JP5746354B2 - Lubrication box for wet shaving equipment - Google Patents

Description

[Cross-reference to related applications]
This application claims benefit based on US Provisional Application No. 61 / 253,540, which is incorporated herein in its entirety by reference to the 21 October 2009 application.

  The present invention relates generally to lubrication boxes for wet shaving equipment, and more specifically to mechanically assembled lubrication boxes that provide lubrication during shaving.

  Wet shaving instruments are generally composed of a shaving cartridge, commonly referred to as a razor cartridge, and a handle. The shaving cartridge can be fixedly or pivotally attached to the handle. In addition, the shaving cartridge may be secured to the handle so that the used shaving cartridge can be replaced with a new shaving cartridge on the same handle after several uses. Such handles and shaving cartridges are often referred to as “system razors”. Alternatively, the shaving cartridge can be fixed to the handle without being intended to be removed from the handle during normal use, and the entire shaving device is discarded with the shaving cartridge used, and a completely new shaving device Is used at the place of this discarded equipment. Such shaving instruments are often referred to as “disposable razors”.

  A shaving cartridge typically includes a guard, a cap, and at least one blade. Prior art guards are placed in front of the blade and act to flatten and / or pre-stretch the skin prior to contact with the blade. Prior art caps are often placed behind the blade to provide lubricant and / or other shaving aids to the previously shaved skin in addition to skin flattening after the skin is shaved You can also Generally, the lubricant and / or shaving aid is provided by a lubricating strip secured to the cap.

  In many cases, these lubricating strips utilize two components: a water soluble component dispersed throughout a water insoluble matrix. The water insoluble matrix maintains the integrity of the lubricating strip during normal use and allows water soluble components to dissolve in the water normally present during shaving. When dissolved in water, the water-soluble shaving aid leaches onto the surface being shaved to provide a shaving benefit. These lubricating strips are typically glued to or mechanically fastened to the wet shaving razor cartridge.

  These forms of lubrication strips are defective. First, the shaving aid tends to leach excessively during the first few shavings. However, the amount of water-soluble shaving aid decreases with each subsequent shaving, thereby dissipating and often lasting other components of the razor cartridge. Thus, in the final few shavings, the lubricant provided on the surface being shaved is also insufficient. Furthermore, current insoluble matrices do not allow complete leaching of all shaving aids and are therefore wasteful.

  Other wet shaving razor embedded lubrication elements, such as US Pat. No. 5,711,076 to Tseng (hereinafter “Tseng”), have a water soluble core coextruded with a water insoluble sheath. Co-extruded core and sheath configurations are taught. The sheath portion of Tseng typically includes holes through which the core material dissolved during shaving leaches. However, Tseng and similar lubrication devices also have defects. These defects include, among other things, the limited flexibility resulting from the coextrusion / co-molding manufacturing process, the high temperatures and high pressures required for extrusion and molding processes that tend to degrade the active shaving aid component, and the core during normal use. And the fact that the co-molding / coextrusion configuration poses substantial problems when it swells.

US Pat. No. 5,711,076

  Accordingly, it is an object of the present invention to provide a lubricant and a method of manufacture that improves the effectiveness and duration of use of the lubricant.

  According to one aspect of the present invention, the lubrication box includes a first portion, a shaving aid material, and a second portion. The first portion of the lubrication box has a skin engaging surface and at least one sidewall that together form a cavity. At least two holes extend through the skin engaging surface of the first portion. The shaving aid material is ultrasonically compressed (also referred to as ultrasonic consolidation) into the cavity such that it at least partially fills at least one of the holes in the skin engaging surface and at least a portion of the cavity. The second portion of the lubrication box is secured to the first portion such that the cavity is substantially closed. There is a gap in the cavity between the shaving aid and the second portion of the lubrication box, allowing the shaving aid material to expand during normal use.

  In accordance with another aspect of the invention, the shaving aid is distributed in the cavity in a series of layers (eg, first, second, third, or more).

