CN107735236A - 聚合物切割刃结构及其制造方法 - Google Patents
聚合物切割刃结构及其制造方法 Download PDFInfo
- Publication number
- CN107735236A CN107735236A CN201680038202.2A CN201680038202A CN107735236A CN 107735236 A CN107735236 A CN 107735236A CN 201680038202 A CN201680038202 A CN 201680038202A CN 107735236 A CN107735236 A CN 107735236A
- Authority
- CN
- China
- Prior art keywords
- cutting edge
- polymeric material
- blade
- foundation structure
- edge structure
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Granted
Links
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- SMZOUWXMTYCWNB-UHFFFAOYSA-N 2-(2-methoxy-5-methylphenyl)ethanamine Chemical compound COC1=CC=C(C)C=C1CCN SMZOUWXMTYCWNB-UHFFFAOYSA-N 0.000 claims description 3
- NIXOWILDQLNWCW-UHFFFAOYSA-N 2-Propenoic acid Natural products OC(=O)C=C NIXOWILDQLNWCW-UHFFFAOYSA-N 0.000 claims description 3
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B26—HAND CUTTING TOOLS; CUTTING; SEVERING
- B26B—HAND-HELD CUTTING TOOLS NOT OTHERWISE PROVIDED FOR
- B26B21/00—Razors of the open or knife type; Safety razors or other shaving implements of the planing type; Hair-trimming devices involving a razor-blade; Equipment therefor
- B26B21/54—Razor-blades
- B26B21/58—Razor-blades characterised by the material
- B26B21/60—Razor-blades characterised by the material by the coating material
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B26—HAND CUTTING TOOLS; CUTTING; SEVERING
- B26B—HAND-HELD CUTTING TOOLS NOT OTHERWISE PROVIDED FOR
- B26B21/00—Razors of the open or knife type; Safety razors or other shaving implements of the planing type; Hair-trimming devices involving a razor-blade; Equipment therefor
- B26B21/40—Details or accessories
- B26B21/4068—Mounting devices; Manufacture of razors or cartridges
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B26—HAND CUTTING TOOLS; CUTTING; SEVERING
- B26B—HAND-HELD CUTTING TOOLS NOT OTHERWISE PROVIDED FOR
- B26B21/00—Razors of the open or knife type; Safety razors or other shaving implements of the planing type; Hair-trimming devices involving a razor-blade; Equipment therefor
