substantially continuous band of material <NUM> may comprise a solid (continuous and without any gaps) band of material that extends completely around the open end 40A of the body <NUM> in a circumferential direction. In other examples, the substantially continuous band of material <NUM> may have one or more gaps or slits represented by lines <NUM> (shown in phantom in <FIG>) defined between adjacent sections of material. In some instances, when a gap/slit is present in the substantially continuous band of material <NUM>, the top shell <NUM> may comprise a pair of recesses (not shown) in place of the single recess <NUM> that are located on either side of the gap/slit (e.g., near the current location of the generally planar sections 143A), and the bottom shell <NUM> may comprise a pair of protrusions (not shown; near the current location of the intermediate portion <NUM>) in place of the single protrusion <NUM> that are received in the pair of recesses to help stabilize the gap/slit and hold the adjacent sections of material in proximity to each other. The substantially continuous band of material <NUM> may define a continuous arc extending circumferentially from about <NUM> degrees to about <NUM> degrees, preferably from about <NUM> degrees to about <NUM> degrees, and most preferably comprises an arc of <NUM> degrees (i.e., continuous and without any gaps or slits). If a gap/slit is provided, it may comprise an arc extending circumferentially slightly greater than <NUM> degrees and less than <NUM> degrees and preferably slightly greater than <NUM> degrees and less than <NUM> degrees.

As shown in <FIG>, in other examples, a handle <NUM>' may comprise a top shell <NUM>' and a bottom shell <NUM>' that are joined to form a body <NUM>', in which the bottom shell <NUM>' comprises a substantially continuous band of material <NUM>' that forms or defines an open end 40A' of the body <NUM>'. In this example, the open end 40A' of the body <NUM>' is formed solely within the bottom shell <NUM>', i.e., solely by the continuous band of material <NUM>' of the bottom shell <NUM>'. An inner edge <NUM>' of the bottom shell <NUM>' comprises a first substantially linear portion 94A' that extends substantially parallel to a major longitudinal axis A<NUM>' of the body <NUM>' and a first connecting portion 96A' that extends between the first substantially linear portion 94A' and the substantially continuous band of material <NUM>'. Although not visible in <FIG>, similar to the top shell <NUM> in <FIG>, the inner edge <NUM>' of the bottom shell <NUM>' may further comprise a second substantially linear portion and a second connecting portion. The shape of the respective inner edges <NUM>', <NUM>' may be as described above in detail with respect to the inner edges <NUM>, <NUM> of the handle <NUM>. In particular, the first and second connecting portions 96A' may be curved or arched, as shown, or may be substantially linear (not shown), as described in detail above. An intermediate portion <NUM>' may extend between and connect the first connecting portion 96A' with the second connecting portion, in which the intermediate portion <NUM>' may comprise at least a portion of the continuous band of material <NUM>', also as described above.

The substantially continuous band of material <NUM>' formed on the bottom shell <NUM>' may comprise features substantially similar to corresponding portions of the substantially continuous band of material <NUM> formed on the top shell <NUM> and may comprise a substantially annular shape which may be defined between a forward edge 90B' and a rear edge 90C'. Also as described above, the substantially continuous band of material <NUM>' may comprise a solid (continuous and without any gaps) band of material that extends completely around the open end 40A' of the body <NUM>' in a circumferential direction, and in other examples (not shown), the substantially continuous band of material <NUM>' may have one or more gaps or slits 'defined between adjacent sections of material. In some instances, the substantially continuous band of material <NUM>' may comprise a relatively small axial section of material, extending generally parallel to the longitudinal axis A<NUM>' of the body <NUM>'. In other instances, the substantially continuous band of material <NUM>' may comprise a larger axial section of material. For instance, in other embodiments and with continued reference to <FIG>, the inner edge <NUM>' of the bottom shell <NUM>' may comprise the substantially linear portion 94A' and one of a first connecting portion <NUM> or a first connecting portion <NUM>', both shown in dotted line and one of which is used in place of the first connecting portion 96A'. Each of the connecting portions <NUM>, <NUM>' may be curved, as shown, or may be substantially linear (not shown).