  According to yet another aspect of the invention, the various layers of the shaving aid may be of the same or different color, amount, and / or chemical composition as one or more of the other layers of the shaving aid. Can do.

  In accordance with yet another aspect of the present invention, the second portion of the lubrication box can include a support structure that extends into the cavity to a position that is in close proximity or in direct contact with the shaving aid.

  These and other aspects of the invention are achieved by the apparatus and methods of carrying out the invention disclosed herein. The present invention will be apparent to those skilled in the art in light of the Detailed Description and the drawings provided.

It is a front view of one embodiment of the wet shaving cartridge of the present invention. It is a front view of another embodiment of the wet shaving cartridge of this invention. It is a front view of further another embodiment of the wet shaving cartridge of this invention. It is a front view of further another embodiment of the wet shaving cartridge of this invention. FIG. 2 is a cross-sectional view of the cartridge of FIG. 1 along the line II-II on the razor handle. 1 is an isometric view of one embodiment of a lubrication box of the present invention. FIG. FIG. 4 is a cutaway view along line IV-IV of a first portion of the lubrication box of FIG. 3 having a first layer of shaving aid therein; FIG. 5 is a cutaway view along line IV-IV of a second layer of shaving aid in the first portion of the lubrication box of FIG. 4. FIG. 4B is a cutaway view along line IV-IV of a third layer of shaving aid in the first portion of the lubrication box of FIG. 4A. FIG. 4B is a cutaway view along line VV of one embodiment of a second portion of the lubrication box secured to the first portion of the lubrication box of FIG. 4A. FIG. 4 is a diagram showing another embodiment of the second portion of the lubrication box of FIG. 3. FIG. 6 is a view showing still another embodiment of the second portion of the lubrication box of FIG. 3. It is a figure which shows the step in the preparation method of a lubrication box. It is a figure which shows another step in the preparation method of a lubrication box. It is a figure which shows another step in the preparation method of a lubrication box. It is a figure which shows another step in the preparation method of a lubrication box. It is a figure which shows another step in the preparation method of a lubrication box. It is a figure which shows another step in the preparation method of a lubrication box.

  With reference to FIGS. 1, 1A, 1B, and 1C, several embodiments of the shaving cartridge 102 of the present invention are shown. The shaving cartridge 102 of the present invention includes at least one frame 104, at least one razor blade 106, and a lubrication box 108.

  The shaving cartridge 102 of the present invention is often used in conjunction with the handle 10 (see FIG. 2). The handle 10 is connected to the shaving cartridge 102 either pivotally or fixedly. The handle 10 can be connected to the shaving cartridge 102 in any suitable manner. For example, the handle 10 can be permanently connected to the razor cartridge 102, as is known in disposable wet shaving instruments. Alternatively, the handle can be selectively detached from the shaving cartridge, as is known in system wet shaving equipment. The handle 10 can be made of any suitable material and is generally ergonomically shaped to be easy to hold by the end user during shaving.

  The shaving cartridge 102 of the present invention includes a frame 104 and at least one blade 106. The frame 104, which can be manufactured in one or more individual parts, typically forms an opening 105 sized to receive the razor blade 106 (described below). In some embodiments, such as the one shown in FIG. 1, the frame 104 includes a guard 12 in front of the blade 106. In these embodiments, the guard 12 can be of any suitable type known in the art.

  The frame 104 can be made of any suitable material. Molded polymeric materials or plastics have been found to be most effective. The frame 104 also often includes a connector (not shown) that is permanently connected to the handle 10 or that allows the user to selectively remove the cartridge from the handle 10.

  The guard 12 is generally disposed longitudinally on the frame in front of the blade 106 and includes an outer skin engaging surface 14. The guard 12 can be made of any suitable material known to those skilled in the art (e.g., rubber) and is usually added such as one or more protrusions 16 that bend when contacting the skin during shaving. Can include a specific element. The guard 12 generally stretches, flattens, and otherwise prepares the skin before it contacts the sharp cutting edge 22. Guards 12 are well known in the art and, therefore, the invention is not further detailed herein, except that it points out that any particular type of guard 12 is not used. .

