JPH06507100A - Improvements regarding razor blades - Google Patents

Abstract

The razor blade comprises a substrate on which is formed a wedge shaped sharpened edge. The wedge has an an included angle of less than thirty degrees and a tip radius of less than 1200 angstroms. An interlayer of material, chosen from the group of molybdenum, nickel, niobium, silicon, silicon carbide, tantalum, vanadium and their alloys, is deposited on the wedge in a thickness less than 500 angstroms. A layer of diamond or diamond like carbon is deposited on the interlayer. This final layer has a thickness of at least 1200 angstroms on the wedge flanks to a tip radius of 40 microns.

Description

[Detailed description of the invention] Improvements regarding razor blades The present invention relates to improved razors and razor blades with durable sharp cutting edges. The present invention relates to a method for manufacturing a razor blade or similar cutting tool.

Razor blades are typically formed from a suitable substrate material such as metal or ceramic. and the edge comprises a leading edge or tip having a radius of about 1000 Å or less. Formed from a wedge-shaped configuration. When shaving is done vigorously, the blade may To improve shaving ability and make shaving easier as the edges of the hair are damaged. , and/or 1 to increase the stiffness and/or corrosion resistance of the shave edge. One or more additional coating materials have been proposed. polymeric materials and Contains metals and diamond and diamond-like carbon (DLC) materials. A number of coating materials have been proposed, such as other materials. Such additional The layers of material ensure that each layer remains firmly attached to the substrate for the life of the razor blade. the shape of the shaving edge and the effectiveness of the cut. Must have adhesive properties.

Diamond or diamond-like carbon material coating on the sharp edges of the substrate The cutting edge of a razor blade by improved mechanical properties by applying It was proposed to provide. Such materials include habo sp3 carbon adhesive, 1.5 a mass of gram/cm3 or more; and about 1331 cm (diamond) or about It is characterized by having a Raman peak of 1552 cm-1 (DLC).

However, such proposals The adhesive tends to adhere to the wedge-shaped edges of the board, i.e., it tends to peel off easily. Therefore, it was not satisfactory. Inserting a layer of molybdenum in between carbon on diamond or diamond against the wedge-shaped edge of the substrate. It was found that it gives adhesive properties by soaking it in hot distilled water at 80 degrees Celsius for 16 hours. Under certain accelerated corrosion test conditions, the diamond-like carbon coating It was found that the molybdenum intermediate layer and the steel blade substrate, where the chemical reaction takes place, peel off. Ta.

According to one aspect of the invention, a substrate having a wedge-shaped edge; Molybdenum, nickel, niobium, silicon, silicon on the edge tip and sides Group consisting of carbides, tantalum, vanadium and alloys of such materials an intermediate layer of material selected from an intermediate layer having a thickness of at least about 1200 and less than about 400. an intermediate layer that defines a full tip radius and an aspect ratio of 1:1-3:1; and a layer of diamond or diamond-like carbon material on top.

The blade exhibits excellent shaving properties and long shaving life.

In certain embodiments, the razor blade is made of steel and diamond or DL. The C coating is at least twice as hard as the metal substrate, and the wedge-shaped edges are Formed by a series of mechanical polishing steps, the intermediate layer material (preferred material is obium) and diamond or diamond-like carbon material in the intermediate layer material and is formed by sputtering the material from a graphite target Ru.

According to another aspect of the invention, the step of providing a substrate and a tilt angle of less than 30° and Preferably a tip radius of less than 1200 (i.e. such a tip radius is edges when observed by a scanning electron microscope at a magnification of at least 25,000x A wedge-shaped sharp edge with a large circle radius) placed within the leading edge of the substrate Forming stages on the edges and molybdenum, nickel, niobium, ke on the sharp edges. Iron, silicon carbide, tantalum, vanadium and alloys of such materials depositing an intermediate layer of a material selected from the group consisting of Diamonds less than about 1,000A by depositing a diamond or diamond-like layer forming a radius at the leading edge of the carbon material on the diamond or diamond; A method of forming a razor blade is provided.

The intermediate layer and the diamond or DLC layer are used for plasma decomposition of hydrocarbon gases, the target sputter deposition, which uses ions from a plasma or ion gun to bombard the , using a beam of carbon ions directly and with an E-beam or sputtering source. For various techniques such as ion beam assisted deposition (IBAD) processing using either Therefore, it is deposited.