With reference to <FIG>, <FIG>, <FIG>, <FIG>, and <FIG>, the shaft <NUM> of the handle-engaging assembly <NUM> may extend between the body <NUM> and the connecting portion <NUM>. In particular, the shaft <NUM> may extend partially into the body <NUM>, i.e., a rear end 52B of the shaft <NUM> may be received in the open end 40A of the body <NUM>, as described herein in more detail. The shaft <NUM> may further be coupled at a forward end 52A to the head assembly <NUM>, and more particularly, to the connecting portion <NUM>. With reference to <FIG>, <FIG>, and <FIG>, the connecting portion <NUM> may comprise a post <NUM> extending outward from the rear end 64B, and the forward end 52A of the shaft <NUM> may fit over and receive a portion of the post <NUM>. The connecting portion <NUM> may comprise inner and outer portions (not separately labeled), in which the inner portion may comprise, for example, ABS and may include the post <NUM> and recesses 118A to 118C (see <FIG>) and the outer portion may comprise, for example, PC/PET and may receive a metallic outer coating, e.g., chrome, via a conventional electroplating process. In the example shown, an interior surface <NUM> of the shaft <NUM> may comprise a shoulder <NUM> that engages the post <NUM>. As described in more detail below, the forward end 52A of the shaft may be coupled to the post <NUM> via a friction fit and/or via one or more other suitable techniques, such as ultrasonic welding or adhesive, and preferably is fixed to the post <NUM> so as not to rotate relative to the post <NUM> or disengage from the post <NUM>.

The spring <NUM> may extend between the body <NUM> and the connecting portion <NUM>, with the shaft <NUM> surrounding at least a portion of the spring <NUM>. The spring <NUM> may comprise, for example, a flat torsion spring with a forward end 54A and a rear end 54B and may comprise, for example, stainless steel. The top shell <NUM> may comprise a first spring receiving structure <NUM>, which may be formed adjacent to and/or share a wall with the shoulder <NUM> and may receive the rear end 54B of the spring <NUM>. The first spring receiving structure <NUM> may comprise, for example, first, second, and third projections 110A-110C formed on the interior surface 42A of the top shell <NUM>. The first and second projections 110A, 110B may be located substantially opposite the third projection 110C. A portion of the first and second projections 110A, 110B may extend toward the third projection 110C, and a portion of the third projection 110C may extend inward at least partially between the first and second projections 110A, 110B, such that when the rear end 54B of the spring <NUM> is inserted into the first spring receiving structure <NUM>, the portion of the third projection 110C contacts the rear end 54B of the spring <NUM> and pushes it against the portions of the first and second projections 110A, 110B to hold the spring <NUM> in place, at least in part, via a friction fit.

The forward end 54A of the spring <NUM> may be received in a second spring receiving structure <NUM> formed within the post <NUM> in the connecting portion <NUM>. Similar to the first spring receiving structure <NUM>, the second spring receiving structure <NUM> may comprise first, second, and third projections 114A-114C, in which the first and second projections 114A, 114B may be located substantially opposite the third projection 114C. A portion of the first and second projections 114A, 114B extend inward toward the third projection 114C, and a portion of the third projection 114C may extend inward at least partially between the first and second projections 114A, 114B, such that when the forward end 54A of the spring <NUM> is inserted into the second spring receiving structure <NUM>, the portion of the third projection 114C contacts the forward end 54A of the spring <NUM> and pushes it against the portions of the first and second projections 114A, 114B to hold the spring <NUM> in place, at least in part, via a friction fit.