- B26B21/54—Razor-blades
- B26B21/58—Razor-blades characterised by the material
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- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B29C35/00—Heating, cooling or curing, e.g. crosslinking or vulcanising; Apparatus therefor
- B29C35/02—Heating or curing, e.g. crosslinking or vulcanizing during moulding, e.g. in a mould
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- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
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- B29C33/44—Moulds or cores; Details thereof or accessories therefor with means for, or specially constructed to facilitate, the removal of articles, e.g. of undercut articles
- B29C33/52—Moulds or cores; Details thereof or accessories therefor with means for, or specially constructed to facilitate, the removal of articles, e.g. of undercut articles soluble or fusible
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- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B29C39/00—Shaping by casting, i.e. introducing the moulding material into a mould or between confining surfaces without significant moulding pressure; Apparatus therefor
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- B29C39/021—Shaping by casting, i.e. introducing the moulding material into a mould or between confining surfaces without significant moulding pressure; Apparatus therefor for making articles of definite length, i.e. discrete articles by casting in several steps
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- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
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Abstract
本发明提供了一种功能性聚合物切割刃结构和使用聚合物材料制造切割刃结构的方法。可使用本发明来形成用于剃刀刀片架的剃刀刀片或用于装配于剃刀刀片架框架中的刀片盒。
Description
技术领域
本发明涉及剃刀和制造切割刃结构的方法,并且更具体地涉及由聚合物材料制造切割刃结构诸如剃刀刀片的方法。
背景技术
剃刀刀片通常由诸如不锈钢的合适金属薄片材料形成,该金属薄片材料被纵切成所需的宽度并被热处理以使金属硬化。硬化操作利用高温炉,在高温炉中,金属可被暴露于大于约1000℃的温度最多约20秒,之后进行淬火,由此使金属快速冷却,以获得某些期望的材料特性。
硬化之后,通常通过研磨刀片来形成切割刃。将钢制剃刀刀片机械地磨快以形成切割刃,该切割刃是锋利且强的以长时间切断毛发。连续研磨过程通常限制刀片形状以具有带大致三角形或楔形轮廓(例如,横截面)的直边缘。切割刃楔形构型通常具有半径小于约1000埃的最终末端。
