EP3378614B1 - Razor blade, razor head, and method of manufacture - Google Patents
Razor blade, razor head, and method of manufacture Download PDFInfo
- Publication number
- EP3378614B1 EP3378614B1 EP18167402.9A EP18167402A EP3378614B1 EP 3378614 B1 EP3378614 B1 EP 3378614B1 EP 18167402 A EP18167402 A EP 18167402A EP 3378614 B1 EP3378614 B1 EP 3378614B1
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- EP
- European Patent Office
- Prior art keywords
- blade
- cutting edge
- strip
- axis
- razor
- Prior art date
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- 238000005520 cutting process Methods 0.000 claims description 70
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Images
Classifications
-
- 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
- B26B21/56—Razor-blades characterised by the shape
- B26B21/565—Bent razor blades; Razor blades with bent carriers
-
- 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
- B26B21/08—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 involving changeable blades
- B26B21/14—Safety razors with one or more blades arranged transversely to the handle
- B26B21/22—Safety razors with one or more blades arranged transversely to the handle involving several blades to be used simultaneously
- B26B21/222—Safety razors with one or more blades arranged transversely to the handle involving several blades to be used simultaneously with the blades moulded into, or attached to, a changeable unit
- B26B21/227—Safety razors with one or more blades arranged transversely to the handle involving several blades to be used simultaneously with the blades moulded into, or attached to, a changeable unit with blades being resiliently mounted in the changeable unit
-
- 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
- B26B21/4012—Housing details, e.g. for cartridges
Definitions
- the instant inventions relate to integrally formed rigid razor blades, razor heads having such blades, and their methods of manufacture.
- the invention is related to methods of manufacture of integrally formed rigid razor blades.
- Such cutting members are so-called 'supported blades', in that the so-called 'cutting part', which has the cutting edge, is assembled to a planar portion of a different part, called 'support part' which has the L-shaped cross-section.
- US 1 734 554 A discloses a method of making narrow-gauge razor blades.
- US 2010/077618 A1 discloses a razor cartridge comprising a housing, a guard disposed toward a front portion of the housing, a cap disposed toward a rear portion of the housing, a plurality of bent blade assemblies, wherein at least one of the blade assemblies comprises one or more perforations along a length of the assembly.
- a razor cartridge comprising a housing, a guard disposed toward a front portion of the housing, a cap disposed toward a rear portion of the housing, a plurality of integrally formed bent blade assemblies, wherein each of the blade assemblies comprises one or more perforations along a length of the assembly.
- an integrally formed razor blade comprising:
- the handled strip can be made longer, and easier to handle. Further, by using a pre-perforated strip, separation of the blade from the strip is performed by imparting minimal deformation to the strip, thereby improving the overall consistency of the manufactured product.
- Figure 1 shows a head 5 of a safety razor (also called wet shaver), a shaver the blades of which are not driven by a motor relative to the blade unit.
- a safety razor also called wet shaver
- the shaving head 5 is to be borne by a handle extending in a longitudinal direction between a proximal portion and a distal portion bearing the blade unit 5 or shaving head.
- the longitudinal direction may be curved or include one or several straight portions.
- the blade unit 5 includes an upper face 6 defining a shaving window, and equipped with one or several cutting members and a lower face 7 which is to be connected to the distal portion of the handle by a connection mechanism.
- the connection mechanism may for instance enable the blade unit 5 to pivot relative to a pivot axis X which is substantially perpendicular to the longitudinal direction. Said connection mechanism may further enable to selectively release the blade unit for the purpose of exchanging blade units.
- connection mechanism usable in the present invention is described in document WO-A-2006/027018 , which is hereby incorporated by reference in its entirety for all purposes.
- the blade unit 5 includes a frame 10 which is made solely of synthetic materials, i.e. thermoplastic materials (polystyrene or ABS, for example) and elastomeric materials.
- the frame 10 includes a plastic platform member 11 connected to the handle by the connection mechanism and having:
- the guard bar 12 is covered by an elastomeric layer 16 forming a plurality of fins 17 extending parallel to the pivot axis X.
- the underside of the platform member 11 includes two shell bearings 18 which belong to the connection mechanism 8 and which may be for example as described in the above-mentioned document WO-A-2006/027018 .
- the frame 10 further includes a plastic cover 19 having a top face and an opposite bottom face, which faces the top face of the components of the platform 11.
- the cover 19 exhibits a general U shape, with a cap portion 20 partially covering the rear portion 14 of the platform and two side members 21 covering the two side members 15 of the platform. In this embodiment, the cover 19 does no cover the guard bar 12 of the platform.
- the cap portion 20 of the cover 19 may include a lubricating strip 23 which is oriented upward and comes into contact with the skin of the user during shaving. This lubricating strip may be formed for instance by co-injection with the rest of the cover.
- the cover 19 is assembled to the platform 11 by any suitable means, such as, for example, by ultra-sonic welding, as explained in WO 2010/06,654 , hereby incorporated here in its entirety for all purposes.
- At least one cutting member 24 is movably mounted in the blade receiving section 13 of the platform.
- the blade receiving section 13 may include several cutting members 24, for instance four cutting members as in the example shown in the drawings.
- Each cutting member 24 is made of a blade which is integrally formed from a flat steel strip.
- martensitic stainless steel with the following composition (in weight):
- Such an alloy has no more than traces of other components, and notably no more than traces of Molybdenum.
- the razor blade has a cutting edge 26 oriented forward in the direction of shaving and an opposed rear edge 54.
- the cutting edge 26 is accessible through the shaving window of the blade-receiving section 13, to cut hair.
- Each blade 25 has an outer face 27 oriented towards the skin to be shaved and an opposed inner face 28.
- the outer and inner faces 27, 28 of the blade include respectively two parallel main surfaces 29, 30 and two tapered facets 31, 32 which taper towards the cutting edge 26.
- Each blade 25 extends longitudinally, parallel to the pivot axis X, between two lateral sides 33, 33'.
- the lateral sides are straight.
- Each blade 25 has a bent profile including:
- the base portion is also sometimes called “guided portion”.