With reference to <FIG>, <FIG>, the cover <NUM> may optionally be positioned between the open end 40A of the body <NUM> and the connecting portion <NUM>. The cover <NUM> may comprise, for example, ABS that may be coated, e.g., using vacuum metal deposition, with a metal such as aluminum, and a clear coat may be applied over the metal coating. The cover <NUM> may comprise a central opening 56A that receives the shaft <NUM> such that the cover <NUM> surrounds at least a portion of the shaft <NUM>. An outer surface <NUM> of the shaft <NUM> may comprise one or more structures that engage one or more portions of the cover <NUM> to, for example, align the shaft <NUM> with the cover <NUM>. As shown in <FIG> and <FIG>, the forward end 52A of the shaft <NUM> may comprise one more circumferential ridges <NUM>-<NUM> to <NUM>-<NUM> formed in the outer surface <NUM> of the shaft <NUM>. The shaft <NUM> may comprise, for example, ABS and may be molded so as to form the circumferential ridges <NUM>-<NUM> to <NUM>-<NUM> and other structures described herein. When the shaft <NUM> is inserted into the central opening 56A of the cover <NUM>, the circumferential ridges <NUM>-<NUM> to <NUM>-<NUM> engage an interior surface <NUM> of the cover <NUM> defining the central opening 56A of the cover <NUM>. One or more of the circumferential ridges <NUM>-<NUM> to <NUM>-<NUM> may comprise a respective extension <NUM>-<NUM> to <NUM>-<NUM> extending radially outward from the ridges <NUM>-<NUM> to <NUM>-<NUM> in a direction perpendicular to a longitudinal axis A<NUM> of the shaft <NUM>. The cover <NUM> may further comprise a notch 56B that is in communication with the central opening 56A. When the shaft <NUM> is inserted into the central opening 56A of the cover <NUM>, the extensions <NUM>-<NUM> to <NUM>-<NUM> may be received in the notch 56B. Engagement between the extensions <NUM>-<NUM> to <NUM>-<NUM> and the notch 56B may align the shaft <NUM> with respect to the cover <NUM>. As will be discussed further below, because the shaft <NUM> is coupled to the connecting portion <NUM> and is provided with an aperture 52C that engages with an extension <NUM> on the bottom shell <NUM>, aligning the shaft <NUM> with respect to the cover <NUM> allows the forward assembly <NUM> to be aligned with respect to the body <NUM>. Engagement between the extensions <NUM>-<NUM> to <NUM>-<NUM> and the notch 56B may further prevent unwanted rotation of the shaft <NUM> with respect to the cover <NUM>.

The cover <NUM> may comprise one or more structures that engage one or more corresponding structures formed in the head assembly <NUM>. For example, as best seen in <FIG>, the cover <NUM> may comprise one or more protrusions 116A to 116C that are received in one or more corresponding recesses 118A to 118C formed in the rear end 64B of the connecting portion <NUM>. Engagement between the one or more protrusions 116A to 116C and the one or more corresponding recesses 118A to 118C may align the cover <NUM> with respect to the head assembly <NUM>, specifically with respect to the connecting portion <NUM>. Engagement between the protrusions 116A to 116C and recesses 118A to 118C may also help to prevent unwanted rotation of cover <NUM> with respect to the connecting portion <NUM>. The forward end 64A of the connecting portion <NUM> is coupled to the cartridge-connecting assembly <NUM>, as shown in <FIG> and <FIG>. In some examples as shown, a section of the connecting portion <NUM> may be offset relative to the longitudinal axis A<NUM> of the body <NUM>.

An outer shape of the cover <NUM> may comprise any suitable shape. In the examples shown, an outer shape of the cover <NUM> may be substantially spherical, and the portion of the substantially continuous band of material <NUM> adjacent to the cover <NUM> may comprise a curved section <NUM> that substantially corresponds to the outer shape of the cover <NUM>, as shown in <FIG> and <FIG>. In other examples (not shown), the cover may be integral with the connecting portion <NUM>. For instance, the cover may comprise a substantially cylindrical section of material that is integral with the rear end 64B of the connecting portion <NUM> and extends outward from the rear end 64B toward the open end 40A of the body <NUM>. In further examples (not shown), the cover may be absent, and the forward assembly <NUM> may be modified such that the connecting portion <NUM> is adjacent to the open end 40A of the body <NUM>. For instance, a dimension of the shaft <NUM> and/or spring <NUM> may be decreased, in a direction parallel to the major longitudinal axis A<NUM> of the body <NUM>, such that the rear end 64B of the connecting portion <NUM> is adjacent to the open end 40A of the body <NUM>.