这种现有技术方法的优点是它是一种经过证明的大量、高速制造刀片的经济性方法。如果此类方法可将较低成本的材料用于刀片成形并且还能够实现不是大致三角形的切割刃轮廓,则其将是特别期望的。
公开了用于一次性餐具或一次性外科手术刀的具有由聚合物材料制成的切割刃的刀片(例如,美国专利6,044,566、美国专利5,782,852)。GB2310819A中公开了由聚合物材料制成的剃刀刀片。现有技术聚合物刀片中任一个的缺点在于制备此类塑性刀片的方法不适于形成末端半径小于1μm的切割刃,如切割毛发所需要的。
通常,现有技术利用熔体流动加工技术。将现有技术的熔融聚合物注入通常为金属的模具腔中,但聚合物通常太粘(通常超过100,000厘泊)而不能完全渗入亚微米(如,小于1微米)尺寸的空间中,该空间是腔中形成剃刀刀片边缘所需的。然而,选择可能有利于渗入亚微米尺寸空间中的较低粘度材料或增加注射压力,导致聚合物材料在模具的两个半块的配合表面之间渗透,这被称为“飞边”,因此不能实现所需的切割刃末端半径。聚合物材料的粘度减小还可通过将聚合物原料加热高于玻璃化转变温度,通常超过200℃来获得。此外,在填充腔之后,流体聚合物材料需要冷却以达到固体状态,这导致刀片形状收缩和边缘变圆,因此不能实现所需的切割刃末端半径。
因此,需要由聚合物制备切割刃结构的更好方法和制备剃刀用切割刃结构的更高性价比方法,所述切割刃结构具有所需的末端半径、更少边缘质量可变性和锋利性以提供相当或改善的剃刮体验。
还期望寻找可形成具有任何形状(如非线性边缘)的切割刃结构和/或提供整合组件的材料和方法。
发明内容
本发明提供了用于由聚合物材料制造一个或多个切割刃结构如剃刀刀片的简单有效的方法和功能性聚合物切割刃结构如剃刀刀片。此外,一些方法适用于生产多个此类切割刃结构,或“刀片盒”,其包括待作为单个单元设置在剃刀刀片架中的形成于聚合物材料中的多个剃刀刀片。
在一个方面,用于制造至少一个切割刃结构的方法包括在容器中提供呈液体形式的第一聚合材料;在所述第一聚合材料内提供至少一个切割刃模板;将所述第一聚合材料固化,同时将所述至少一个切割刃模板设置于所述第一聚合材料中以形成基础结构;移除所述模板以在所述基础结构中获得腔;用第二材料填充所述腔,所述第二材料为聚合物材料的前体;固化所述第二材料,以及将所述基础结构与所述固化的第二聚合材料分离,所述至少一个切割刃结构由所述固化的第二聚合材料构成。
此外,第二前体材料由单体材料、低聚物材料,或它们的任何组合构成。至少一个切割刃结构包括哥特式弧形、罗马弧形、或一个或多个底切。至少一个切割刃结构的末端半径小于1微米。
在一个方面,第一聚合材料由聚(甲基丙烯酸甲酯)(PMMA)或聚二甲基硅氧烷(PDMA)构成。在第二方面,第二前体材料由基于丙烯酸或环氧化物的材料构成。在另一方面,第二前体材料的粘度小于约10000厘泊。
在本发明的另一方面,基础结构仅为一个部分,并且腔完全包含于基础结构中的单个部分中。在另一个方面,在形成之后,腔的一部分不由基础结构包封。
此外,第二前体材料、固化的第二聚合物材料和腔的至少一个侧面中的至少一者对于在250至1500纳米范围内的波长下的电磁辐射是透过的。
此外,本发明的分离步骤包括从固化的第二聚合材料切割刃结构中物理或化学移除基础结构。在一个方面,第一聚合材料是柔顺的。在另一方面,分离的基础结构可在填充步骤时再使用。
在本发明的另一方面,在固化步骤之前,将按组合物的重量计约1%至约3%的光引发剂添加到第二前体材料。
本发明的固化步骤包括交联或聚合,并且固化步骤经由热、光如紫外光,或它们的组合介导。
在本发明的另一方面,使用本文方法形成的至少一个切割刃结构为剃刀或剃刀盒的一部分,并将剃刀刀片或刀片盒固定到剃刀刀片架外壳或框架中。剃刀盒可由不同类型的切割刃结构构成。
本发明的另一个实施方案包括刀片盒,该刀片盒包括至少一个切割刃结构、联接到所述至少一个切割刃结构的至少一个非切割刃结构,所述切割刃结构和非切割刃结构两者由聚合物材料构成,所述聚合物材料由聚合物材料的前体材料制成。
本发明的另一个实施方案为剃刀刀片,其包括至少一个切割刃结构,所述至少一个切割刃结构由聚合物材料构成,所述聚合物材料由所述聚合物材料的前体材料制成。
下文的附图和描述中给出了本发明的一个或多个实施方案的详情。从说明书及附图以及从权利要求中可显而易见本发明的其它特征、目的和优点。
附图说明
图1描述了现有技术的基础结构的剖视图。
图2a和2b是根据本发明的一个优选实施方案由聚合物制造剃刀刀片的方法的流程图。
图3为用作根据本发明的图2a和2b中的切割刃模板的钢制刀片的显微照片。
图4为根据本发明的腔的剖视图的显微照片。
图5为根据本发明制成的复制刀片的显微照片。