- each cutting member 24 is borne by two elastic fingers 44 which are molded as a single piece with the platform 11 and which extend towards each other and upwardly from both side members 15 of the platform.
- all the fingers 44 extending from a given side member are identical.
- the base portions 35 of the blades are slidingly guided in slots 45 provided in the inner face of each side member 15 of the platform.
- the slots are, for example, substantially perpendicular to the shaving plane.
- the blades 24 are elastically biased by the elastic arms 44 toward a nominal position. In this nominal position, the outer faces 27 of the blades, at each lateral end of the blades, bear against corresponding upper stop portions 52 which are provided on the bottom stopping face of each side member 21 of the cover, said side member 21 covering the slots 45.
- the nominal position of the blades 24 is well defined, therefore enabling a high shaving precision.
- the inner faces 28 of the blades, at each lateral end of the blades, are borne by corresponding top portions 55 of the elastic arms.
- the distance between the two top portions is for example of 22 to 30 mm, preferably between 25 and 27 mm.
- the guiding slots 45 define a direction Y for the razor head.
- the direction Z is the normal to the X-Y plane.
- the base portion 35 extends in a base portion plane.
- the base portion axis is the main axis of the base portion other than its profile axis, i.e. other than the X axis. In the present embodiment, it is the Y axis. In other words, the main axis along which the base portion extends is the same as the axis defined by the slots 45 in the razor head.
- the cutting edge portion 39 extends in a cutting edge portion plane.
- the cutting edge portion axis is the main axis of the cutting edge portion other than its profile axis, i.e. other than the X axis. In the present embodiment, it is a U axis. In other words, the cutting edge portion axis extends in an X-U plane.
- a V axis is defined normal to the X-U plane.
- a first embodiment of a bent blade is shown on Figs 3a and 3b .
- the geometrical characteristics of the blade are here nominal characteristics, which do not take into account the actual geometry of the blade due to the manufacturing process or dispersion. In particular, due to the manufacturing process, thickness variations and/or bow, sweep, camber of some blade portions are possible, and are even intrinsic to the product.
- a suitable razor blade shows the following geometric properties: Paramete r Nomina l value Dispersio n Paramete r Nomina l value Dispersio n T 0.1 mm Hb 1.43 mm L 37.1 mm R 0.6 mm H 2.33 mm Hc 0.28-1.14 mm D 1.35 mm +/-0.05 mm T 5.3 mm ⁇ 0.003 mm A 108° +/-2° h 0.13-0.32 mm T1 2 mm
- Hc This value indicated for Hc is in fact an average between the value measured for Hc on both lateral sides of the blade. Due to the deformation of the blade, these two values were different, amounting in average to 0.81 mm and 0.85 mm, respectively. Hc might extend between 0.28 and 1.14 mm, preferably between 0.4 and 1 mm.
- FIG. 5 Yet another embodiment is shown on Fig. 5 . This embodiment differs from the second embodiment mainly by different values for T and T 1 .
- the rear edge is not serrated.
- the geometric datas for this embodiment are: Parameter Nominal value Parameter Nominal value t 0.1 mm Hb 1.57 mm L 37.1 mm R 0.6 H 2.58 mm Hc 1.07 D 1.45 mm ⁇ 112°
- a cutting plane (P) is defined for the head from the tangents to guard bar before the window receiving the blades and the cap behind it.
- a force will be applied to the blade by the user, along a direction F which is sensibly normal to the plane (P).
- the blades 24 are oriented in the head 5 such that the cutting edge portion forms an angle with the cutting plane (P).
- the force F is applied sensibly in the Y direction at approximately ⁇ 5°.
- the above material provided a bent blade providing the best compromise between formability and cutting edge performance.
- the above material can be formed as a successful cutting edge of a razor blade, provided with current cutting edge processing including grinding, coating with a strengthening material and coating with a telomere layer.
- the above material can be formed as a successful bent region with enhanced consistency, high reproductibility, and without producing too much corrosion prone macro-cracks during manufacturing.
- the dimension D has proven to be a critical dimension of the blade.
- the distance between the two contact points of the blade to the springs is between 22 and 30 mm, preferably between 25 and 27 mm, when ⁇ is taken between 95° and 140°, preferably between 108° and 112°, R over 0.4 mm, preferably between 0.5 mm and 1 mm, t between 0.07 mm and 0.12 mm, preferably between 0.095 and 0.105 mm, Hc between 0.4 mm and 1.0 mm, preferably between 0.81 mm and 0.85 mm.
- Such a preferential behaviour is also expected to be met for bent blades with lower carbon range, for example from 0.5% carbon in weight.
- the R dimension is selected over 0.5 mm, preferably over 0.55 mm.
- the R dimension is preferably lower than 1 mm.
- the radius of curvature of the outer face at the bent portion is at least 0.57 mm.
- the median radius of curvature at the bent portion is at least 0.535 mm. Indeed, when the radius of curvature is lower than that, it is difficult to manufacture the blade without generating high stresses which would cause the appearance of macro-cracks in the bent region.
- Fig. 10 now schematically shows an example of a process for the manufacture of the above bent blades.
- a strip of suitable material is for example stainless steel in ferritic form with secondary carbides, and having the above composition.
- a strip is any kind of product suitable to be manufactured into a bent blade as above.
- the strip 56 is shown on Fig. 8a . It is substantially straight. It has the thickness of the future razor blade. It has the length L of the future razor blade. Along the transverse height direction, it comprises, from top to bottom on Fig. 8a , a cutting edge portion 57, a to-be-bent portion 58, a base portion 59, and a removable portion 60.
- the cutting edge portion 57, the to-be-bent portion 58 and base portion 59 together define a blade portion of the strip.
- Notches 61 are provided, which extend oblongly along the long direction, between the base portion 59 and the removable portion 60.
- the notches 61 are shaped to receive transport fingers of the manufacture apparatus, in order to transport the strip from one station to another, along the manufacturing line, and to hold the strip in respective stations, as will be explained below in relation to Fig. 11 .
- a metallurgical hardening process 102 is performed on the strip. This process initiates martensitic transformation of the steel.
- the top edge of the strip which is to become the cutting edge, i.e. the edge of the strip which belongs to the cutting edge portion 57, is shaped as the cutting edge of a razor blade.