To assemble the handle <NUM>, in one example, the post <NUM> of the connecting portion <NUM> may be inserted into the central opening 56A of the cover <NUM> such that the protrusions 116A to 116C of the cover <NUM> are inserted into the recesses 118A to 118C formed in the connecting portion <NUM>, which may involve a friction fit between the post <NUM> and the central opening 56A and/or the protrusions 116A to 116C and the recesses 118A to 118C. The forward end 52A of the shaft <NUM> may then be inserted into the cover <NUM> and over the post <NUM> of the connecting portion <NUM>, with the extensions <NUM>-<NUM> to <NUM>-<NUM> engaging the notch 56B to align the shaft <NUM> with respect to the cover <NUM> (and with respect to the connecting portion <NUM>). The shaft <NUM>, the cover <NUM>, and the connecting portion <NUM> may then be ultrasonically welded together. The forward end 54A of the spring <NUM> may be inserted into the shaft <NUM> and pressed into the second spring receiving structure <NUM> formed in the connecting portion <NUM>. The spring <NUM> may be inserted before or after the shaft <NUM>, the cover <NUM>, and the connecting portion <NUM> are joined together by ultrasonic welding. The rear ends 52B, 54B of the shaft <NUM> and spring <NUM>, respectively, may then be inserted into the open end 40A of the body <NUM>, with the rear end 54B of the spring <NUM> being pressed into the first spring receiving structure <NUM>. Alternatively, following joining of the shaft <NUM>, the cover <NUM>, and the connecting portion <NUM>, the rear end 52B of the shaft <NUM> may be inserted into the open end 40A of the body <NUM>, after which the spring <NUM> may be installed by tilting the shaft <NUM> slightly, inserting the forward end 54A of the spring <NUM> into the second spring receiving structure <NUM>, and inserting the rear end 54B of the spring <NUM> into the first spring receiving structure <NUM>. Thereafter, the top and bottom shells <NUM>, <NUM> may be pressed together, which may involve a friction or snap fit between one of more of the structures formed on the interior surfaces 42A, 44A, as described above. The top and bottom shells <NUM>, <NUM> may then be joined together along one or more portions of their respective inner edges <NUM>, <NUM> using, for example, ultrasonic welding and/or adhesive.

In another example, the cover <NUM> and the connecting portion <NUM> may be assembled as described above and, thereafter, an adhesive may be introduced into the central opening 56A of the cover <NUM>. The adhesive may comprise, for example, a polyurethane resin, such as a two-component resin that cures at room temperature. The forward end 52A of the shaft <NUM> may be inserted into the cover <NUM> and over the post <NUM>, as described above, which results in a bond being formed between the shaft <NUM>, the cover <NUM>, and the connecting portion <NUM> via the adhesive. The spring <NUM> may be inserted before or after the shaft <NUM>, the cover <NUM>, and the connecting portion <NUM> are joined together by the adhesive. Assembly of the handle <NUM> may then proceed as described above. The handle <NUM>' depicted in <FIG> may be assembled in a similar manner. In all examples, at any point during assembly of the handle <NUM>, the cartridge-connecting assembly <NUM> including the button <NUM> may be installed in the forward end 64A of the connecting portion <NUM>.

According to the invention, one or more components of the handle-engaging assembly <NUM> extend past a joint between the top and bottom shells <NUM>, <NUM> in a direction toward the second end 40B of the body <NUM>. With reference to <FIG>, <FIG>, and <FIG>, the top and bottom shells <NUM>, <NUM> comprise one or more joints, or one continuous joint, along their respective inner edges <NUM>, <NUM> at which the top and bottom shells <NUM>, <NUM> are joined, with a forward joint <NUM> being formed between the top shell <NUM> and a forwardmost point 44B of the bottom shell <NUM>. One or more components of the handle-engaging assembly <NUM>, e.g., the shaft <NUM> and/or the spring <NUM>, may extend past the forward joint <NUM> in a direction toward the second end 40B of the body <NUM>. Although not visible in <FIG>, one or more of the components of the handle engaging-assembly (not labeled) would similarly extend past a forward joint <NUM>' formed between the bottom shell <NUM>' and a forwardmost point (not labeled) of the top shell <NUM>' in a direction toward the second end 40B' of the body <NUM>'.

In addition, in all embodiments, a forward end of the substantially continuous band of material <NUM> may be closer to a joint between the top and bottom shell <NUM>, <NUM> than to the cartridge-connecting assembly <NUM>. With reference to <FIG>, <FIG>, <FIG>, and <FIG>, the forward edge 90B of the substantially continuous band of material <NUM>, which may define the forward end of the substantially continuous band of material <NUM>, may be closer to the forward joint <NUM> than to a rear edge 30A of the cartridge-connecting assembly <NUM>. Similarly, as shown in <FIG>, the forward edge 90B' of the substantially continuous band of material <NUM>', which may define the forward end of the substantially continuous band of material <NUM>', may be closer to the forward j oint <NUM>' between the top and bottom shells <NUM>', <NUM>' than to a rear edge (not shown) of the cartridge-connecting assembly <NUM>. In some particular examples, as shown in <FIG> and <FIG>, the respective substantially continuous bands of material <NUM>, <NUM>' may be adjacent to the joint <NUM>, <NUM>'.