  The opening 105 in the frame 104 is sized and shaped to receive a razor blade 106 disposed therein. Any suitable number (eg, 1, 2, 3, 4, 5, 6, or more) of blades 106 may be disposed within the opening 105 of the frame 104. In general, the opening 105 is larger for a shaving cartridge 102 having more blades 106 and smaller for a shaving cartridge 102 having fewer blades 106. Each blade 106 is generally planar and defines a length 18 and a width 20 and is positioned within the opening 105 of the frame 104 such that the sharpened cutting edge 22 is at the appropriate angle for shaving. In embodiments having more than one blade 106, the blades 106 are generally arranged in a parallel relationship between the front 58 and rear 60 of the frame 104. Each of the blades 106 has a front end 24 and a rear end (not shown) that extend on opposite sides along the length 18 of the blade 106. The pointed cutting edge 22 extends on the forward end 24 along at least a portion of the blade 106 width 20. Each blade 106 is disposed on the frame 104 such that the sharp cutting edge 22 of each blade 106 is located substantially close to the shaving plane. In other words, the pointed cutting edge 22 of each blade 106 may be in substantial contact with the shaving plane and slightly above or slightly below. In addition, each blade 106 can be mounted on the frame 104 such that the pointed cutting edge 22 is movable relative to the shaving plane under the force experienced during normal shaving. For example, in some embodiments, the pointed cutting edge 22 is located above the shaving plane when the shaving cartridge 102 is stationary, but is typically below the shaving plane due to forces on the blade 106 during shaving. To deflect. The position of each blade 106 relative to the shaving plane does not depend on the position of each other blade 106 relative to the shaving plane.

  In general, the blade 106 is made of a flexible material and is typically supported within the frame 104 to prevent or at least slightly suppress bending of the blade 106 during shaving. Several schemes for supporting the blade 106 are known in the art. For example, in some embodiments, each blade 106 can be welded to a bending blade support (see, eg, FIG. 2) that provides the blade 106 with a rigid support structure.

  For example, referring to FIGS. 3, 4, 4A, and 4B, according to one embodiment of the present invention, the lubrication box 108 includes a first box portion 28, a shaving aid 30, and a second box portion 32. including. One embodiment of the lubrication box 108 of the present invention is shown in FIG. The lubrication box 102 is attached to the frame 104 directly or indirectly. For example, as shown in FIG. 1, the lubrication box 108 can be located behind the blade 106. Alternatively, as shown in FIG. 1A, in other embodiments, the lubrication box 108 may be located in front of the blade 106. In yet another embodiment, the lubrication box 108 may be located in front of and behind the blade 106, as shown in FIG. 1B. In yet another embodiment, the lubrication box 108 can substantially surround the blade 106, as shown in FIG. 1C.

  One embodiment of the first portion 28 of the lubrication box 108 can be seen in FIG. The first portion 28 includes a skin engaging surface 34 and at least one sidewall 34 that extends from the skin engaging surface 34 and creates a cavity 40. The skin engaging surface 34 can be any suitable size and shape and includes at least two holes 38 extending into the cavity. As shown in FIGS. 1, 1A, and 1B, the skin engaging surface 34 is substantially rectangular and is about 3 mm wide and about 40 mm long. Alternatively, as shown in FIG. 1C, the skin engaging surface 34 can be generally oval with a central hole through which the shaving cartridge 102 can pass. However, the present invention is not limited by the shape and / or size shown and disclosed, and can be any shape suitable for the designer. Similarly, the at least two holes 38 can be any suitable size and shape based on the requirements and desires of the designer. Although at least two holes 38 are shown in FIG. 1 as being in a single row, they can be arranged in multiple rows and any suitable pattern, including symmetric and asymmetric patterns. The first portion 28 can be made of any suitable material including, but not limited to, plastic, metal, and rubber. Preferably, the entire first portion 28 is a single piece made of a single material portion, but the invention is not so limited. For example, although not shown, the skin engaging surface 34 can be made of a different material than the sidewall 36.