- This shaping is a sharpening process performed by grinding the edge to the acute required geometry.
- the cutting edge is defined by convergent faces which taper toward a tip having an angle of about 10°-30°.
- a strengthening coating is applied on the ground cutting edge.
- the ground blades are stacked in a stack, with their cutting edges all oriented in the same direction, and a strengthening coating is applied thereto.
- the strengthening coating will comprise one or more layers with different characteristics.
- the layers may comprise one or more of metal (s) (notably chromium or platinum) and carbon (possibly in DLC form).
- This coating is for example deposited by sputtering. Sputtering may also be used to precisely shape the geometry of the cutting edge before or after coating. The global geometry of the cutting edge is maintained at this step.
- telomere coating is applied on the blade edge.
- a suitable telomere is for example a PTFE.
- a suitable deposition method is spraying.
- the blade body is the part of the blade which is made of steel, exclusive the coatings.
- a bending step is applied on the up-to-now straight strip.
- one part of the strip is held, and a force is applied on the other part, so as to provide the strip with a bent portion 63, as shown on Fig. 8b .
- the cutting edge portion 57 is angled with respect to the base portion by sensibly the above angle ⁇ . Permanent deformation is imparted on the bent portion. Bending could for example be performed by stamping. Alternately, bending could be done by a number of other suitable methods. A method which reduces the generation of macro-cracks in the strip, notably to its bent portion, is preferred.
- the bent strip exiting from this step will not have the nominal geometry described above. In particular, it will exhibit some degree of camber, bow or sweep. Further, due to the material's mechanical properties, the dispersion of the geometry of the products can be large. This is particularly the case when the process used for applying the bending is only mildly severe to the strip (in order to avoid appearance of cracks). In such case, the amount of spring-back of the material after deformation is high and hardly predictable.
- a straightening step is performed.
- a forming process is used in order to reduce the dispersion in the geometry of products.
- permanent deformation is applied on the inner face of the bent portion of the strip. This permanent deformation straightens the overall blade, and reduces the dispersion in blade geometry among the products.
- a straightening station 70 comprises a support 71 to receive the bent strip 72.
- the support 71 has a V-shaped groove 73 having an included angle corresponding to the nominal angle for the bent blade.
- the bent strip is placed in the groove 73 with its outer surface resting on the arms of the V-shaped groove. It may be maintained there by any suitable means, such as by vacuum suction or the like.
- a deformation tool 74 is placed above the groove 73.
- the deformation tool 74 has a base 75 receiving a carriage 76 movably mounted with respect to the base 75 along the length direction of the strip (transverse to the plane of Fig. 9 ).
- the carriage 76 bears a pressure-application tip 77.
- the position of the pressure-application tip 77 with respect to the carriage 76 is settable, so as to bring the pressure-application tip at controlled distance to the base 71.
- the distance between the edge of the tip 77 and the groove 73 will determine the level of pressure applied by the tip to the strip.
- the pressure-application tip may comprise a support 78 receiving a spring-loaded ball 79 at its edge.
- the ball has dimensions of the order of the bent portion of the strip.
- the support 78 allows rotation of the ball 79 therein.
- the tip 77 Upon use, the tip 77 is held in an upper position until a strip is placed in the groove 73. The tip 77 is moved down until the ball 79 contacts the bent portion of the strip with suitable pressure. The ball 79 does not contact the straight portions of the strip. The contact is made at one lateral side of the strip. Then, the carriage 76 is moved with respect to the base 75 along the length of the strip until the other lateral side, to form the bent portion of the strip. The ball rolls during this movement. Possibly, this movement is performed back-and-forth. The tip 77 is then moved again to its up position, to remove the straightened strip from the straightening station 70.
- the formed strip is controlled. For example, its geometry is measured with a suitable measurement apparatus. These measurements enable to set the level of pressure applied by the tip for straightening steps on future products.
- a cutting step 108 is performed.
- the removable portion 60 is removed, to result in the final bent blade.
- it is made use of the notches 61 which are provided between the base portion and the removable portion of the blade, to remove the removable portion. It enables to remove the removable portion by imparting minimal stress on the bent blade, thus minimizing the level of permanent deformation applied to the bent blade, and potentially affecting its geometry. Further, as the cut part surface is minimized, initiation of corrosion is also reduced to the small cut area.
- Cutting can be performed in a cutting station 80 partially shown on Fig. 11 .
- the station 80 has a base 81 from which two lateral pins 82 extend.
- the pins 82 are shaped to enter in corresponding notches 61 of the strip, and together precisely locate the strip in the station.
- Vacuum may additionally be used to retain the strip in the station by suction.
- the strip at various stages of its manufacture, can be held in manufacturing stations, and/or moved from one station to the next, using similar principles.
Description
- The instant inventions relate to integrally formed rigid razor blades, razor heads having such blades, and their methods of manufacture.
- The invention is related to methods of manufacture of integrally formed rigid razor blades.
- In the field of mechanical wet shavers, it has long been provided with a shaver which has a head receiving one or more cutting members.
- Recently, the trend has been to provide cutting members which have a sensibly L-shaped cross-section, with a cutting edge portion and a base portion which is angled with respect thereto in cross-section transverse to the length direction of the blade.
- An example of a commercially successful such product can be found in
WO 2007/147,420 . Such cutting members are so-called 'supported blades', in that the so-called 'cutting part', which has the cutting edge, is assembled to a planar portion of a different part, called 'support part' which has the L-shaped cross-section. - Yet, the assembly of these two parts raises the following problems: It is logistically difficult to handle these two different parts; it is difficult to technically handle these very tiny parts in a manufacturing apparatus operating at speeds suitable to reach the demand; it is difficult to guarantee precision of this assembly at these operating speeds, and these assemblies may corrode at the location of the attachment, thereby reducing life expectancy of the overall product.