图6是根据本发明的一个实施方案具有聚合物剃刀刀片的剃刀刀片架的前视图。
图7为本发明的另选实施方案的剖视图,其描述了基础结构中的五个腔。
图8为本发明另一个实施方案中的基础结构中的多个刀片盒的顶视图,其各自具有多个刀片和框架。
图9为根据本发明用于插入剃刀刀片架中的刀片盒的顶视图。
图10是根据本发明的另一个实施方案的具有形成于其中的多个非线性切割刃的结构的透视图。
图11描述了本发明切割刃结构的多种轮廓。
具体实施方式
本公开的方法提供了切割刃结构(例如,可用于剃刮装置或剃刀中的剃刀刀片)的制造。具体地,本发明公开的是用于由聚合物材料制造用于剃刮装置的切割刃或剃刀刀片的方法。
如本文所用,聚合物材料表示由聚合物形成的材料,后者是由单体(其为小分子)组成的大的链状分子。一般来讲,聚合物可以是天然存在的或合成的。在本发明中,优选的实施方案包括合成或半合成聚合物。合成或半合成聚合物材料通常可以两种形式或状态出现。第一状态可以为软或流体状态并且第二状态可以为硬或固体状态。一般来讲,在第一状态(例如,液体或软的)时合成聚合物模塑或挤塑并且随后形成为处于第二状态(例如,硬的或固体)的物体。在一些情况下,材料是可逆的(例如,处于第二状态的材料可转换回其第一状态),然而在其它情况下,聚合是不可逆的(例如,材料不能转换回其第一状态)。
热塑性聚合物为一类逆聚合物,其在升高的温度下(例如200℃且以上)处于软的或液体第一状态,并且在冷却至环境温度时转换成固体第二状态。热塑性聚合物通常用于现有技术的注塑或挤出技术。
就其中第二状态经由不可逆聚合由第一状态获得的那些聚合物材料而言,聚合材料的第一状态通常可被认为是聚合物材料的第二状态的“前体”。因此,在本发明中,聚合物材料可由前体材料或处于第一状态的材料产生。
通常是本发明切割刃结构所期望的材料是处于第一软或液体状态的材料,其包含单体或被称为低聚物的短链长(例如,或低分子量)聚合物或上述两者。单体和低聚物两者在本文中均被称为“前体”。这些前体通过聚合或交联方法(本文中被称为固化方法)转换成处于第二固体状态的长链长聚合物材料。将前体材料固化通常可在热、光、离子或高能辐射或它们的任何组合的影响下实现。在固化之后,实现固体聚合物材料。
图1描述了现有技术的基础结构的剖视图。在一个现有技术实施方案中,基础结构10示出具有两个部分,上部分11和下部分12,然而在另一个现有技术实施方案中,基础结构13示出具有左部分14和右部分15。在每个现有技术基础结构的配合表面或界面16之间是可形成切割刃结构17的位置。应当注意现有技术的基础结构材料通常由金属加工而成。在两个基础结构10和13中,为了形成切割刃结构17,每个基础结构的两个部分分别必须存在于所述基础结构中并且牢固地接合在一起。基础结构实际上是闭合体系,其仅具有用于待注射的液体聚合物的一个或多个小流体通道。此外,在两个基础结构10和13中,在注射和固化聚合物之后,基础结构必须打开或分开以便移除切割刃结构17。
在图12a中,示出了根据本发明的一个优选实施方案由一种或多种聚合物材料制造剃刀刀片的方法的流程图20a。在步骤100处,提供容器105。容器可具有任何类型、形状或尺寸,但优选被选择成制备适当的基础结构405,在所述基础结构中形成切割刃结构诸如剃刀刀片。关于基础结构的尺寸(例如,高度、长度)也没有限制,但理想地所述基础结构可具有至少约5mm的高度和至少约30mm的长度。
一般来讲,期望用于形成基础结构405的本发明的第一聚合材料220具有第一未固化流体状态,使得其可在步骤200a处分配到容器105中。通常对于可用于形成基础结构405的第一聚合材料的类型没有限制。在一个优选的实施方案中,第一聚合材料和相关前体为聚(甲基丙烯酸甲酯)(PMMA)、聚二甲基硅氧烷(PDMS)、或通常用于微复制或纳米压印光刻的其它材料,并且因此步骤200a的第一聚合材料220优选由得自Dow Corning的184构成。的粘度为约5100厘泊。容器105可以在所述方法结束时保持或移除,如将在下文描述的。
应当注意的是,基础结构405可被认为是将形成切割刃结构(例如,剃刀刀片)的模具的一部分。在本发明的流程图20a中,基础结构405有效地表示通常不能被分成其它部分的单部分模具。基础结构405可认为是典型模具的一半(例如,下半部),这是由于另一半(例如上半部)不是本发明的部件。这通过仅具有单部分模具或模具的一个半部而与图1所示的现有技术的基础结构形成对比,避免了现有技术熔体流动方法中存在的存在于两部分模具中的“飞边”的问题。
在步骤300a处将切割刃模板310插入液体第一聚合材料205中。切割刃模板310可具有期望的任何类型,但通常优选为具有图3所示类型的三维不锈钢刀片。切割刃模板310还可由硅、蓝宝石或金刚石构成。不考虑材料组成,模板310可具有对切割刃可行的任何形状或轮廓。例如,模板的形状,并且继而,最终切割刃结构形状可以是直的、弯曲的、椭圆形、凹口的或齿状的,或具有内部开口,所述内部开口包括如期望存在于所得聚合物刀片中那样多的斜角和切面。能够在本发明中形成的多种形状或轮廓示于图10和11中。
