Patent Description:
Razor cartridges are typically provided with a guard in front of the blades and a cap behind the blades which contact the skin before and after the blades respectively. The guard and cap may aid to establish the "shaving geometry" i.e. the parameters which determine blade orientation and position relative to the skin and have a strong influence on shaving performance and efficiency of the razor. The cap provides a lubricating agent to the skin surface after contacting the blades. Certain razors may also include an additional member in front of the blades to manage the skin and stretch the skin prior to contact with the blade to ensure optimal contact with the blade without negative skin sensations. These skin contacting members are typically projections of various shapes injection molded from an elastomeric to further improve skin tactile and stretching performance. The elastomeric projections are designed to stretch skin and deform under typical shaving loads. Accordingly, they may not provide sufficient exfoliation in front of the blades.

Exfoliation can generally be described as the peeling off of flakes or scales of dead skin. The look and overall feel of the skin can be improved by exfoliation. Exfoliation may be achieved, for example, by the use of cosmetics that include abrasive particles or by rubbing the skin with an abrasive material, such as a loofah. Exfoliation is generally known to enhance the tactile properties of a wet shaving system, for example, providing shaving systems with a roughened guard surface.

In shaving systems of the wet shave type, factors such as the frictional drag of the razor across the skin, the force needed to sever hairs, and irritation of preexisting skin damage can create a degree of shaving discomfort, especially if an exfoliant is incorporated as part of the shaving razor. Accordingly, there is a need for an exfoliation bar in place of or in addition to a guard (and a skin stretching member) that provides sufficient exfoliation, but does not exacerbate shaving discomfort.

Other features and advantages of the invention will be apparent from the description and drawings, and from the claims.

In one aspect, the invention features, a shaving razor as defined in claim <NUM>.

Referring to <FIG>, the present disclosure shows a shaving razor <NUM> having a shaving cartridge <NUM> mounted to a shaving razor handle <NUM>. The handle <NUM> may have a gripping portion <NUM> with a distal end <NUM> to which the shaving cartridge <NUM> is mounted. The shaving cartridge <NUM> may include a housing <NUM> dimensioned to receive at least one blade <NUM>. The housing <NUM> may have a front portion <NUM> with exfoliation bar <NUM> positioned in front of the blades <NUM>. A guard <NUM> may be positioned between the exfoliation bar <NUM> and the blade <NUM>. The housing <NUM> may also have a rear portion <NUM> with a cap <NUM> positioned behind the blades <NUM>. Although five blades <NUM> are shown, the shaving cartridge <NUM> may have more or fewer blades <NUM> depending on the desired performance and cost of the shaving razor <NUM>.

The shaving cartridge <NUM> may be pivotably (i.e., rotation of the cartridge <NUM> about an axis relative to the shaving razor handle <NUM>) and/or detachably engaged to the shaving razor handle <NUM>. It is understood that certain embodiments may include shaving cartridges <NUM> that pivot in relation to the handle <NUM>, but are also secured to the razor handle <NUM> (i.e., not detachably engaged to the razor handle <NUM>). In this embodiment, the entire shaving razor <NUM> may be discarded when the blade <NUM> or blades <NUM> have become dulled (i.e., disposable razor). Disposable razors may have either a pivoting or non-pivoting type cartridge <NUM>.

The housing <NUM>, the handle <NUM> and the exfoliation bar <NUM> may be injection molded from a semi-rigid polymeric material. In certain embodiments, the housing <NUM> and/or the handle <NUM> may be molded from Noryl™ (a blend of polyphenylene oxide (PPO) and polystyrene developed by General Electric Plastics, now SABIC Innovative Plastics). The housing <NUM>, exfoliation bar <NUM> and/or the handle <NUM> may comprise a material having a Shore A hardness greater than <NUM>, for example, about Shore A <NUM> to about Shore D <NUM>. Materials for the housing <NUM>, exfoliation bar <NUM> and/or the handle <NUM> may include, but not limited to acrylonitrile butadiene styrene (ABS), polyoxymethylene (POM), polypropylene (PP), high impact polystyrene (HIPS), or any combinations thereof. As will be explained in greater detail below, the exfoliation bar <NUM> comprising a stiffer material that does not deform under shaving load may provide additional shaving benefits. In certain embodiments, the exfoliation bar <NUM> may be positioned between the guard <NUM> and one or more elastomeric projections <NUM> (e.g., fins). The elastomeric projections <NUM> may help stretch the skin during a shaving stroke to facilitate exfoliation of the skin for a more efficient shave.

The cap <NUM> may also be molded from the same material as the housing <NUM>. In certain embodiments, the cap <NUM> may be molded from a lubricious polymeric material or a shaving aid to provide lubrication to the surface of the skin during shaving. Alternatively, the cap <NUM> may have a separate molded or extruded component that is assembled to the housing <NUM>. The cap <NUM> may be molded or extruded from the same material as the housing <NUM> or may be molded or extruded from a more lubricious material that has an effective amount of a water-leachable shaving aid composition to provide increase comfort during shaving.