- Therefore, efforts have been made to replace these so-called 'supported blades' by integral bent blades. An example of such efforts can be found for example in
US 2007/234,577 . However, development of such an integral bent blade is very difficult. Indeed, in supported blades, it is possible to tailor the support part to its specific function, i.e. accurately providing the L-shape, and to separately tailor the cutting part to its specific function, i.e. optimized shaving performance. However, for integral bent blades, there is a need to provide a product both with excellent formability and cutting performance, while still considering the manufacturing process and cost issues. - In particular, it is necessary to limit as much as possible the degree of deformations applied to the blades during their manufacture, so as to not introduce permanent deformations which would affect shaving performance.
-
US 2007/234,577 proposed slots between to-be adjacent cutting members. However, it is still difficult to handle such tiny strips, or parts separated therefrom, at high speed. - The instant invention has notably for object to improve the efficiency of the manufacturing process, while not adversely affecting the characteristics of the final product.
US 1 734 554 A discloses a method of making narrow-gauge razor blades.US 2010/077618 A1 discloses a razor cartridge comprising a housing, a guard disposed toward a front portion of the housing, a cap disposed toward a rear portion of the housing, a plurality of bent blade assemblies, wherein at least one of the blade assemblies comprises one or more perforations along a length of the assembly. In another embodiment, a razor cartridge comprising a housing, a guard disposed toward a front portion of the housing, a cap disposed toward a rear portion of the housing, a plurality of integrally formed bent blade assemblies, wherein each of the blade assemblies comprises one or more perforations along a length of the assembly. - To this aim, it is provided a method of manufacturing an integrally formed razor blade comprising:
- providing a strip having, in cross-section transverse to a long axis, a blade portion and a removable portion, wherein weakening holes are provided along the long axis between the blade portion and the removable portion,
- separating the blade portion from the removable portion by breaking the strip at the weakening holes,
- providing the razor blade with a profile having:
- a cutting edge portion extending along a cutting edge portion axis, and having a cutting edge at one end,
- a base portion extending along a base portion axis, and having an abutment edge at one end,
- a bent portion intermediate the cutting edge portion and the guided portion, wherein the abutment edge is corrugated along the long axis, with corrugations with a height of at most 0.32 millimeters.
- Thereby, the handled strip can be made longer, and easier to handle. Further, by using a pre-perforated strip, separation of the blade from the strip is performed by imparting minimal deformation to the strip, thereby improving the overall consistency of the manufactured product.
- Other characteristics and advantages of the invention will readily appear from the following description of some of its embodiments, provided as a non-limitative examples, and of the accompanying drawings.
- On the drawings :
-
Fig. 1 is an exploded perspective view of a razor head according to an embodiment, -
Figs 2a and 2b are two opposed perspective views of an embodiment of an integral bent blade, -
Fig. 3a is a rear view of the blade ofFigs. 2a and 2b , -
Fig. 3b is a lateral view of the blade ofFig. 3a , -
Figs. 4a and 4b are views corresponding respectively toFigs. 3a and 3b for a second embodiment of a bent blade, -
Fig. 5 is a view corresponding toFig. 3a for a third embodiment of a bent blade, -
Figs. 6a and 6b are views corresponding respectively toFigs. 3a and 3b for a fourth embodiment of a bent blade, -
Fig. 7 is a schematic sectional view along line VII-VII onFig. 1 , -
Figs. 8a and 8b are schematic views of intermediate products of the manufacture of a razor blade, -
Fig. 9 is a lateral view of an embodiment of a forming tool used for the manufacture of a bent blade, -
Fig. 10 is a chart of a manufacturing process for a bent blade, -
Fig. 11 is a perspective schematic view of a holding tool for a bent blade. - On the different Figures, the same reference signs designate like or similar elements.
-
Figure 1 shows ahead 5 of a safety razor (also called wet shaver), a shaver the blades of which are not driven by a motor relative to the blade unit. - The shaving
head 5 is to be borne by a handle extending in a longitudinal direction between a proximal portion and a distal portion bearing theblade unit 5 or shaving head. The longitudinal direction may be curved or include one or several straight portions. - The
blade unit 5 includes anupper face 6 defining a shaving window, and equipped with one or several cutting members and a lower face 7 which is to be connected to the distal portion of the handle by a connection mechanism. The connection mechanism may for instance enable theblade unit 5 to pivot relative to a pivot axis X which is substantially perpendicular to the longitudinal direction. Said connection mechanism may further enable to selectively release the blade unit for the purpose of exchanging blade units. One particular example of connection mechanism usable in the present invention is described in documentWO-A-2006/027018 , which is hereby incorporated by reference in its entirety for all purposes. - The
blade unit 5 includes aframe 10 which is made solely of synthetic materials, i.e. thermoplastic materials (polystyrene or ABS, for example) and elastomeric materials. - More precisely, the
frame 10 includes aplastic platform member 11 connected to the handle by the connection mechanism and having: - a
guard bar 12 extending parallel to the pivot axis X, - a
blade receiving section 13 situated rearward of theguard 12 in the direction of shaving, - a
rear portion 14 extending parallel to the pivot axis X and situated rearward of theblade receiving section 13 in the direction of shaving, - and two
side portions 15 joining the longitudinal ends of theguard bar 12 and of therear portion 14 together. - In the example shown in the figures, the
guard bar 12 is covered by anelastomeric layer 16 forming a plurality offins 17 extending parallel to the pivot axis X. - Further, in this particular example, the underside of the
platform member 11 includes twoshell bearings 18 which belong to the connection mechanism 8 and which may be for example as described in the above-mentioned documentWO-A-2006/027018 . - The
frame 10 further includes aplastic cover 19 having a top face and an opposite bottom face, which faces the top face of the components of theplatform 11. Thecover 19 exhibits a general U shape, with acap portion 20 partially covering therear portion 14 of the platform and twoside members 21 covering the twoside members 15 of the platform. In this embodiment, thecover 19 does no cover theguard bar 12 of the platform. - The
cap portion 20 of thecover 19 may include alubricating strip 23 which is oriented upward and comes into contact with the skin of the user during shaving. This lubricating strip may be formed for instance by co-injection with the rest of the cover. Thecover 19 is assembled to theplatform 11 by any suitable means, such as, for example, by ultra-sonic welding, as explained inWO 2010/06,654 - The present description of a housing is exemplary only.