在切割刃模板310插入第一聚合材料中之后,并且在步骤300a处在模板310设置于第一聚合材料205中时,第一聚合材料205在步骤400处聚合,使得液体第一聚合材料205变成固体聚合物材料,从而形成基础机构405。例如,如果第一聚合材料205由PDMS构成,则将PDMS加热以便变得固化或聚合。PDMS通常通过不可逆的涉及水(例如,从空气中吸收的水)的化学反应来固化或硬化。虽然完全固化材料的过程通常可以是相对慢的过程,但其可优选用加热420来加速。
图2b描述了本发明的另选工艺流程20b,其中在步骤200b处,在将第一液体聚合材料220设置于容器中之前,将切割刃模板310插入容器105中。如上所述,切割刃模板310可具有期望的任何类型,但通常优选具有图3所示类型的三维不锈钢刀片。切割刃模板310还可由硅、蓝宝石或金刚石构成。不考虑材料组成,模板310可具有对切割刃可行的任何形状或轮廓。例如,模板的形状,并且继而,最终切割刃结构形状可以是直的、弯曲的、椭圆形、凹口的或齿状的,或具有内部开口,该内部开口包括如期望存在于所得聚合物刀片中那样多的斜角和切面。能够在本发明中形成的多种形状或轮廓示于图10和11中。
在图2b中的步骤300b处,被选择成制备基础结构405的第一聚合材料205优选处于第一未固化流体状态220,使得其可设置于容器105中并围绕切割刃模板310,如步骤300b中所示。通常对于可用于形成基础结构405的第一聚合材料的类型没有限制。在一个优选的实施方案中,第一聚合材料和相关前体为聚(甲基丙烯酸甲酯)(PMMA)、聚二甲基硅氧烷(PDMS)、或通常用于微复制或纳米压印光刻的其它材料,并且因此步骤300b的第一聚合材料220优选由得自Dow Corning的184构成。的粘度为约5100厘泊。容器105可以在所述方法结束时保持或移除,如将在下文描述的。
基础结构405可被认为是将形成切割刃结构(例如,剃刀刀片)的模具的一部分。与图2a的流程图20a一样,在本发明的流程图20b中,基础结构405有效地表示通常不能被分成其它部分的单部分模具。基础结构405可认为是典型模具的一半(例如,下半部),这是由于另一半(例如上半部)不是本发明的部件。这通过仅具有单部分模具或模具的一个半部而与图1所示的现有技术的基础结构形成对比,避免了现有技术熔体流动方法中存在的存在于两部分模具中的“飞边”的问题。
应当注意的是超出图2a的步骤300a和图2b的步骤300b的工艺步骤基本上相同。因此,在步骤300a或300b之后,过程20a和过程20b两者可继续到步骤400,其中从形成的基础结构405中移除切割刃模板310,从而在基础结构405中露出腔510。步骤400(第一聚合材料的固化)的持续时间可以为在25度下约48小时。腔510具有带期望的末端半径(例如小于1μm)的剃刀刀片形状。图4中示出了使用本发明的PDMS基础结构405在步骤500中形成的腔510的剖视图的显微照片。
应当注意的是,如图2a和2b所示,腔是通过复制切割刃的模板而形成的单个部分。如上所示,通过仅包括单部分模具或模具的一个半部,避免了在现有技术融体流动加工中在两部分模具的界面处存在的“飞边”问题。
如步骤600所示,在由第一聚合材料220制成的基础结构405中形成的腔510用第二聚合材料620填充,该第二聚合材料通常呈第二聚合物的前体形式。本发明中的前体可优选为单体或短链长度或低分子量的低聚物材料。
理想地,本发明的填充或倾倒步骤600在约10摄氏度至约40摄氏度的环境温度下进行,或者可以被加热至直至100摄氏度以进一步降低其粘度。虽然通常对可用于填充腔的第二聚合材料的类型没有限制,但期望聚合物前体在环境温度或接近环境温度下比用于融体流动加工的聚合物材料更具流动性且更少粘性,以便实现材料在腔510中的全渗透并且以期望的剃刀刀片和末端的形状填充腔510。因此,本发明的第二聚合材料前体的优选粘度小于约10000厘泊,更优选地小于约5000厘泊,并且最优选地约3000厘泊或更小。
在本发明中,第二前体材料优选为基于丙烯酸的材料,更优选地具有单体或低聚物制剂的聚合物诸如Femtobond 4B,并且最优选地得自家族的聚合物材料,诸如ORMOCORE,其由Microresist Technology GmbH供应。ORMOCORE材料具有在环境温度下约2900厘泊的粘度。可用作前体的称为的另一种材料具有约340厘泊的粘度。前体材料具有的粘度低于基础结构或第一聚合材料的粘度。值得注意的是在本发明中,非聚合材料,诸如ORMOCORE,可加热直至100摄氏度以进一步降低粘度。通常,高于100摄氏度的加热可以不可取地导致将固化的结构冷却下来时的收缩。