The side wall 36 extends from the skin engaging surface 34 to create a cavity 40. For example, as shown in FIGS. 1-1C, the side wall 36 extends substantially perpendicular to the skin engaging surface 34, but those skilled in the art will recognize that the invention is not so limited. For example, the skin engaging surface 34 transitions to the side wall 36 through a smooth curve so that the edge of the lubrication box 108 is gently pressed against the user's skin during normal shaving. The sidewall 36 can be any suitable height based on the designer's requirements and desires. As shown in FIGS. 2 and 3, the side wall 36 is about 4 mm high, creating a cavity 40 that does not include at least two holes 38 and has a volume of about 480 mm ³ .

  The first layer 50 of shaving aid is ultrasonically compressed in the first portion 28 of the lubrication box 108 such that the first layer 50 of shaving aid is consolidated in at least a portion of the cavity 40, preferably A portion of the first layer 50 of shaving aid is consolidated to substantially fill at least one hole 38; Even more preferably, the first layer 50 of shaving aid is consolidated to substantially fill all holes 38. Most preferably, the first layer 50 of shaving aid fills all the holes 38 completely. The shaving aid 30 is typically added in the solid state (eg, as a powder) and is ultrasonically compressed to form a unitary solid that substantially matches the internal shape of the cavity 40 and the hole 38. Consolidation of the material causes the first layer 50 of shaving aid to be more frictionally secured in the desired location (ie, at least a portion of the hole 38 and a portion of the cavity 40 adjacent to the hole 38).

  The shaving aid 30 preferably comprises 100% water soluble shaving aid, although water insoluble shaving aid materials are acceptable. For example, the shaving aid 30 can include any material that enhances shaving performance. The material can, for example, improve the comfort of shaving (eg, by skin lubrication, improved shaving efficiency, wrinkle conditioning, or skin conditioning). Suitable shaving aids 30 include lubricating water soluble polymers such as polyethylene oxide, polyvinyl pyrrolidone, polyacrylamide, hydroxyethyl cellulose, hydroxypropyl cellulose, polyvinyl imidazoline, polyhydroxyethyl methacrylate, polyvinyl alcohol. A preferred lubricating water-soluble polymer is polyethylene oxide. More preferred polyethylene oxides will preferably have a molecular weight of about 100,000 to 8 million, most preferably about 300,000 to 5 million. The most preferred polyethylene oxide comprises a blend of about 40 to 80% polyethylene oxide having an average molecular weight of about 5 million and about 20 to 60% polyethylene oxide having an average molecular weight of about 300,000.

  The polyethylene oxide formulation may contain a plasticizer in an advantageous manner. The use of a plasticizer allows the use of a substantially lower temperature during processing time to cause the flowability of polyethylene oxide during ultrasonic compression without substantially reducing the molecular weight of polyethylene oxide. Preferred plasticizers are polyethylene glycols having a molecular weight of 400 to 4000, water soluble polypropylene glycols having a molecular weight of 400 to 4000, water soluble copolymers of ethylene and propylene oxide, water soluble alkylphenol ethoxylates, glycerin, sorbitol, and water. . An especially preferred plasticizer is octylphenol ethoxylate having propylene glycol and 9 moles of ethylene oxide.