With reference to <FIG>, <FIG>, <FIG>, <FIG>, and <FIG>, the body <NUM> and/or shaft <NUM> may comprise one or more structures to retain the shaft <NUM> within the body <NUM>. In some examples, the rear end 52B of the shaft <NUM> may comprise the aperture 52C, and an interior surface 40C of the body <NUM> may comprise a structure that engages the aperture 52C. For instance, the interior surface 44A of the bottom shell <NUM> may comprise an extension <NUM> that engages the aperture 52C. As shown in <FIG> and <FIG>, upon assembly of bottom shell <NUM> to the top shell <NUM>, engagement between the aperture 52C and the extension <NUM> prevents the shaft <NUM> from moving forward out of the open end 40A of the body <NUM>. The aperture 52C may extend fully through a thickness of the shaft <NUM>, as shown, or may extend only partially through the thickness of the shaft <NUM> (not shown). In other examples (not shown), such as when the bottom shell <NUM>' comprises the substantially continuous band of material <NUM>' (see <FIG>), an interior surface of the top shell <NUM>' may comprise an extension that engages the aperture 52C formed in the shaft <NUM> and prevents the shaft <NUM> from moving forward out of the body <NUM>'. In further examples (not shown), an outer surface <NUM> of the shaft <NUM> may comprise an extension, and the interior surface 40C of the body <NUM> may comprise a recess that receives and engages the extension so as to secure the shaft <NUM> within the body <NUM>. In some instances, the extension may be formed on, i.e., integral with, the shaft <NUM> or body <NUM> (e.g., molded during the manufacturing process). In other instances, the extension may be a separate element such as a pin or rod coupled to the shaft <NUM> and/or the body <NUM> during manufacture (e.g., via ultrasonic welding or by insertion). Although the aperture 52C is depicted in <FIG> and <FIG> as having a substantially oval shape and the extension <NUM> is depicted in <FIG> as having a substantially circular or cylindrical shape, it is understood that the aperture 52C and the extension <NUM> may comprise any suitable shape, such as a square or rectangular shape.

In other embodiments (not shown), the shaft <NUM> may comprise a raised collar that extends at least partially around a circumference of the shaft <NUM> and engages the extension formed in the interior surface 40C of the body <NUM>, in which engagement between the raised collar and the extension prevents the shaft <NUM> from moving forward out of the body <NUM>. In further embodiments (not shown), the shaft <NUM> may comprise a generally cylindrical cage-like or lattice structure with one or more additional openings.

In other embodiments, one or more structures of the body <NUM> and/or shaft <NUM> may engage one or more additional components (not shown), such as a washer ring or other structure, to retain the shaft <NUM> within the body <NUM> via an indirect engagement between the body <NUM> and the shaft <NUM>. For instance, a semicircular or horseshoe-shaped element (not shown) may fit over the shaft <NUM> and engage a structure (e.g., a groove or raised collar; not shown) defined on the outer surface <NUM> of the shaft <NUM> and extending at last partially around the circumference of the shaft <NUM>. The interior surface 40C of the body <NUM> may comprise a structure (e.g., a groove or ledge; not shown) that engages the element to retain the shaft <NUM> within the body <NUM> and prevent the shaft <NUM> from moving forward out of the body <NUM>.