- At least one cutting
member 24 is movably mounted in theblade receiving section 13 of the platform. Theblade receiving section 13 may include several cuttingmembers 24, for instance four cutting members as in the example shown in the drawings. - Each cutting
member 24 is made of a blade which is integrally formed from a flat steel strip. - In particular, one may use a martensitic stainless steel with the following composition (in weight):
- Carbon : between 0.62% and 0.75%,
- Chromium : between 12.7% and 13.7%,
- Manganese : between 0.45% and 0.75%,
- Silicon : between 0.20% and 0.50%,
- Iron: Balance
- Such an alloy has no more than traces of other components, and notably no more than traces of Molybdenum.
- The razor blade has a
cutting edge 26 oriented forward in the direction of shaving and an opposedrear edge 54. Thecutting edge 26 is accessible through the shaving window of the blade-receivingsection 13, to cut hair. Each blade 25 has anouter face 27 oriented towards the skin to be shaved and an opposedinner face 28. The outer andinner faces main surfaces facets edge 26. - Each blade 25 extends longitudinally, parallel to the pivot axis X, between two
lateral sides 33, 33'. For example, the lateral sides are straight. - Each blade 25 has a bent profile including:
- a substantially flat base portion 35 (for example substantially perpendicular to the shaving plane) having a periodically
serrated edge 54, - a substantially flat
cutting edge portion 39 comprising thecutting edge 26, - a
bent portion 53 extending between the base portion and the cutting edge portion. The bent portion has aconcave face 28 and an opposedconvex face 27. The face of the blade having the concave face is called inner face, and the other one the outer face. - When the blade is mounted to slide in the head, the base portion is also sometimes called "guided portion".
- As shown in
figure 1 , each cuttingmember 24 is borne by twoelastic fingers 44 which are molded as a single piece with theplatform 11 and which extend towards each other and upwardly from bothside members 15 of the platform. For example, all thefingers 44 extending from a given side member are identical. - Besides, as shown in
figure 2 , thebase portions 35 of the blades are slidingly guided inslots 45 provided in the inner face of eachside member 15 of the platform. The slots are, for example, substantially perpendicular to the shaving plane. - The
blades 24 are elastically biased by theelastic arms 44 toward a nominal position. In this nominal position, the outer faces 27 of the blades, at each lateral end of the blades, bear against correspondingupper stop portions 52 which are provided on the bottom stopping face of eachside member 21 of the cover, saidside member 21 covering theslots 45. - Therefore, the nominal position of the
blades 24 is well defined, therefore enabling a high shaving precision. - In this nominal position, the inner faces 28 of the blades, at each lateral end of the blades, are borne by corresponding
top portions 55 of the elastic arms. The distance between the two top portions is for example of 22 to 30 mm, preferably between 25 and 27 mm. - The guiding
slots 45 define a direction Y for the razor head. The direction Z is the normal to the X-Y plane. Thebase portion 35 extends in a base portion plane. The base portion axis is the main axis of the base portion other than its profile axis, i.e. other than the X axis. In the present embodiment, it is the Y axis. In other words, the main axis along which the base portion extends is the same as the axis defined by theslots 45 in the razor head. - The
cutting edge portion 39 extends in a cutting edge portion plane. The cutting edge portion axis is the main axis of the cutting edge portion other than its profile axis, i.e. other than the X axis. In the present embodiment, it is a U axis. In other words, the cutting edge portion axis extends in an X-U plane. A V axis is defined normal to the X-U plane. - A first embodiment of a bent blade is shown on
Figs 3a and 3b . Below, some geometrical characteristics of the blade are given. The geometrical characteristics of the blade are here nominal characteristics, which do not take into account the actual geometry of the blade due to the manufacturing process or dispersion. In particular, due to the manufacturing process, thickness variations and/or bow, sweep, camber of some blade portions are possible, and are even intrinsic to the product. - Following parameters are defined:
- t: thickness of the blade;
- L: length of the blade from one
lateral side 33 to another 33'; - H: height of the blade, measured along direction Y, from the
rear edge 54 to thecutting edge 26; - D: cantilever dimension, measured along direction Z, from the
cutting edge 26 to the plane of the base portion (X-Y); - α: included angle, measured between the base portion plane and the cutting edge portion plane;
- Hb: height of the blade base portion, measured along direction Y, from the
rear edge 54 to thebent portion 53; - R: radius of curvature of the inner face of the bent portion;
- Hc: Extent of the cutting edge portion, measured along direction U, from the
cutting edge 26 to thebent portion 53; - T: period of the serrated edge;
- T1: extent of the protrusion of the serration;
- h: height of the serrated end.
- According to the first embodiment, a suitable razor blade shows the following geometric properties:
Paramete r Nomina l value Dispersio n Paramete r Nomina l value Dispersio n T 0.1 mm Hb 1.43 mm L 37.1 mm R 0.6 mm H 2.33 mm Hc 0.28-1.14 mm D 1.35 mm +/-0.05 mm T 5.3 mm ±0.003 mm A 108° +/-2° h 0.13-0.32 mm T1 2 mm - This value indicated for Hc is in fact an average between the value measured for Hc on both lateral sides of the blade. Due to the deformation of the blade, these two values were different, amounting in average to 0.81 mm and 0.85 mm, respectively. Hc might extend between 0.28 and 1.14 mm, preferably between 0.4 and 1 mm.
- Other embodiments were successfully manufactured, which showed satisfactory. According to a second embodiment, shown on
Figs. 4a and 4b , the other parameters are alike, apart from α=112°, H = 2.4 mm, Hc = 0.96 mm. - Yet another embodiment is shown on
Fig. 5 . This embodiment differs from the second embodiment mainly by different values for T and T1. - According to yet another embodiment, as shown on
Figs. 6a and 6b , the rear edge is not serrated. The geometric datas for this embodiment are:Parameter Nominal value Parameter Nominal value t 0.1 mm Hb 1.57 mm L 37.1 mm R 0.6 H 2.58 mm Hc 1.07 D 1.45 mm α 112° - As shown on
Fig. 7 below, a cutting plane (P) is defined for the head from the tangents to guard bar before the window receiving the blades and the cap behind it. Hence, upon shaving, a force will be applied to the blade by the user, along a direction F which is sensibly normal to the plane (P). Theblades 24 are oriented in thehead 5 such that the cutting edge portion forms an angle with the cutting plane (P). In other words, the force F is applied sensibly in the Y direction at approximately ± 5°. - According to the first invention, tests have shown that, surprisingly, the above material provided a bent blade providing the best compromise between formability and cutting edge performance. In particular, the above material can be formed as a successful cutting edge of a razor blade, provided with current cutting edge processing including grinding, coating with a strengthening material and coating with a telomere layer. In addition, the above material can be formed as a successful bent region with enhanced consistency, high reproductibility, and without producing too much corrosion prone macro-cracks during manufacturing.