In a particular method, the substrate is mechanically polished in a series of polishing steps to form sharp edges. polished to a layer of niobium and diamond or diamond-like carbon material is successively deposited by sputtering, and the intermediate layer of niobium is approximately 50% Diamond or niobium coated cutting edge with thickness less than 0. or DLC coating has a thickness of at least about 1200A and has a diamond The diamond-like carbon layer has a Raman peak at about 1331 cm-1 and is composed of diamond-like carbon ( D L C) The material layer is approximately 1550 cm p　3　R Regular Contact 11. Has a mass of 1.5 g/cm or more, and is made of adhesive polymer coat. cutting is applied to a diamond or DLC coated cutting advance.

According to another aspect of the invention, an edge of the blade fixed to the support structure and at least one Consists of a blade support structure that grows an outer surface for engaging the user's skin on two blade members A shaving unit is provided. A razor-edged structure fixed to the support structure is by a facet with an inclination angle of less than 17° at a distance of 40 micrometers from the sharp tip. a substrate with a wedge-shaped cut edge defined by molybdenum;

Nickel, niobium, silicon, silicon carbide.

From tantalum, vanadium and alloys of such materials and the sharp tips of said substrates On an intermediate layer with a thickness of at least 120 OA at a distance of 40 micrometers a layer of reinforcing material of at least about 0.1 micrometers in length; Also, the inclination angle of 60 degrees, the radius of the tip of the reinforcing material less than 400A, 1:1-3: and a tip defined by a facet defining an aspect ratio in the range of 1.

In certain shaving units, the razor blade structure includes two steel substrates. , the wedge-shaped edges are arranged parallel to each other between the skin-engaging surfaces and The intermediate layer of Bium is placed between the steel substrate and the edge reinforcement layer, and the edge reinforcement layer is diamond or DLC material and each niobium layer is less than about 500 nm thick and each diamond or DLC coating has approximately 200 OA (typically has a thickness in the range of 1800-2200A) depending on processing parameters, and has a substantial sp3 carbon bonded to, mass over 1.5 g/ca+3, diamond layer is approx. 1331CI11-1 (diamond) and approximately 1550cti-' (D L C) The adhesive polymer coating is characterized by having a Raman peak at Diamond or DLC coat applied on cut edge.

The shaving unit can be coupled to and detached from the razor handle. May be disposable cartridge type or integral with handle, with blade When dull, it can be replaced as a unit with a complete blade. Front view The rear skin-engaging surfaces cooperate with the edges of the blade to define the shave shape. Special Preferred shaving units are disclosed in U.S. Pat. No. 4,586,255.

Other features and advantages of the invention will become apparent from the description of the embodiments with reference to the drawings. Ru.

FIG. 1 is a schematic diagram of a shaving unit according to the invention.

FIG. 2 is a perspective view of another shaving unit according to the invention.

FIG. 3 is a sectional view showing an example of the shape of the razor blade edge according to the present invention.

FIG. 4 is a perspective view of an apparatus according to an embodiment of the present invention.

Figures 5 and 6 show Raman spectra of the DLC material deposited on the apparatus of Figure 4. It's Toru.

Description of specific embodiments Referring to Figure 1, shaving unit], 0 is attached to the razor handle. a high-impact point including a front transversely extending skin-engaging surface 14; and a platform member 12 formed from listyrene. sharp edge 18 A leading edge blade 16 having a sharp edge 22 and a trailing edge blade 20 having a sharp edge 22 form a platform member. It is attached to 12. Molded high impact polystyrene cap member 2 4 has a structure that defines a skin-engaging surface 26, which skin-engaging surface 26 extends from the edge of the blade. 22 , and a shaving aid 28 is fixed to the cap member 24 . Ru.