另选地,基于环氧化物的材料,诸如由MicroChem供应的SU8,其具有在2.5至1250厘泊的粘度范围,可用作第二聚合材料。
在图2a和图2b的固化步骤700之前,可将按组合物的重量计约1%至约3%的光引发剂添加到第二聚合材料。光引发剂通常通过吸收辐射,通常可见光或紫外光,并且形成与单体或低聚物反应的自由基并将其连接在一起来使聚合物材料的前体的聚合或交联(例如固化)过程开始。通常与基于丙烯酸酯的前体一起使用的光引发剂为α-羟基酮,其以商品名由BASF出售。在ORMOCORE的情况下,光引发剂可以为也由BASF提供的
在图2a和图2b的步骤700处进行第二聚合材料620的固化以形成固体聚合物710。固化过程可由热或光720构成或由热或光720介导,但更优选地本发明的固化过程是光。固化的温度可以是任何温度,包括优选地环境温度或室温。理想地,本发明的固化过程在约10摄氏度至约40摄氏度的环境温度下进行,或者可以被加热直至100摄氏度以进一步降低其粘度。一般来讲,施用的温度越高,材料发生固化或硬化越快。前体(例如,用于形成固体聚合物的单体或低聚物)的固化可涉及聚合,即,分子链成形或现有分子链的交联,或上述两者。本发明的固化优选通过使前体或第二聚合材料620暴露于电磁辐射,例如紫外光来进行。电磁辐射的波长可以在约250纳米至1500纳米,并且优选地约400纳米至约1100纳米的范围内。如果使用光引发剂,则聚合物材料在该范围内(对所用光引发剂最佳选择)在特定波长下是透过的。因此,本发明的第二聚合材料的前体和固化的固体聚合物和/或腔的至少一个侧面通常需要对于有效的电磁辐射波长是至少部分透过的。聚合物的透过滤选择对于效果是必要的,因为如果光不能在聚合物表面下方透过,则当使用光时,整个物体(例如,切割刃结构)的固化或聚合通常不能进行。虽然优选光固化以避免收缩,但热也可产生与利用光的那些大致相同的结果。该步骤避免了材料的膨胀、收缩或变形,并且由第二聚合材料620形成切割刃结构710。步骤700处的固化持续时间可在约一分钟或更长至约一小时的范围内,并且这可能取决于以下变量,诸如:激光功率、温度、第二聚合材料的厚度以及其它因素。
在一个优选的实施方案中,形成基础结构405的第一聚合材料220和相关前体为聚(甲基丙烯酸甲酯)(PMMA)或二甲基硅氧烷(PDMS)。用于形成基础结构的材料优选是柔顺的,这表示材料是柔性的或可变形的,使得由第二材料,诸如ORMOCORE或Femtobond 4B或SU8形成的复制切割结构710可在固化之后从基础结构405容易地移除。在PDMS形成的基础结构405的情况下,PDMS材料的弹性和低表面能特性允许切割刃模板310的期望的移除。弹性提供基础结构405的变形以释放切割刃模板310,同时也允许基础结构405在移除切割刃模板310之后返回到其原始形状。PDMS材料的低表面能防止切割刃模板310粘到基础结构405并且也防止在移除期间对基础结构405的损伤。具有这两种特性,基础结构材料在有助于移除切割刃模板方面起到有利的作用。
在步骤800时,将基础结构405从切割刃结构810移除。基础结构可通过物理或化学方式移除。物理移除可包括将基础结构405弯曲与切割刃结构810分开并远离切割刃结构810。如果通过物理方式移除基础结构,则可需要首先将容器105与基础结构分离。在一些情况下,基础结构405可具有橡胶属性,使得基础结构和切割刃结构和/或容器105之间的物理移除可行。化学移除过程可包括溶解基础结构405。如果基础结构溶解,则容器105可保持。用于溶解基础结构的化学物质的类型可包括有机溶剂,并且如果由PMMA制成,则可包括溶剂诸如丙酮、乙腈、1,2-二氯乙烷和二氯苯,并且如果由PDMA制成,则可包括溶剂例如TBAF(氟化四丁基铵)的NMP(N-甲基吡咯烷酮)或DMF(二甲基甲酰胺)或THF(四氢呋喃)或PMA(丙二醇甲基醚乙酸酯)或它们的任何组合的溶液。
移除过程可通过溶解、湿蚀刻(例如,经由化学溶剂)、熔融、或它们的任何组合来实现。
切割刃结构810表示呈最终切割刃或剃刀刀片边缘的形状的结构。
已经由本发明的方法避免了飞边,这是由于本发明的基础结构能够在基础结构的一部分内形成聚合物刀片,因为如与现有技术的两个配合部分或半部相反,基础结构由一个部分形成(图1)。
在图5中,示出具有根据本文所述的制造方法制造的实际释放的切割刃结构的显微照片视图。复制的切割刃结构或刀刃由ORMOCORE制成(第二聚合材料),所述ORMOCORE使用本发明的方法从PDMS(第一聚合材料基础结构)模具中移除。
由本发明方法制备的切割刃结构的末端半径理想地在小于约1微米的范围内。诸如由形成的聚合物切割刃结构的硬度在切割之后可达到近100MPa。在SU8的情况下,切割刃结构可在图2a和图2b的步骤800中将其从基础结构移除之后热解,以进一步增加硬度。在聚合时,SU8具有约180MPa的硬度并且热解的SU8具有约1GPa的硬度。