<FIG> is a front view of a shaving razor handle <NUM> of the shaving razor <NUM> of <FIG>. In certain embodiments, the exfoliation bar <NUM> may be part of the handle <NUM> and is mounted to the shaving cartridge <NUM> (<FIG>). The exfoliation bar <NUM> may be pivotably attached to a distal end <NUM> of the handle <NUM>. Accordingly, the exfoliation bar <NUM> may pivot relative to a gripping portion <NUM> of the handle <NUM>. The exfoliation bar <NUM> may be inserted into an opening <NUM> of the shaving cartridge <NUM> (e.g., within the housing <NUM>), as shown in <FIG>. Accordingly, the exfoliation bar <NUM> may be temporarily locked within the housing <NUM> facilitating the pivoting of the shaving cartridge <NUM> relative to the gripping portion <NUM> of the handle <NUM> during a shaving stroke. It may be desirable to incorporate the exfoliation bar <NUM> into the handle <NUM> rather than the shaving cartridge <NUM>. For example, the exfoliation bar <NUM> may require higher performance polymeric materials to efficiently exfoliate the skin. The incorporation of higher performance polymeric materials on the shaving cartridge <NUM> may be cost prohibitive. Furthermore, incorporating higher performance polymeric materials on the handle <NUM>, allows the exfoliation bar <NUM> to be used over an extended life cycle (e.g., several years), unlike a shaving razor cartridge that may be used for only one month. It is believed, without being held to theory that the incorporation of the exfoliation bar <NUM> into a pivot mechanism <NUM> (e.g., a pin pivot or shell bearing) of the handle <NUM> may allow the user to better control the pressure that is transferred from the exfoliation bar <NUM> to the skin during shaving, thus improving the user's ability to exfoliate without discomfort. However, it is understood that an exfoliation bar <NUM> may be incorporated into a shaving razor cartridge <NUM>, as shown in the embodiment of <FIG>. The shaving razor cartridge <NUM> may be substantially the same as the shaving cartridge <NUM>, with the exception the exfoliation bar <NUM> is permanently incorporated into a housing <NUM> of the shaving razor cartridge <NUM> instead of a handle.

Referring to <FIG> and <FIG>, a front view and an enlarged view of the exfoliation bars <NUM> and <NUM> are shown. One important aspect of the exfoliation bars <NUM> and <NUM> may be to provide a large area over which contact can be made with the skin during shaving, and a circumscribing perimeter extending about the skin contacting surface confines an area, referred to hereinafter as the "footprint area". The exfoliation bars <NUM> and <NUM> may have a skin contacting footprint of at least <NUM><NUM> and more preferably about <NUM><NUM> to about <NUM><NUM> which may allow for sufficient skin contact and exfoliation. In other embodiments, the skin contacting footprint may be greater than <NUM><NUM>, for example when exfoliating and shaving larger body parts, such as the legs. As will be described in greater detail below, a larger skin contacting area may also spread out the pressure exerted on the skin by a plurality of skin protrusion elements <NUM> on the exfoliation bars <NUM> and <NUM>. The exfoliating bars <NUM> and <NUM> and/or the plurality of skin protrusion elements <NUM> may comprise a material having a Shore A hardness greater than <NUM>, as previously discussed above. Skin protrusions that comprise softer materials may deform under typical shaving forces. Accordingly, the geometry of the skin protrusion is not constant and may negatively impact exfoliation performance. The plurality of skin protrusion elements <NUM> may comprise a polymeric material having a coefficient of friction of about <NUM> to about <NUM> (ASTM D3702, Dynamic Coefficient of Friction, <NUM> psi, <NUM> fpm). A lower coefficient of friction of may improve glide of the exfoliation bars <NUM> and <NUM> which made help in decreasing irritation, especially for harder materials because they may apply more pressure to the skin during a shaving stroke.

The skin protrusion elements <NUM> are spaced apart discrete elements, as shown, or may be continuous elements that extend along a length L1 of the footprint area. The length L1 may be about <NUM> to about <NUM>. The exfoliation bar <NUM>, <NUM> may have a width "w1" of about <NUM> to about <NUM>. The skin protrusion elements <NUM> may be spaced apart in alternating rows (e.g., skin protrusion elements <NUM> of one row overlap skin protrusion elements <NUM> in a rows immediately forward and after). In certain embodiments, the skin protrusion elements <NUM> may be spaced apart within a row by a distance "d1" of about <NUM> to about <NUM>. The skin protrusion elements <NUM> may be spaced apart from skin protrusion elements <NUM> in an immediately adjacent row by a distance "d2" of about <NUM> to about <NUM>. The distances between skin protrusion elements <NUM> may be calculated from a center <NUM> of a tip <NUM> (i.e., upper most top surface) of the skin protrusion elements <NUM>. The plurality of skin protrusion elements <NUM> may have a pair of inclined side faces <NUM> and <NUM> that extend to the tip <NUM>. The tip may have a radius in the shave direction of about <NUM> to <NUM> and more preferably about <NUM> to <NUM>. A leading face <NUM> and/or a rear face <NUM> of the plurality of skin protrusion elements <NUM> may be semicircular.