Additional ingredients to the shaving aid 30 can include:
A. For example, a lubricant that reduces the frictional force between the skin engaging element, which is microencapsulated silicone oil, and the skin.
B. Any additive that reduces drag between the skin engaging element and the shaver surface, for example non-ionic polyacrylamide and / or natural polysaccharides from plant materials such as “gua gum”.
C. For example, an agent that alters the chemical structure of body hair so that at least one razor blade 106, for example a hair removal agent, can easily pass through the eyelids.
D. For example, a detergent that can wash wrinkles and skin debris from skin engaging elements during shaving, which is a detergent such as silicon polyethylene oxide block copolymer and sodium lauryl sulfate.
E. An agent for killing bacteria or healing skin damage or abrasions.
F. A cosmetic agent for softening, smoothing, conditioning or improving the skin.
G. A blood coagulant for the control of bleeding from cuts.
H. An astringent for constricting the flow of body fluids, such as lymph, that can cause blood vessels to contract and thereby leach out of irritated skin during shaving.

  An additional layer 54 of shaving aid can be added to the cavity 40 of the first portion of the lubrication box 28. In some embodiments, the designer can choose to have a subsequent layer 54 contained within the lubrication box 102 that is substantially similar if not identical in amount and / or chemical composition to the preceding layer. . However, the designer may prefer that the subsequent layer 54 be different from the previous layer in one or more aspects. For example, the trailing layer 54 can be designed to differ in amount, chemical composition, and / or color from the leading layer. Such changes can be used to provide the user with various shaving benefits and / or to inform the user that, for example, the lubrication box 108 has almost reached its expiration date.

  As shown in FIGS. 5, 5A, and 5B, the second portion 32 of the lubrication box is secured to the first portion 28 of the lubrication box and substantially encases the shaving aid 30 therein. The second portion 32 of the lubrication box substantially comprises the open end of the cavity 40 in which the second portion 32 of the lubrication box is formed by the side wall 36 and the skin engaging surface 34 of the first portion 28 of the lubrication box. Any suitable shape and size can be provided under the condition of covering. Further, the second portion 32 of the lubrication box is preferably shaped such that there is a gap between the shaving aid 30 and the inner surface 44 of the second portion 32 of the lubrication box. The air gap 42 provides a space that expands when the shaving aid 30 is wet. Otherwise, the expansion of the shaving aid 30 will cause an excessive amount of the shaving aid 30 to exit through the at least two holes 38 and / or the first portion 28 and / or the second portion of the lubrication box. Cause 32 to separate from each other, deform and / or crack.

  The second portion 32 of the lubrication box can be made of any material, but it is often desirable to make it from plastic, metal, or rubber. The second portion 32 of the lubrication box can be attached to the first portion 28 of the lubrication box in any suitable manner. The manner in which the two parts 28, 32 of the lubrication box are attached depends in many cases on the type of material used. For example, ultrasonic welding of the two parts 28, 32 of the lubrication box shows a particular utility when, for example, the two parts 28, 32 of the lubrication box are made of plastic. However, the invention is not limited to this and the two parts 28, 32 of the lubrication box can be glued or otherwise joined together. Further, in some embodiments, a physical connection (eg, male / female connector, press fit) is appropriate.

  The size of the gap between the shaving aid 30 and the second portion 28 of the lubrication box is not limited to the following, but is the size of the lubrication box 108 and the shaving aid 30 added to the cavity 40. Depends on several factors including quantity. In some cases, the small holes 55 (see, eg, FIG. 5B) that pass through the first portion 28 or the second portion 32 of the lubrication box may cause excessive pressure buildup in the lubrication box 108 during normal use. Helps reduce.

  In some embodiments, and specifically referring to FIG. 5A, the second portion 32 of the lubrication box is one or more extending into the cavity 40 proximate to or in direct contact with the shaving aid 30. Many additional support features 46 can be included. During use, as water mixes with the shaving aid 30, a portion of the shaving aid 30 begins to dissolve. As the shaving aid 30 dissolves more, the consolidated shaving aid 30 will often move from a position in the cavity 40 which is undesirable in many cases. The support feature 46 tends to hold the shaving aid 30 in the cavity 40 near the at least two holes 38, where the shaving aid 30 is most likely to mix with water and against the skin during normal use. Provide maximum shaving benefits. The support feature 46 can be located adjacent to the side wall 36 and / or can be located away from the side wall 36 in the direction of the center of the cavity 40. Preferably, the support feature 46 provides support for the shaving aid 30 at several locations within the cavity 40.