The shaving unit 30 shown in FIG. It is of the type shown in No. 55 and has a front section 34 and a rear section 36. It has a main body 32. The main body 34 has a guard member 38. Leading edge blade unit 40 and A trailing edge blade unit 42 is elastically fixed. Each blade unit 40.42 has a sharp The blade member 44 has a sharp edge 46. The shaving aid 48 is applied to the rear portion 36 frictionally secured within the groove of the

A schematic representation of the edge areas of blades 16, 20 and 44 is shown in FIG. The blade is wedge-shaped. It has a stainless steel body portion 50 with sharp edges, which typically The tip portion 5 typically has a radius of less than 500A and a facet extending at an angle of approximately 13°. 2 by a series of edge forming honing operations. tip 52 and an intermediate layer 58 of niobium having a thickness of approximately 300 Å on facets 54, 56. is located. Diamond-like carbon (D L There is an outer layer 60 of C), which layer has a thickness of approximately 2000A and has a facet of 62°6. 4, each having a length of approximately 1/4 micrometer, merge into major facets 66.68. The major facets 66.68 define an angle of inclination of approximately 80° and an angle of approximately 1.7°. aspect ratio (distance from DLC tip 70 to stainless steel tip 52) The distance (a) is the ratio of the width of the DLC coating 60 at the tip 52). be placed. On layer 60 there is a layer having a substantial thickness as the laminate thickness, but A single layer 72 of adhesive telomer is disposed within the baldness, which is reduced to a single layer thickness.

A device for processing blades of the type shown in FIG. 3 is schematically illustrated in FIG. Ru. The device is manufactured by Bakchik Systems in Baulda, Colorado. Having a DC planar magnetron sputtering system, this equipment can Body 80. A door 82 and a port 86 connected to a suitable vacuum device (not shown) are formed. It has a stainless steel chamber 74 with a base structure 84 made of . A circular support 88 with an upright support member 90 is mounted within the chamber 74. with a sharp edge 94 aligned facing outwardly from the support 90. Sea urchin razor blades 92 are stacked and arranged. In addition, inside the room 74, there is a black Support structure 78 for target member 98 of lead (99,999% pure) and Niobi A support structure 76 for a 99.99% pure target member 96 is disposed. There is. Targets 96 and 98 are each about 12 centimeters wide and about 37 centimeters long. It is a centimeter vertically arranged plate. Support structure 76.78 and 88 are electrically isolated from chamber 74 and are connected to DC through switch 106. Proposed for connecting blade stack 92 to provide RF power from power source 104. targets 96 and 98 are connected to the DC magnets through switches 108 and 110. It is connected to the netron power supply 112. Shutter structures 114 and 116 are The target is designed to allow movement between the release position and the position that obscures the target adjacent to it. It is located adjacent to the targets 96 and 98.

The circular support 88 is spaced approximately 3 centimeters from the opposing target plate 96.98. supports a stack of blades 92 having curved blade edges 94; a first position and a stack of blades 92 aligned oppositely to the target 96 of the graphite about a vertical axis between a second position oppositely aligned with target 98 of It can be rotated to

In certain processing methods, a stack of blades 92 (of 5 centimeters in height) is supported. 96.98 for 5 minutes, with the chamber 74 evacuated and the cleaned by DC sputtering over a period of time, switch 102 is closed, The blade 92 has a pressure of 10 millitorr (millito++) and an aluminum of 200 SCCm. in an argon environment for 5 minutes with a flow of argon and a power of 1.5 kilowatts. RF cleaned, argon flow was applied in chamber 74 for 150 seconds at a pressure of 2.0 mTorr. m, and switch 106 applies a DC bias of 125 volts on blade 92. When closed for use, switch 108 sputters at 1 kilowatt of power. The shutter 11 in front of the niobium target 96 is closed to begin programming. 4 to deposit an approximately 300 m thick niobium layer 58 on the edge 94 of the blade. It is opened for 0 seconds. The shutter is then closed and switch 106 and 108 is opened and the circular conveyor 88 carries the graphite target 98 and the blades of the blade stack 92. is rotated through 90° to juxtapose the edges. The pressure inside the chamber 74 is 15 maintained at 2 mTorr with a 0 sec argon flow and switch 110 at 750 mTorr. Closed and switched to sputter graphite target 98 with 102 is an 800 watt (-420 volt DC self-bias voltage) on blade 92. Closed to apply 13.56MHz RF bias, resulting in shutter 116 deposits a DLC layer 60 approximately 2000 nm thick on the niobium layer 58. It will be open for 20 minutes to allow for DLC coating 60 is approximately 80° and an aspect ratio of approximately 1.9:1. It has a radius at the tip 70 of approximately 350 people. As shown in Figure 5, this method The deposited coating material 60 has a wavenumber between approximately 1350 and 1530 cm-1. A broad Raman beak extending to 118, showing a typical spectrum of DLC structures. .