如图5所示,使用图2a和图2b的方法形成的剃刀刀片50包括聚合物主体部分或基底52,其包括具有末端54的楔形锋利边缘。末端54具有刀刃53,该刀刃具有约15度的刀片夹角55,如图5所示。切面56和58从末端54分开。
虽然图5示出了常规的剃刀刀片楔形轮廓,但是本发明设想了具有任何数(例如多于2个或3个)的切面的切割刃结构,并且这些切面不必需是平面的。本发明的多种示例性形状示于下图10和11中,但本发明设想任何期望的可行的形状。
应当注意,如果在步骤800处不溶解或熔融以移除切割刃结构,则图2a和图2b的基础结构405可再次用于形成附加的切割刃结构。基础结构可使用的次数可以根据用于基础结构的第一聚合材料的类型和每次使用之后的基础结构的稳健性而受到限制。返回到图2a和图2b的步骤600的箭头612描述了基础结构的再使用。
一旦脱离基础结构,则生产的每个切割刃结构通常可单独装配到剃刀刀片架中。例如,可将一个或多个聚合物剃刀刀片附着到刀片支撑体上(例如,利用胶、超声焊接)并且装配到剃刀刀片架外壳中。一旦从基础结构移除,然后就可在图2a和图2b的步骤900处,加工或涂覆所述刀片(如果必要)并装配到剃刀刀片架中。
可如图6所示装配剃刀刀片架60,所述剃刀刀片架具有一个或多个由本发明聚合物64制成的切割刃结构或剃刀刀片62。剃刀刀片架60类似于利用钢制刀片并且具有塑料外壳和框架组件66的可商购获得的剃刀刀片架。在装配步骤900中,聚合物剃刀刀片62在插入框架66或外壳中之前被固定到安装组件,或它们可直接安装在框架上。
虽然主要参考单个切割刃结构(例如剃刀刀片)给出本文所述的制造方法,但是所述方法易于适用于多个切割刃结构的同时制造。
在图7中,示出具有根据本文所述的方法生产的多个腔74(例如,五个腔)的基础结构72。多个切割刃结构(例如,剃刀刀片)的制造按照图2a和图2b的方法,但包括同时(如果多于一个)或依次(如果仅一个)被压入基础结构中的一个或多个切割刃模板(未示出)。在此类“分批”制造基础结构上的多个切割刃结构诸如剃刀刀片之后,切割刃结构可如上文结合图2a和图2b所述分离,准备进一步装配到剃刀刀片架中。应当注意,根据期望的切割刃结构的尺寸,基础结构72的尺寸可以大于图2a和图2b的基础结构405。
转到图8,多个剃刀刀片82可以具有小框架84的三个刀片的组的形式簇集在一起形成。所述框架为非切割刃结构,然而剃刀刀片为切割刃结构。所述簇具有大致矩形形状,为了便于讨论,在本文称为刀片盒86。可以此簇集组织结构制造多个剃刀刀片82,以减少剃刀系统装配中的下游工艺步骤。刀片盒86具有通过框架84包封的3个单独的剃刀刀片82,如图所示。刀片盒86可以相同方式制造,或者它们可以是不同的,诸如每个盒子在刀片间距、刀片夹角、刀片数量、刀片取向等方面具有差异。这些差异可由上述各种方法步骤诸如利用不同模板和在不同取向上压制等的改变造成。可以如上所述相同的方式,但使得独立成套的刀片盒86为单个整体部分,从基础结构中移除刀片盒86。在图9中,将刀片盒86插入剃刀刀片架90的外壳94的开口92中并固定于其中或在开始时完全形成为剃刀刀片架(未示出)。
以这种方式装配剃刀刀片架消除了将每个单独的剃刀刀片附连至剃刀支撑体或外壳、将每个刀片支撑体-剃刀刀片对或每个刀片插入剃刀刀片架外壳中、以及将每个单独的剃刀刀片与期望的刀片高度、角度和间距对准的有些费时或困难的步骤。通过利用本文所述的方法,将多个剃刀刀片对准并固定于刀片盒中,从而消除了附连单独刀片支撑体的需要和将3个或更多个单独的剃刀刀片对准到剃刀刀片架外壳中的困难过程。虽然图8和9示出具有3个剃刀刀片的刀片盒86,但是应当理解,可将任何数目的剃刀刀片簇集或形成在一起,诸如2、4、5、或更多个。
虽然到目前为止附图示出的刀片具有大致线性的刀刃,但是通过本文所述的方法可产生其它刀片形状和边缘图案。
为此,在其它另选实施方案中,在本发明中还可设想用于刀刃的除了直刃或楔形构型之外的不同切割结构。
这些其它形状通过在步骤300a/200b中使用切割刃模板来产生,该切割刃模板包括不同轮廓。在一些情况下,使用具有开口154的材料片或框架153,该开口包含如图10的刀片盒150中所示的非线性的内部切割刃152。在本发明的该实施方案中,可优选使用图2a和图2b的方法,将片材153设置于基础结构中。
本发明设想切割刃模板的任何数量的形状或轮廓,因此设想了将形成的一个或多个切割刃结构的任何数量的形状或轮廓。本发明包括但不限于图11中所述的附加例示性实施方案。图11示出了两种弧形切割刃轮廓,例如哥特式弧形轮廓162、罗马弧形轮廓164,但本发明包括任何其它可行的切割刃结构形状(例如,波浪形、锯齿形、锯齿等)。此外,图11中也示出了具有一个或多个底切167的切割刃轮廓166。