- These tests were performed both for a head with a blade according to the first embodiment above, and for another blade with an angle α of 112°. It is expected that this material would provide improved behavior even when modifying other parameters of the blade. In particular, it is believed to be verified for α taken between 95° and 140° ; preferably between 108° and 112°, R over 0.4 mm, preferably between 0.5 mm and 1 mm, t between 0.07 mm and 0.12 mm, preferably between 0.095 mm and 0.105 mm, Hc between 0.28 mm and 1.14 mm, preferably between 0.4 mm and 1.0 mm. The thus obtained blade may also be used fixed in a razor head, if necessary.
- According to the second invention, with the
blade edge portion 39 being supported only by the twosprings 44, the shaving force being applied along direction F therebetween, and the base portion constrained to move parallel to the X-Y plane, the dimension D has proven to be a critical dimension of the blade. - Tests have shown that an optimum can be reached when the D dimension is selected between 1.1 mm and 1.8 mm. If D exceeded 1.8 mm, the blade would be submitted to large deflection during shaving, thereby reducing shaving performance. Head rinsability would also be reduced. Further, there would be a risk of appearance of macro-cracks in the blade, notably in the inner face of the bent region, and/or permanent deformation of the blade. Macro-cracks ought to be avoided, because they are a preferred site for the corrosion of the blade. Permanent deformation ought to be avoided, because it would negatively affect shaving performance. When D becomes lower than 1.1 mm handling and manufacturability are dramatically impaired. There is a risk of damaging the cutting edge during handling and head manufacture. Further, applying a suitable spring force on the blade becomes difficult.
- These tests were performed for a head with a blade according to the first embodiment above, but it is expected that heads provided with movable blades guided along their base portion axis, and with the selected D dimension would provide improved performance, even when modifying other parameters of the blade, such as its material, or other geometrical parameters. In particular, it is believed to be verified when the distance between the two contact points of the blade to the springs is between 22 and 30 mm, preferably between 25 and 27 mm, when α is taken between 95° and 140°, preferably between 108° and 112°, R over 0.4 mm, preferably between 0.5 mm and 1 mm, t between 0.07 mm and 0.12 mm, preferably between 0.095 and 0.105 mm, Hc between 0.4 mm and 1.0 mm, preferably between 0.81 mm and 0.85 mm. Such a preferential behaviour is also expected to be met for bent blades with lower carbon range, for example from 0.5% carbon in weight.
- According to the third invention, tests have shown that an optimum can be reached when the R dimension is selected over 0.5 mm, preferably over 0.55 mm. The R dimension is preferably lower than 1 mm. In other words, the radius of curvature of the outer face at the bent portion is at least 0.57 mm. The median radius of curvature at the bent portion is at least 0.535 mm. Indeed, when the radius of curvature is lower than that, it is difficult to manufacture the blade without generating high stresses which would cause the appearance of macro-cracks in the bent region.
- These tests were performed for a blade according to the first embodiment above, but it is expected that the above would remain true even when modifying other parameters of the blade. In particular, it is believed to be verified for α taken between 95° and 140°, preferably between 108° and 112°, t between 0.07 mm and 0.12 mm, preferably between 0.095 and 0.105 mm. The thus obtained blade may also be used fixed in a razor head, if necessary.
-
Fig. 10 now schematically shows an example of a process for the manufacture of the above bent blades. - At
step 101, one provides a strip of suitable material. The material is for example stainless steel in ferritic form with secondary carbides, and having the above composition. A strip is any kind of product suitable to be manufactured into a bent blade as above. For example, thestrip 56 is shown onFig. 8a . It is substantially straight. It has the thickness of the future razor blade. It has the length L of the future razor blade. Along the transverse height direction, it comprises, from top to bottom onFig. 8a , acutting edge portion 57, a to-be-bent portion 58, abase portion 59, and aremovable portion 60. Thecutting edge portion 57, the to-be-bent portion 58 andbase portion 59 together define a blade portion of the strip.Notches 61 are provided, which extend oblongly along the long direction, between thebase portion 59 and theremovable portion 60. - In particular, the
notches 61 are shaped to receive transport fingers of the manufacture apparatus, in order to transport the strip from one station to another, along the manufacturing line, and to hold the strip in respective stations, as will be explained below in relation toFig. 11 . - At
step 102, ametallurgical hardening process 102 is performed on the strip. This process initiates martensitic transformation of the steel. - At
step 103, the top edge of the strip, which is to become the cutting edge, i.e. the edge of the strip which belongs to thecutting edge portion 57, is shaped as the cutting edge of a razor blade. This shaping is a sharpening process performed by grinding the edge to the acute required geometry. The cutting edge is defined by convergent faces which taper toward a tip having an angle of about 10°-30°. - At
step 104, a strengthening coating is applied on the ground cutting edge. For example, the ground blades are stacked in a stack, with their cutting edges all oriented in the same direction, and a strengthening coating is applied thereto. The strengthening coating will comprise one or more layers with different characteristics. The layers may comprise one or more of metal (s) (notably chromium or platinum) and carbon (possibly in DLC form). This coating is for example deposited by sputtering. Sputtering may also be used to precisely shape the geometry of the cutting edge before or after coating. The global geometry of the cutting edge is maintained at this step. - At
step 105, a telomere coating is applied on the blade edge. A suitable telomere is for example a PTFE. A suitable deposition method is spraying. - What is referred to as being the blade body is the part of the blade which is made of steel, exclusive the coatings.