Next, a polytetrafluoroethylene coating 72 is applied to the DLC coated edges of the blade. Applies to. This method involves heating the blade in a neutral atmosphere of argon and Add adhesive and a polymer coating of solid PTEF on top. coating 58 and 60 are firmly glued to the blade body 50 and have a first low wool feel cut. Provides shearing force (wet wool sensation (L5) is approximately 0.45 kg), and the wool This force withstands repeated applications of the kattaka of the senses. He remained unaffected by exposure to the harsh conditions of the strike for 16 hours. It remains firmly attached to the main body 50 even after being immersed in distilled water at 80°C. and A cartridge unit 3 in which the blade element 44 is of the type shown in FIG. 0 results in excellent shaving results.

In another example, target 96 is molybdenum and target 98 is graphite. . In a particular process method for this device, chamber 74 is evacuated and the target 96°98 was cleaned by DC sputtering for 5 minutes and the blade 92 was cleaned by 1. of argon at a pressure of 10 mtorr with an argon flow of 5 kW and 2005 cm. RF cleaned in the environment and reduced to 150 sec at a pressure of 2 mTorr in chamber 74. , the shutter 114 in front of the molybdenum target 96 is opened, and the target 9 6 to deposit a molybdenum layer 58 approximately 200 mm thick on the edge 94 of the blade. Splash with 1 kilowatt of power at 1150 volts bias on 82 for 22 seconds. will be tallied. Shutter 114 is then closed and carousel 88 is The target 98 is rotated 90 degrees so that it is juxtaposed with the blade stack 92. room 74 The pressure above the graphite was maintained at 2 mTorr with a 1505 cm argon flow. Target 98 deposits a DLC layer 60 approximately 800 Å thick on molybdenum layer 58. Apply 900 watts at a bias of -150 volts onto the blade 92 for 10 seconds to load. sputtering with a power of As shown in Figure 6, the deposited by this method The Raman spectrum of coating material 60 is centered at approximately 1525 cm−1 wavenumber. As a broad Raman peak 120, a typical spectrum of a DLC structure is shown.

The DLC coating 60 is firmly adhered to the blade body 50 and has a wool-like coating. This sense cutter has withstood the rigors of testing to withstand repeated application of taka. It has no substantial adverse effects when exposed to It remains as it was worn. Its tip 7° has a radius of 700A and an aspect ratio of 1.7:1. It has a high oct ratio.

The polytetrafluoroethylene telomer coating 72 is then described in U.S. Pat. No. 3.518,110 is applied to the DLC edge of the blade. This method is , a neutral gas such as nitrogen or argon, or a reduced gas such as cracked ammonia. Heating of the blade in a small gas and friction-reducing pots of adhesive and solid PTFE on the cutting edge of the blade. including providing a remer coating. The resulting blade element 44 is , assembled in a cartridge unit 30 of the type shown in FIG. Shave to get the best shave result.

In another processing sequence, the chamber 74 is evacuated and the DC scrubbed for 5 minutes. DC cleaned by puttering, the blade 82 is powered at 1.5 kilowatts for 10 mlit/l, (7) pressure and 200 sec for 2 min. RF cleaning in an argon environment with one argon flow to a pressure of 2 mTorr in chamber 74. 150 sec in front of the molybdenum target 96. 14 is opened and deposits a layer 58 of molybdenum approximately 300A thick on the edge 94 of the blade. Spatter at 1 kW at -150 volts bias for 32 seconds to build up will be processed. Shutter 114 is closed and carousel 88 is closed to the graphite target. The cut 98 is rotated 90 degrees to juxtapose the stack 92 of blades. Pressure inside chamber 74 The force was maintained at 2 mTorr with a 150 sec argon flow and the shutter 116 is opened, and the graphite target 98 has about 1,000 people on the molybdenum layer 58. 1100 vols on the blade 92 for 10 minutes to deposit a thick DLC layer 60. With the root bias, it is snotted at 500 watts. As a result, the blade Has a 60% adhesive DLC coating to remove beards with excellent shaving results. I was able to shave.