The body <NUM> and/or shaft <NUM> may further comprise one or more structures that allow rotation of at least a portion of the forward assembly <NUM> relative to the body <NUM>, as indicated by arrow C in <FIG>. In particular, at least a portion of the handle-engaging assembly <NUM> may rotate, such that the head assembly <NUM> is able to rotate relative to the body <NUM>. For example, the shaft <NUM> and a portion of the spring <NUM> may rotate relative to the body <NUM>. The shaft <NUM> may comprise one or more circumferential features that contact one or more respective bearing surfaces formed on the interior surface 40C of the body <NUM> and allow the shaft <NUM> to rotate relative to the body <NUM>. As shown in <FIG> and <FIG>, the outer surface <NUM> of the shaft <NUM> may comprise one or more additional circumferential ridges <NUM>-<NUM>, <NUM>-<NUM>. A first one of the additional circumferential ridges <NUM>-<NUM> may be located at or near a middle portion of the shaft <NUM> and may engage a first circumferential bearing surface, which may be defined by a portion of an interior surface <NUM> of the substantially continuous band of material <NUM> (see also <FIG>). In some examples, the first circumferential bearing surface may be located entirely within the substantially continuous band of material <NUM>. As shown in <FIG>, <FIG>, and <FIG>, a second one of the additional circumferential ridges <NUM>-<NUM> may be located near a rear edge (not separately labeled) of the shaft <NUM> and may engage a second circumferential bearing surface, which may be defined by a top bearing surface <NUM>-<NUM> that is formed in the top shell <NUM> and a bottom bearing surface <NUM>-<NUM> that is formed in the bottom shell <NUM>. Alternatively, or in addition to the circumferential ridges <NUM>-<NUM>, <NUM>-<NUM>, the one or more circumferential features may comprise a plurality of pads (not separately labeled) that are arranged circumferentially on the outer surface <NUM> of the shaft <NUM> at or near a location of the circumferential ridges <NUM>-<NUM>, <NUM>-<NUM>. These pads may be separate or discontinuous (i.e., they do not extend around an entirety of the circumference of the shaft <NUM>) and may replace or augment the circumferential ridges <NUM>-<NUM>, <NUM>-<NUM> to, for example, ensure a close fit between the shaft <NUM> and the circumferential bearing surfaces of the body <NUM>.

As described above, the interconnect member <NUM> of the cartridge <NUM> is releasably received by the cartridge-connecting assembly <NUM>, the cartridge-connecting assembly <NUM> is fixedly coupled to the forward end 64A of the connecting portion <NUM>, and the shaft <NUM> is fixedly coupled to the rear end 64B of the connecting portion <NUM>, such that the head assembly <NUM>, i.e., the connecting portion <NUM> and the cartridge-connecting assembly <NUM>, as well as the cartridge <NUM>, are able to rotate with the shaft <NUM>, relative to the body <NUM>. When present, the cover <NUM> may be coupled to the connecting portion <NUM> and the shaft <NUM> also as described above, such that the cover <NUM> rotates with the shaft <NUM> and the head assembly <NUM>. The curved section <NUM> of the substantially continuous band of material <NUM> may accommodate the outer shape of the cover <NUM> to allow the cover <NUM> to rotate freely without contacting the body <NUM>.

As described above, the spring <NUM> may be coupled at the forward end 54A to the connecting portion <NUM> and at the rear end 54B to the body <NUM>, and a portion of the spring <NUM> may rotate or flex upon rotation of the head assembly <NUM>. In particular, upon rotation of the head assembly <NUM>, the portion of the spring <NUM> extending between the first and second spring receiving structures <NUM>, <NUM> may rotate or flex from a neutral or starting position (<NUM> degrees) to a flexed position. The flexed position may be from about +/- <NUM> degrees from the neutral position. Twisting of the spring <NUM> generates a return torque that biases the spring <NUM>, along with the head assembly <NUM> and shaft <NUM>, back to their respective starting positions. Rotation of the head assembly <NUM> may occur, for example, as a user is shaving and the head assembly <NUM> rotates and twists to accommodate the contours of a surface that is being shaved.