The skin protrusion elements <NUM> extend from a lower surface <NUM> of the exfoliation bars <NUM> and <NUM> to the tip <NUM> by a distance of about <NUM> to about <NUM>. In certain embodiments, adjacent skin protrusion elements <NUM> may be spaced apart to define a gap <NUM> having a width "w2" of about <NUM> to about <NUM>. The gap <NUM> makes the exfoliation bar easier to clean and manages the hair during a shaving stroke so that the protrusion elements can better clear dead skin and debris from around the hair, resulting in a more efficient and closer shave. The skin protrusion elements <NUM> may not deflect under typical shaving conditions, accordingly the gap <NUM> may not decrease in size or become covered up by adjacent skin protrusion elements <NUM>. Accordingly, the rigidity of the polymeric material of the skin protrusion elements <NUM> helps maintain a consistent geometry of the gap <NUM> and the skin protrusion elements <NUM>.

Referring to FIG. SA, a cross section view is taken generally along the line <NUM>-<NUM> of <FIG>. It is understood that <FIG> also represents a cross section view taken generally along a cross section taken along the line <NUM>-<NUM> of <FIG> because <FIG> illustrates the shaving cartridge <NUM> with the exfoliation bar <NUM> and <NUM>. The one or more blades <NUM> may each have a cutting edge <NUM> defining a shaving plane P1. In certain embodiments, a plane P2 of the leading face <NUM> of one or more of the skin protrusion elements <NUM> may intersect the shaving plane at an angle "A1" of about <NUM> degrees to <NUM> degrees. The angle "A1" may also be calculated from an intersection of an average tip plane P3 (i.e., a plane created from the average position of all of the tips <NUM> of the skin protrusion elements <NUM>) and the plane P2 of the leading face <NUM>. In certain embodiments, the average tip P3 plane may extend along the shaving plane P1.

Referring to <FIG>, an enlarged view of the shaving cartridge <NUM> of <FIG> is illustrated. The exfoliation bar <NUM> and <NUM> may be spaced apart from the guard <NUM> to define an elongated gap <NUM> that extends along the length of the exfoliation bar <NUM> and has a depth of about <NUM> to about <NUM> from the tip <NUM> of the skin contacting element nearest the guard <NUM> to a bottom surface <NUM> of the gap <NUM>. The gap <NUM> may have a width "w3" of about <NUM> to about <NUM>. In certain embodiments, the tips <NUM> of the skin protrusion elements <NUM> may be about <NUM> below to about <NUM> above a plane P5 of a top surface <NUM> of the guard <NUM>. In certain embodiments, the tips <NUM> may be about <NUM> above to about <NUM> below the plane P5 to balance exfoliation performance and comfort.

Referring to <FIG>, an enlarged front view of one of the skin protrusion elements <NUM> is illustrated. A construction plane "CP" may isolate a volume of the skin protrusion elements <NUM> about <NUM> below the tip <NUM>. The volume isolated by the construction plane "CP" divided by the skin contacting footprint area may be about <NUM><NUM> to <NUM><NUM> per mm<NUM> of footprint area. It is believed, without being held to theory that the construction plane represents the approximate depth the skin protrusion elements <NUM> (e.g., the front face <NUM>) push into the skin and thus engage the skin for exfoliation.

Claim 1:
A shaving razor (<NUM>) comprising:
a shaving razor cartridge (<NUM>) having a guard (<NUM>), a cap (<NUM>) and at least one blade (<NUM>) between the guard and the cap;
a plurality of blades between the guard and the cap, the blades having a respective cutting edge (<NUM>) that define a shave plane (P1);
an exfoliation bar (<NUM>, <NUM>) positioned in front of the guard, the exfoliation bar comprising
a skin contacting footprint area of at least <NUM><NUM> and comprising a material having a Shore A durometer greater than <NUM>; and
a plurality of spaced apart skin protrusion elements (<NUM>), wherein the skin protrusion elements each have a tip (<NUM>) with a radius of <NUM> to <NUM> positioned within the skin contacting footprint area, the skin protrusion elements extending from a lower surface of the exfoliation bar to the tip by a distance of about <NUM> to about <NUM>, the skin protrusion elements having a leading face (<NUM>) intersecting the shave plane at an angle of <NUM> degrees to <NUM> degrees, wherein a volume isolated by a construction plane <NUM> below the tip of the skin protrusion elements divided by the skin contacting footprint area is <NUM><NUM> to <NUM><NUM> per mm<NUM> of skin contacting footprint area, and wherein the shaving razor cartridge defines an opening (<NUM>) and the exfoliation bar is positioned within the opening