- At
step 106, a bending step is applied on the up-to-now straight strip. At the bendingstep 106, one part of the strip is held, and a force is applied on the other part, so as to provide the strip with abent portion 63, as shown onFig. 8b . After this step, thecutting edge portion 57 is angled with respect to the base portion by sensibly the above angle α. Permanent deformation is imparted on the bent portion. Bending could for example be performed by stamping. Alternately, bending could be done by a number of other suitable methods. A method which reduces the generation of macro-cracks in the strip, notably to its bent portion, is preferred. - Due to the natural characteristics of the material, the bent strip exiting from this step will not have the nominal geometry described above. In particular, it will exhibit some degree of camber, bow or sweep. Further, due to the material's mechanical properties, the dispersion of the geometry of the products can be large. This is particularly the case when the process used for applying the bending is only mildly severe to the strip (in order to avoid appearance of cracks). In such case, the amount of spring-back of the material after deformation is high and hardly predictable.
- According to the fifth invention, at
step 107, a straightening step is performed. At this step, a forming process is used in order to reduce the dispersion in the geometry of products. In particular, permanent deformation is applied on the inner face of the bent portion of the strip. This permanent deformation straightens the overall blade, and reduces the dispersion in blade geometry among the products. - As an example, as shown on
Fig. 9 , a straighteningstation 70 comprises asupport 71 to receive thebent strip 72. For example, thesupport 71 has a V-shapedgroove 73 having an included angle corresponding to the nominal angle for the bent blade. The bent strip is placed in thegroove 73 with its outer surface resting on the arms of the V-shaped groove. It may be maintained there by any suitable means, such as by vacuum suction or the like. Adeformation tool 74 is placed above thegroove 73. Thedeformation tool 74 has a base 75 receiving acarriage 76 movably mounted with respect to thebase 75 along the length direction of the strip (transverse to the plane ofFig. 9 ). Thecarriage 76 bears a pressure-application tip 77. The position of the pressure-application tip 77 with respect to thecarriage 76 is settable, so as to bring the pressure-application tip at controlled distance to thebase 71. The distance between the edge of thetip 77 and thegroove 73 will determine the level of pressure applied by the tip to the strip. - The pressure-application tip may comprise a
support 78 receiving a spring-loadedball 79 at its edge. The ball has dimensions of the order of the bent portion of the strip. Thesupport 78 allows rotation of theball 79 therein. - Upon use, the
tip 77 is held in an upper position until a strip is placed in thegroove 73. Thetip 77 is moved down until theball 79 contacts the bent portion of the strip with suitable pressure. Theball 79 does not contact the straight portions of the strip. The contact is made at one lateral side of the strip. Then, thecarriage 76 is moved with respect to thebase 75 along the length of the strip until the other lateral side, to form the bent portion of the strip. The ball rolls during this movement. Possibly, this movement is performed back-and-forth. Thetip 77 is then moved again to its up position, to remove the straightened strip from the straighteningstation 70. - The formed strip is controlled. For example, its geometry is measured with a suitable measurement apparatus. These measurements enable to set the level of pressure applied by the tip for straightening steps on future products.
- Back to
Fig. 10 , a cuttingstep 108 is performed. At this step, theremovable portion 60 is removed, to result in the final bent blade. According to a fourth invention, it is made use of thenotches 61 which are provided between the base portion and the removable portion of the blade, to remove the removable portion. It enables to remove the removable portion by imparting minimal stress on the bent blade, thus minimizing the level of permanent deformation applied to the bent blade, and potentially affecting its geometry. Further, as the cut part surface is minimized, initiation of corrosion is also reduced to the small cut area. - Cutting can be performed in a cutting
station 80 partially shown onFig. 11 . Thestation 80 has a base 81 from which twolateral pins 82 extend. Thepins 82 are shaped to enter incorresponding notches 61 of the strip, and together precisely locate the strip in the station. Vacuum may additionally be used to retain the strip in the station by suction. The strip, at various stages of its manufacture, can be held in manufacturing stations, and/or moved from one station to the next, using similar principles. - In various embodiments, the order in which some of the above steps are implemented may be changed.
Claims (15)
- A method of manufacturing an integrally formed razor blade comprising:- providing a strip (56) having, in cross-section transverse to a long axis, a blade portion (57-59) and a removable portion (60),
wherein weakening holes (61) are provided along the long axis between the blade portion and the removable portion,- separating the blade portion from the removable portion by breaking the strip at the weakening holes,- providing the razor blade with a profile having:wherein the abutment edge (54) is corrugated along the long axis, with corrugations with a height (h) measured in a direction extending from the abutment edge towards the bent portion (Y) of at most 0.32 millimeters.• a cutting edge portion (57) extending along a cutting edge portion axis, and having a cutting edge (27) at one end,• a base portion (59) extending along a base portion axis, and having an abutment edge at one end,• a bent portion (58) intermediate the cutting edge portion and the base portion, - Method according to claim 1, wherein the blade portion of the strip is provided with said geometry.
- Method according to claim 1 or 2 wherein, before separating, the strip is held in a processing station (80) having a fixed base (81), a tool movable with respect to the fixed base for processing the strip, and locating pins (82) movable with respect to the fixed base between a holding position where the pins pass through the holes to hold the strip in the station,
and a release position where the pins do not cooperate with the strip, thereby allowing the strip to be removed from the station. - An integrally formed rigid razor blade (24) having in cross-section transverse to a long axis:- a cutting edge portion (57) extending along a cutting edge portion axis, and having a cutting edge (27) at one end,- a base portion (59) extending along a base portion axis, and having an abutment edge at one end,- a bent portion (58) intermediate the cutting edge portion and the base portion, characterized in that the abutment edge (54) is corrugated along the long axis, with corrugations with a height (h) measured in a direction extending from the abutment edge towards the bent portion (Y) of at most 0.32 millimeters.
- Razor blade according to claim 4, wherein each blade is made of martensitic stainless steel.
- Razor blade according to any of claims 4 or 5, wherein the blade further has- an included angle (α) measured between the cutting edge portion axis and the base portion axis is between 95°and 140°, preferably between 108° and 112°.