以本文所述的方式由聚合物生产用于剃刮的剃刀刀片的许多优点之一是所得的切割刃结构或所形成的刀刃具有与模板切割刃非常类似的表面粗糙度。因此,当复制钢制刀片时,也复制钢制模板切割刃的磨痕。如果模板由单晶材料诸如硅或蓝宝石制成,则可形成不具有磨痕的非常平滑的切面表面。因此,所得的切割刃结构具有与模板切割刃相似的表面粗糙度。模板切割刃材料的变化将改变所得切割刃的表面粗糙度。
因此,其它实施方案在以下权利要求书的范围之内。
本文所公开的量纲和值不应理解为严格限于所引用的精确数值。相反,除非另外指明,否则每个这样的量纲旨在表示所述值以及围绕该值功能上等同的范围。例如,公开为“40mm”的量纲旨在表示“约40mm”。
除非明确排除或换句话讲有所限制,否则将本文引用的每篇文献,包括任何交叉引用或相关专利或申请,全文均以引用方式并入本文。任何文献的引用不是对其相对于任何本发明所公开的或本文受权利要求书保护的现有技术的认可,或不是对其单独地或以与任何其它参考文献或多个参考文献的组合提出、建议或公开了任何此类发明的认可。此外,如果此文献中术语的任何含义或定义与以引用方式并入本文的文献中相同术语的任何含义或定义相冲突,将以此文献中赋予该术语的含义或定义为准。
虽然已经举例说明和描述了本发明的特定实施方案,但是对于本领域技术人员而言显而易见的是,在不脱离本发明的实质和范围的情况下可作出各种其它变化和修改。因此,本文旨在于所附权利要求中涵盖属于本发明范围内的所有这些变化和修改。
Claims (15)
1.一种用于制造至少一个切割刃结构的方法,包括以下步骤:
在容器中提供呈液体形式的第一聚合材料;
在所述第一聚合材料内提供至少一个切割刃模板;
固化所述第一聚合材料,同时将所述至少一个切割刃模板设置在所述第一聚合材料中以形成基础结构;
移除所述模板以在所述基础结构中获得腔;
用第二材料填充所述腔,所述第二材料为聚合物材料的前体;
固化所述第二材料;以及
将所述基础结构与所述固化的第二聚合材料分离,所述至少一个切割刃结构由所述固化的第二聚合材料构成。
2.根据权利要求1所述的方法,其中所述第二前体材料由基于丙烯酸的材料、单体材料、低聚物材料、粘度小于约10000厘泊的材料,或它们的任何组合构成。
3.根据权利要求1或2所述的方法,其中在所述固化步骤之前,将按组合物的重量计约1%至约2%的光引发剂添加到所述第二前体材料。
4.根据权利要求1至3中任一项所述的方法,其中所述第二前体材料、所述固化的第二聚合材料和所述腔的至少一个侧面中的至少一者对于在250至1100纳米范围内的波长下的电磁辐射是透过的。
5.根据权利要求1至4中任一项所述的方法,其中所述至少一个切割刃结构包括哥特式弧形、罗马弧形、或一个或多个底切,并且其中所述至少一个切割刃结构的末端半径小于1微米。
6.根据前述权利要求中任一项所述的方法,其中所述第一聚合材料由聚(甲基丙烯酸甲酯)(PMMA)或聚二甲基硅氧烷(PDMS)构成,并且其中所述第一聚合材料是柔顺的。
7.根据前述权利要求中任一项所述的方法,其中所述基础结构仅由一个部分构成。
8.根据前述权利要求中任一项所述的方法,其中所述至少一个腔完全包括于所述基础结构中的单个部分中,或者其中所述至少一个腔的一部分在成形之后不被所述基础结构包封。
9.根据前述权利要求中任一项所述的方法,其中所述分离步骤包括从所述固化第二聚合材料切割刃结构物理或化学移除所述基础结构。
10.根据前述权利要求中任一项所述的方法,其中所述分离的基础结构在所述填充步骤时再使用。
11.根据前述权利要求中任一项所述的方法,其中所述固化步骤包括交联或聚合,其中所述固化步骤由热、光或它们的组合介导。
12.根据前述权利要求中任一项所述的方法,其中所述至少一个切割刃结构为剃刀刀片或刀片盒的一部分。
13.根据前述权利要求中任一项所述的方法,还包括将所述剃刀刀片或所述刀片盒固定到剃刀刀片架外壳或框架中的步骤。
14.一种刀片盒,包括:
至少一个切割刃结构;
至少一个非切割刃结构,所述至少一个非切割刃结构联接到所述至少一个切割刃结构,所述切割刃结构和所述非切割刃结构两者由聚合物材料构成,所述聚合物材料由所述聚合物材料的前体材料制成。
15.一种剃刀片,包括:
至少一个切割刃结构,所述至少一个切割刃结构由聚合物材料构成,所述聚合物材料由所述聚合物材料的前体材料制成。
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CN103273512B (zh) * | 2007-04-20 | 2016-07-13 | 吉列公司 | 剃刀刀片架 |
CN102958653A (zh) * | 2010-07-01 | 2013-03-06 | 吉列公司 | 用于剃刀刀片架的易蚀标签 |
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