The body <NUM> and/or shaft <NUM> may optionally comprise one or more structures to limit rotational movement of the portion(s) of the forward assembly <NUM> relative to the body <NUM>. In particular, in the embodiment illustrated in <FIG>, <FIG>, and <FIG>, engagement between the extension <NUM> and the aperture 52C may limit rotational movement of the shaft <NUM>, thereby limiting rotational movement of the portion(s) of the forward assembly <NUM> and providing a hard stop. The aperture 52C may have axial and circumferential inner dimensions, and engagement between the extension <NUM> and circumferentially spaced apart edges 52C-<NUM>, 52C-<NUM> of the aperture 52C may define the amount of rotation of the portion(s) of the forward assembly <NUM> relative to the body <NUM>, i.e., limits an extent of rotational motion by the shaft <NUM> relative to the body <NUM>, thereby limiting rotational movement of the portion(s) of the forward assembly <NUM> relative to the body <NUM>. The aperture 52C and the extension <NUM> may each comprise any suitable shape, as described above, and/or dimension that allows engagement therebetween. In one particular example, the circumferential dimension of the aperture 52C may be greater than the axial dimension of the aperture 52C and the extension <NUM> has an outer diameter that is closer in size to the aperture axial dimension than to the aperture circumferential dimension. As shown in <FIG>, <FIG>, and <FIG>, an inner dimension of the aperture 52C may be larger, in a circumferential direction, than an outer dimension of the extension <NUM> such that the shaft <NUM> is able to rotate about its longitudinal axis A<NUM>, with engagement between the extension <NUM> and the circumferentially spaced apart edges 52C-<NUM>, 52C-<NUM> of the aperture 52C limiting the amount of rotation of the shaft <NUM>. Preferably, the shaft <NUM> may rotate from about +/- <NUM> degrees from a neutral position (<NUM> degrees). In further examples, it is contemplated that the shaft <NUM> could rotate beyond +/- <NUM> degrees.

In other embodiments (not shown) in which the shaft <NUM> comprise the extension and the interior surface 40C of the body <NUM> comprises a recess, an inner dimension of the recess may be configured to similarly limit an extent of rotational motion of the shaft <NUM> relative to the body <NUM>. In further examples (not shown), the body <NUM> and/or shaft <NUM> may comprise one or more additional structures (other than the structure(s) that retain the shaft <NUM> within the body <NUM>) that limit rotational movement of the portion(s) of the forward assembly <NUM> relative to the body <NUM>. For instance, in examples in which the shaft <NUM> receives the horseshoe-shaped element (not shown) described above, the body <NUM> may comprise an additional groove or ledge that engages the horseshoe-shaped element to limit rotation of the shaft <NUM>.

In all embodiments, during assembly, the shaft <NUM> comprising the one or more structures may pass through the open end 40A of the body <NUM> formed by the substantially continuous band of material <NUM>. When the shaft <NUM> comprises the aperture 52C and the interior surface 40C of the body <NUM>, i.e., the bottom shell <NUM>, comprises the extension <NUM> as shown in <FIG>, <FIG>, and <FIG>, the outer diameter of the rear end 52B of the shaft <NUM> may be configured to be only slightly smaller than the inner diameter of the opening 90A defined by the substantially continuous band of material <NUM>. Because the extension is not on the shaft <NUM>, the inner diameter of the opening 90A does not need to be made larger to accommodate the extension. In other words, the opening 90A may be only slightly larger than the outer diameter of the rear end 52B of the shaft <NUM>, which allows for a more stable connection of the forward assembly <NUM> to the body <NUM>, thereby reducing or substantially preventing wobble or side-to-side movement of the forward assembly <NUM> relative to the body <NUM>. When the shaft <NUM> comprises the extension (not shown), the inner diameter of the opening 90A defined by the substantially continuous band of material <NUM> and the outer diameter of the rear end 52B of the shaft <NUM> may be substantially as described above, except that the opening 90A may comprise a small notch (not shown; extends partially through the substantially continuous band of material <NUM>) sized to allow the shaft <NUM> with the extension to pass through the opening 90A during assembly of the handle <NUM>. Although not visible, the substantially continuous band of material <NUM>' of the handle <NUM>' depicted in <FIG> may similarly comprise an opening with an inner diameter that is only slightly larger than the outer diameter of the rear end 52B of the shaft <NUM>.