  One method of manufacturing the shaving cartridge 102 of the present invention includes first providing a first portion 28 of the lubrication box. As mentioned above, the first portion 28 of the lubrication box can be made of any suitable material by any known means (eg, molding the first portion 28 of the plastic lubrication box). The first portion 28 of the lubrication box is placed in the support nest 62 and a first amount of shaving aid 30 is dispensed into the cavity 40.

  With the first amount of shaving aid 30 distributed in the cavity 40 of the first portion 28 of the lubrication box, the piston 48 then applies pressure one or more times to a certain amount. Of ultrasonic energy is provided (eg, by an ultrasonic horn). Piston pressure and ultrasonic energy ultrasonically consolidate the first amount of shaving aid 30 to form a first layer 50 of shaving aid. For example, in an embodiment using 25-45 mg of polyethylene oxide with vitamin E additive, the piston applies a force of about 100-150 lbs and an energy of 15-20 J is about 0.1 to 0.2 seconds during a single cycle. Provided by an ultrasound source with a retention time of. The actual number, duration, amount of energy provided, and / or force applied by the piston, as provided by the ultrasonic horn, is not limited to the following, but the amount of shaving aid to be consolidated, consolidation May vary depending on a number of factors, including the type of shaving aid being realized, the actual size and shape of the lubrication box, and the desired level of compaction. Ultrasonic consolidation processes allow for good consolidation of the material and conditions that tend to interfere with the material's ability to provide the intended shaving benefits by degrading the active ingredients in the shaving aid 30 (eg, long term The active ingredients are not subjected to high temperature and / or high pressure). As a benefit of the ultrasonic consolidation treatment, a high percentage of the active ingredient in the shaving aid 30 remains available during normal use, providing the expected benefit.

  With the first layer 50 of shaving aid formed or consolidated, a second amount of shaving aid 30 is optionally dispensed into the cavity 40 of the first portion 28 of the lubrication box. The ultrasonic consolidation process described above is repeated.

  Optionally, with the second layer 52 of the shaving aid being consolidated, an additional amount of the third, fourth, or more layer 54 of the shaving aid is added to the cavity 40 of the lubrication box 108. It is distributed inside and consolidated. During the consolidation process, the shaving aid 30 powder is often agitated due to the speed of the piston 48 and the gap between the side edge of the piston 48 and the inside of the side wall 36. A vacuum (not shown) can be provided to remove any portion of the shaving aid 30 that is not consolidated during ultrasonic consolidation.

  With the shaving aid layers 50, 52, 54 consolidated within the first portion of the lubrication box 28, the second portion 32 of the lubrication box is the opening of the cavity 40 in the first portion of the lubrication box 28. Placed on top of the part and fixed. The lubrication box 108 is then secured directly or indirectly to the frame 104 of the shaving cartridge 102 so that the skin engaging element contacts or is accessible to the user's skin during normal use. In some embodiments, the lubrication box 108 is removable and replaceable on the frame 104 of the shaving cartridge 102.

  In use, the shaving cartridge 102 is secured to the handle 10 and the user wets the shaving cartridge 102. Water enters at least two holes 38 of the lubrication box 108 and mixes with the shaving aid 30. The shaving aid 30 typically expands when wet and fills at least a portion of the gap 42 in the lubrication box 108. At the same time, a portion of the shaving aid 30 dissolves in the water and exits through at least two holes 38. Next, the shaving cartridge 102 is placed in contact with the user and pulled across the skin. As the dissolved shaving aid 102 is distributed on the skin at this point, the blade 106 of the shaving cartridge 102 shaves the hair and provides benefits.

  Although only some embodiments of the invention are shown in the drawings, it should be pointed out that many other modifications are considered within the scope of the following claims.