In another processing sequence, chamber 74 is evacuated and targets 96,98 are Cleaned by DC sputtering for 5 minutes, the blade was cleaned at 1.5 kilowatts. Argon flow at 200 SCCm for 2 minutes at a pressure of 10 mTorr at a power of The alcon stream is RF cleaned in an environment of secm, and the shaft ivy 114 is When opened, the target 96 is approximately 200 mm thick molybdenum on the edge 94 of the blade. Sputtering was performed to deposit layer 58. The shutter 114 is closed, A carousel 88 is used to juxtapose a stack of blades 92 to a graphite target 98. rotated 90°. The pressure inside the chamber 74 is 2 mm with a 150 sec argon flow. The shutter 116 is opened and the graphite target 98 is exposed to molybdenum. Spun at 600 watts to deposit a DLC layer approximately 300 Å thick on layer 58. will be tattered. DLC coating 60 firmly adheres to the resulting ceiling. The DLC tip 70 has a radius of approximately 500A.

While specific embodiments of the invention have been shown and described, various modifications will be apparent to those skilled in the art. Ru. Therefore, this invention is not limited to the disclosed embodiments or details thereof. However, variations thereof may be made within the spirit and scope of the invention.

OM-I FIG.5 FIG. 6

Claims (10)

[Claims] 1. a step of preparing a substrate; The substrate has an inclination angle of 30° or less and a tip radius of 1200 Å or less. forming a wedge-shaped sharp edge; Molybdenum, nickel, niobium, silicon, silicon carbide on the sharp edges selected from the group consisting of tantalum, tantalum, vanadium and alloys of such materials. depositing an intermediate layer of the selected material; depositing diamond or diamond-like carbon material on the intermediate layer; A razor blade manufacturing method consisting of: 2. The intermediate layer on the cutting edge has a thickness of about 500 Å or less, and the intermediate layer has a thickness of about 500 Å or less; The diamond or diamond-like carbon layer on the cutting edge has a sharp tip. claim having a thickness of at least 1200 Å to a distance of 40 micrometers from Item 1. Razor blade manufacturing method according to item 1. 3. The substrate is made of metal, and the diamond or diamond-like carbon layer The razor according to claim 1 or 2, wherein the hardness is at least twice that of the metal substrate. Riblade manufacturing method. 4. The diamond or diamond-like layer is a graphite and niobium target. The niobium target is deposited in an argon environment within a vacuum chamber in which the target is placed. energize the blade and deposit an intermediate layer of niobium on the edge of the blade by sputtering. energize the graphite target while applying an RF bias to the substrate. a layer of diamond on the niobium interlayer or a carbon material on the diamond 4. A method according to any one of claims 1 to 3, wherein the method comprises depositing: 5. The wedge-shaped edge has an angle of 30° or less and a tip of 1,200 Å or less. The diamond or diamond-like carbon material has an end radius of approximately 400 Å A predetermined radius at the tip of the diamond or diamond-like carbon material below. 5. A method according to any one of claims 1 to 4. 6. The diamond or diamond-covered carbon layer on the sharp edge is 2000 6. A method according to any one of claims 1 to 5, having a thickness of Å. 7. Adhesive poly to the sharp edges of the diamond or diamond-like carbon coat. 7. A manufacturing method according to claims 1 to 6, comprising the step of applying a macoating. 8. A razor blade produced by the manufacturing method according to any one of claims 1 to 7. 9. The layer of diamond or diamond-like carbon (DLC) material is about 13 31cm-1 (diamond) or about 1552cm-1 (DLC), about 3:1 Aspect ratio below, carbon adhesion near sp3 and quality above 1.5 g/cm2 9. The razor blade of claim 8, having a quantity of . 10. a support structure defining spaced skin-engaging surfaces and secured to the support structure; The razor blade structure according to claim 8 or 9, wherein the diamond or A diamond-like carbon-coated wedge-shaped edge is positioned between the skin-engaging surface and the skin-engaging surface. razor unit.