By forming the open end of the body from the substantially continuous band of material as described herein, a bending strength of the razor handle formed from the body may be increased. Razor handles are subjected to a variety of forces in everyday use, including bending and impact forces. For example, during shaving and cartridge replacement, the user typically holds one end of the handle rigid and places the other end under a load, e.g., by pressing the cartridge against a surface to be shaved, pushing the button to eject an old cartridge, and/or pressing a new cartridge onto the handle. In addition, the razor handle may be subjected to impact and bending forces when it is, for example, dropped, packed tightly in a travel bag and pressed against other objects, etc. Many razor handles are formed from plastic and comprise a two-piece construction in which the top and bottom halves are joined, at least in part, using ultrasonic welding. A forward portion of a joint between the top and bottom halves is often positioned near a location of stress concentration, such as a point of rotation or a geometric discontinuity in the razor handle (e.g., a portion that is offset relative to the major longitudinal axis of the razor handle). When the razor handle is subjected to bending forces, this forward portion of the joint may break, as the individual welds may be relatively weak, and the two halves may begin separating along the remainder of the joint. Separation of the two halves compromises the bending strength of the razor handle, and in some cases, one or both of the halves may also begin to crack in a direction perpendicular to the longitudinal axis of the razor handle. The razor handle may continue to function as intended for a time without the user noticing an appreciable change in operation, but the amount of separation between the two halves and/or the decrease in bending strength may eventually become significant enough that the razor handle loses its ability to function and/or the user becomes dissatisfied with the feel of the razor handle. In addition, in razor handles with rotating components, even a small amount of separation between the two halves may allow one or more of the rotating components to dislodge, which may result in a loss of the rotating function and/or detachment of the rotating components from the razor handle.

It is believed that razor handles in accordance with the present disclosure will provide improved bending strength and may help to avoid separation of the top and bottom shells. When the second end of the razor handle is held rigid and the razor handle is subjected to a bending force (e.g., by exerting an upward force on the forward assembly), an area of highest stress concentration occurs near the substantially continuous band of material. This area is formed from a continuous or substantially continuous piece of material, such that the bending strength of the razor handle may be limited primarily by the properties of the material comprising the substantially continuous band of material, as opposed to being limited by the strength of the joint between the top and bottom shells. The forward joint between the top and bottom shells is spaced away from this area of stress concentration, which reduces the likelihood that the top and bottoms shells will separate.

In embodiments in which the top and bottom shells are joined along their inner edges, wherein the inner edges are defined by curved connecting portions and an intermediate portion extending between corresponding pairs of the connecting portions, a force exerted on the forward portion of the joint between the top and bottom shells will generally be distributed more evenly and over a larger area. This structure in which connecting portions with a curved or arched shape are joined by an intermediate portion demonstrates much greater mechanical strength when subjected to a bending force, as compared to a joint between inner edges having substantially linearly shaped portions that extend substantially the entire extent of the top and bottom shells from a rear portion to a forward open portion. The arched shape causes the force to be distributed along the curve of the arch, rather than concentrating in one small area. In addition, razor handles in accordance with the present disclosure may use a two-piece construction that may take advantage of the benefits of molding, while still maintaining the structural integrity of the razor handle. In particular, a thickness of the material forming the top and bottom shells may be minimized to retain a particular aesthetic look and feel for the razor handle. Forming the razor handle via molding also allows the formation of one or more hollow cavities to accommodate, for example, the metal rod and of one or more structures on the inner surface(s) of the top and/or bottom shells that securely retain the rotating components within the razor handle.

Formation of the open end of the razor handle by the substantially continuous band of material further allows tight control of the inner diameter of the opening. In razor handles in which the open end is formed by two halves, the inner diameter of the opening may vary widely depending on manufacturing tolerances, which may allow unwanted motion of any components that are received in the open end. The open end of razor handles in accordance with the present disclosure is contained entirely within one of the top shell or the bottom shell and may thus be more precisely formed during manufacture. This more exact control of dimensional variations may help to reduce the amount of wobble and other unwanted motion of the forward assembly and may provide a more robust handle. In addition, because of this more precise control, the interior surface of the substantially continuous band of material may define one of the circumferential bearing surfaces for the shaft.

Claim 1:
A shaving razor handle (<NUM>) comprising:
a body (<NUM>) defined by a top shell (<NUM>) joined to a bottom shell (<NUM>), the body (<NUM>) comprising an open end (40A),
wherein one of the top shell (<NUM>) or the bottom shell (<NUM>) comprises a substantially continuous band of material (<NUM>) that forms the open end (40A) of the body (<NUM>),
wherein the shaving razor handle (<NUM>) further comprises a handle-engaging assembly (<NUM>) received in the open end (40A) of the body (<NUM>), characterised in that one or more components of the handle-engaging assembly (<NUM>) extend past a joint (<NUM>) between the top shell (<NUM>) and the bottom shell (<NUM>) in a direction toward a second end (40B) of the body (<NUM>).