12 Guard 30 Shaving aid 102 Shaving cartridge 105 Opening 106 Blade 108 Lubrication box

Claims (19)

Lubrication box:
A first portion of a lubrication box having a skin engaging surface and at least one side wall, the skin engaging surface and the at least one side wall forming a cavity;
At least two holes extending through the skin engaging surface of the first portion;
A shaving aid material ultrasonically compressed in the cavity that at least partially fills at least one of the holes in the skin engaging surface and at least a portion of the cavity;
A second portion of the lubrication box secured to the first portion such that the cavity is substantially closed;
Including
A gap exists in the cavity between the shaving aid and the second portion of the lubrication box, allowing the shaving aid material to expand during normal use ;
The shaving aid includes at least one hole and a first layer of shaving aid that at least partially fills at least a portion of the cavity of the first portion of a lubrication box;
The shaving aid includes a second layer of shaving aid located in the cavity of the first portion of the lubrication box;
Lubrication box characterized by that.   The lubrication box according to claim 1, wherein the skin engaging portion is substantially rectangular.   The lubrication box according to claim 1, wherein the skin engaging portion includes at least five holes.   The lubrication box according to claim 3, wherein the skin engaging portion includes at least 10 holes.   The lubrication box according to claim 4, wherein the skin engaging portion includes at least 15 holes.   4. A lubrication box according to claim 3, wherein the holes are aligned in a single row.   The lubrication box of claim 1, wherein the second layer is directly adjacent to the first layer of shaving aid.   The lubrication box of claim 1, wherein the first and second layers of shaving aid have substantially the same chemical composition.   The lubrication box of claim 1, wherein the first and second layers of shaving aid have different chemical compositions.   The lubrication box of claim 1, wherein the first and second layers of shaving aid are provided in substantially the same amount.   The lubrication box of claim 1, wherein the first and second layers of shaving aid are provided in unequal amounts.   The lubrication box of claim 1, wherein the shaving aid includes a third layer of shaving aid located in the cavity of the first portion of the lubrication box.   The lubrication box of claim 12, wherein the third layer of shaving aid is directly adjacent to the second layer of shaving aid.   The lubrication box of claim 12, wherein at least one layer of shaving aid is a different color than at least one other layer of shaving aid.   The lubrication box of claim 1, wherein the second portion includes at least one support structure proximate to the shaving aid.   The lubrication box of claim 1, wherein the second portion includes at least one support structure in direct contact with the shaving aid. A method for manufacturing a lubrication box, comprising:
Providing a first portion of a lubrication box having a skin engaging surface forming at least one cavity and at least one side wall through which at least two holes pass;
Dispensing a first amount of shaving aid into the cavity of the first portion of the lubrication box;
Ultrasonically compressing the first amount of shaving aid and forming a first layer of shaving aid such that the first layer fills at least a portion of one of the holes;
An additional step of dispensing a second amount of shaving aid into the cavity of the first portion of the lubrication box onto the ultrasonically compressed first layer;
Ultrasonically compressing the second amount of the shaving aid so that the second layer fills at least a portion of the cavity in the cavity with the second layer of shaving aid adjacent to the first layer of shaving aid in the cavity; And forming into
A gap remains between the shaving aid that ultrasonically compresses the second portion of the lubrication box that covers the open end of the cavity of the first portion and the inner surface of the second portion of the lubrication box. The stage of preparation,
Securing the second portion of the lubrication box to the first portion of the lubrication box;
A method comprising the steps of:   The method of manufacturing a lubrication box according to claim 17, wherein the step of preparing the first portion of the lubrication box includes molding the first portion of a polymer material.   An additional step of dispensing a third amount of shaving aid into the cavity of the first portion of the lubrication box onto the ultrasonically compressed second layer, and then the third amount. An ultrasonic compression of the shaving aid of the shaving aid to form a third layer of shaving aid adjacent to the second layer of shaving aid in the cavity such that the third layer fills at least a portion of the cavity 18. A method of manufacturing a lubrication box according to claim 17, comprising the steps of:

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