- Razor blade according to any of claims 4 to 6, wherein:- the blade has an inner face (28) and an opposed outer face (27), and extends between a first lateral side and a second lateral side along a long axis, and the bent portion has, in cross-section transverse to the long axis, a radius of curvature (R) over 0.4 mm, preferably between 0.5 mm and 1 mm.
- Razor blade according to any of claims 4 to 7, wherein:- the blade has an inner face (28) and an opposed outer face (27), and a thickness (t), measured between said faces, between 0.07 mm and 0.12 mm, preferably between 0.095 mm and 0.105 mm.
- Razor blade according to any of claims 4 to 8, wherein:- the extent of the cutting edge portion along the cutting edge portion axis is between 0.4 mm and 1.0 mm, preferably between 0.81 millimeter and 0.85 mm.
- Razor blade according to any of claims 4 to 9, wherein the cantilever dimension (D), measured as the distance between the cutting edge and the base portion axis, is between 1.1 millimeter and 1.8 millimeter.
- Razor blade according to claim 10, wherein the cantilever dimension is between 1.3 millimeter and 1.4 millimeter.
- A razor head (5) comprising:- a housing having a top face (6) defining a shaving window, and an opposed stopping face (7), the housing further comprising at least one guide (45),- at least one integrally formed rigid razor blade (24), each freely mounted in the housing, according to any one of claims 4 to 11,wherein the base portion cooperates with the guide so that each blade is independently translatable with respect to the housing along a sliding direction parallel to the base portion axis, under the effect of shaving forces applied to the blade during shaving.
- Razor head according to claim 12, wherein the housing further comprises at least one biasing device (44), wherein the cutting edge portion has a top face, wherein the biasing device cooperates with the blade to bias the blade until the top face of the cutting edge portion abuts on the stopping face of the housing, and in opposition to the shaving forces.
- Razor head according to claim 13, wherein the housing has two lateral sides (33, 33'), wherein the biasing device comprises an elastic support provided in each lateral side, wherein each elastic support has a contact portion contacting the blade, wherein a distance between the two contact portions is between 22 mm and 30 mm, preferably between 25 mm and 27 mm.
- Razor head according to any of claims 12 to 14, wherein the top face comprises a guard bar (12) before said at least one blade and a cap (20) beyond said at least one blades, wherein said guard bar and cap define a shaving plane, and
wherein an angle between the shaving plane and the base portion axis is between 85° and 95°.
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
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PL18167402T PL3378614T3 (en) | 2011-10-06 | 2012-10-08 | Razor blade, razor head, and method of manufacture |
Applications Claiming Priority (3)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
EP2011067451 | 2011-10-06 | ||
EP12769444.6A EP2763823B1 (en) | 2011-10-06 | 2012-10-08 | Razor blade and razor head |
PCT/EP2012/069883 WO2013050606A1 (en) | 2011-10-06 | 2012-10-08 | Razor blade, razor head, and method of manufacture |
Related Parent Applications (2)
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EP12769444.6A Division-Into EP2763823B1 (en) | 2011-10-06 | 2012-10-08 | Razor blade and razor head |
EP12769444.6A Division EP2763823B1 (en) | 2011-10-06 | 2012-10-08 | Razor blade and razor head |
Publications (3)
Publication Number | Publication Date |
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EP3378614A2 EP3378614A2 (en) | 2018-09-26 |
EP3378614A3 EP3378614A3 (en) | 2019-01-09 |
EP3378614B1 true EP3378614B1 (en) | 2020-08-19 |
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EP18167402.9A Active EP3378614B1 (en) | 2011-10-06 | 2012-10-08 | Razor blade, razor head, and method of manufacture |
EP18169778.0A Active EP3375578B1 (en) | 2011-10-06 | 2012-10-08 | Razor blade and razor head |
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EP18169778.0A Active EP3375578B1 (en) | 2011-10-06 | 2012-10-08 | Razor blade and razor head |
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CN113544298A (en) * | 2019-02-28 | 2021-10-22 | Edgewell个人护理品牌有限责任公司 | Razor blade and composition for razor blade |
EP3771532B1 (en) | 2019-07-31 | 2023-10-25 | BIC Violex Single Member S.A. | Razor cartridge |
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EP0485641B1 (en) * | 1990-11-10 | 1994-07-27 | Wilkinson Sword Gesellschaft mit beschränkter Haftung | Razor blade steel having high corrosion resistance, razor blades and a process for manufacturing razor blades |
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WO2006027018A1 (en) | 2004-09-07 | 2006-03-16 | Bic-Violex Sa | Razor handle and shaver including such a handle |
US8011104B2 (en) | 2006-04-10 | 2011-09-06 | The Gillette Company | Cutting members for shaving razors |
US8499462B2 (en) * | 2006-04-10 | 2013-08-06 | The Gillette Company | Cutting members for shaving razors |
MX2008016496A (en) | 2006-06-20 | 2009-03-02 | Bic Violex Sa | Razor blade unit head and safety razor including such a blade unit. |
EP2276591B2 (en) * | 2008-05-05 | 2020-01-22 | Edgewell Personal Care Brands, LLC | Method of making a razor blade |
WO2010006654A1 (en) | 2008-07-18 | 2010-01-21 | Bic-Violex Sa | Process and station for manufacturing a safety razor cartridge, and safety razor cartridge |
AU2009296283A1 (en) * | 2008-09-29 | 2010-04-01 | The Gillette Company | Razor cartridges with perforated blade assemblies |
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US20110314678A1 (en) * | 2010-06-29 | 2011-12-29 | Mark Peterson | Bent razor blades and manufacturing thereof |
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2012
- 2012-10-08 EP EP18167402.9A patent/EP3378614B1/en active Active
- 2012-10-08 EP EP18169778.0A patent/EP3375578B1/en active Active
- 2012-10-08 PL PL12769444T patent/PL2763823T3/en unknown
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EP3375578B1 (en) | 2020-09-23 |
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EP3378614A3 (en) | 2019-01-09 |
EP3378614A2 (en) | 2018-09-26 |
EP3375578A1 (en) | 2018-09-19 |
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