阅读说明：本技术 具有可移动构件的剃刀柄部 (Razor handle with movable member ) 是由 R·H·约翰逊 M·S·鲍尔 J·A·华盛顿 C·J·巴塞特 C·拉姆 S·M·布尔奎 于 2019-03-27 设计创作，主要内容包括：本发明公开了一种用于剃刀的柄部,其中该柄部包括框架和可移动构件组件,该可移动构件组件可操作地联接到框架,使得框架设置在可移动构件组件与其中可移动构件组件的上部部分和下部部分被构造成在框架上方和下方两者移动的位置之间。移动可以是线性的或旋转的。可移动构件组件包括一个或多个弹簧。(A handle for a shaving razor is disclosed, wherein the handle includes a frame and a movable member assembly operably coupled to the frame such that the frame is disposed between the movable member assembly and a position in which upper and lower portions of the movable member assembly are configured to move both above and below the frame. The movement may be linear or rotational. The movable member assembly includes one or more springs.)

1. A method of manufacturing a razor structure, the method comprising the steps of:

a) providing a rigid member;

b) providing an upper portion and a lower portion;

c) securing the upper portion to the lower portion within the rigid member extending between the upper portion and the lower portion.

2. The method of claim 1, wherein the rigid member further comprises a rigid member positioning feature.

3. The method of claim 1 or 2, wherein in the securing step (c), the elements of the upper portion, the elements of the lower portion, or a combination thereof pass through or around the rigid member positioning features.

4. The method of any one of claims 1 to 3, wherein the upper portion comprises one or more upper elements, or the lower portion comprises one or more lower elements, or both the upper portion and the lower portion comprise one or more elements.

5. The method of any preceding claim, wherein the upper portion comprises one or more locating features, the lower portion comprises one or more locating features, or both upper and lower portions comprise one or more locating features.

6. The method of any preceding claim, wherein the rigid member, the upper portion, and the lower portion each comprise one or more locating features.

7. The method of any preceding claim, wherein the positioning features are substantially similar in shape.

8. The method of any preceding claim, wherein the locating feature comprises a hole, a slot, one or more protrusions, or any combination thereof.

9. The method of any preceding claim, further comprising, after step (c), the step (e) of aligning a rigid member locating feature with an upper portion locating feature and a lower portion locating feature.

10. The method of any preceding claim, wherein the securing step (c) further comprises mechanical engagement, chemical engagement, frictional engagement, or any combination thereof.

11. The method of any preceding claim, wherein the frictional engagement comprises ultrasonic welding, the mechanical engagement comprises snap fitting, and the chemical engagement comprises gluing.

12. The method of any preceding claim, wherein the upper portion, the lower portion, or a combination thereof comprises a spring mechanism, wherein the spring mechanism comprises a spring member, the method further comprising the step (d) of mounting the spring member to the rigid member, to the upper portion or the lower portion, or any combination thereof, prior to step (c).

13. The method of any preceding claim, wherein the spring member is an annular spring or a V-spring.

14. The method of any preceding claim, wherein at least one or more elements of the upper portion or the lower portion do not move relative to the rigid member, one or more elements of the upper portion and one or more elements of the lower portion move relative to each other, or any combination thereof.

15. The method of any preceding claim, wherein the razor structure is a razor handle; the rigid member includes a rigid member platform having a width to thickness ratio of about 7 to about 60, the rigid member including one or more metals, impact resistant alloys, metal die cast alloys, glass reinforced polymers, plastics, glass, stainless steel, or combinations thereof.

Technical Field

The present invention relates generally to handles for shaving razors, and more particularly, to handles having movable portions.

Background

Since the invention of safety razors in the 50's of the 19 th century, four major design architectures for razors (safety razors, disposable edge safety razors, modern cartridge system razors, and disposable razors) have been dominant in the market. During this time, both the razor handle and the razor cartridge/blade provide benefits to the razor.

Over the past fifty years, the premium wet shaving market has dominated razors that use replaceable cartridges, which are the only components that contact the skin during shaving. Consumer benefits of these cartridge razors are primarily limited to safety, convenience, ergonomics, and/or control of blade geometry, and are primarily driven by improvements to the cartridge.

Handles for razors using replaceable cartridges have been improved by better ergonomics of the handle grip, better cartridge attachment and detachment mechanisms, and utilization of multiple axes of rotation of the cartridge relative to the handle. Typically, these improvements require additional components, including some with prescribed motion therein. These additional components typically require tight tolerances with little margin for error. Thus, current methods present complexity, cost, and durability issues for manufacturing, assembling, and using such razors.

Moreover, recent advances in razor handles using replaceable cartridges have enabled other consumer experience benefits to be delivered from the handle near or on the shaving surface. Such razor handles include liquid dispensing razors and heated razors. Most of these razor handles have been adapted to fit cartridges such as those currently manufactured for existing premium system handles. These handle and cartridge systems have a number of disadvantages including being expensive to manufacture, requiring heating elements in the cartridge, for example, and having poor handle ergonomics and shaving performance due to the large contact area of the interface between the handle and the cartridge and the shaving surface.

What is needed, then, is a better design or architecture of the cartridge and razor handle system that achieves good core shaving performance, good product integrity and safety, multiple axes of movement of the cartridge relative to the handle, easy attachment and detachment of the cartridge from the razor handle, and simple, reliable, and cost-effective manufacture when compared to existing razors. Such a design architecture would apply to both electric and non-electric razors suitable for wet or dry shaving, and to both durable and disposable razor handles. Such a design may also be applied to razors that deliver benefits from the handle near or on the skin.

Disclosure of Invention

The invention relates to a method for producing a razor structure, comprising the following steps: providing a rigid member; providing an upper portion and a lower portion; the upper portion is secured to the lower portion within a rigid member that extends between the upper and lower portions.

The rigid member includes a rigid member positioning feature. In the securing step, the elements of the upper portion, the elements of the lower portion, or a combination thereof pass through or around the rigid member to position the feature. The upper portion comprises one or more upper elements, or the lower portion comprises one or more lower elements, or both the upper portion and the lower portion comprise one or more elements. The upper portion includes one or more upper portion locating features and the lower portion includes one or more lower portion locating features, or both the upper portion and the lower portion include one or more locating features.

The rigid member, the upper portion, and the lower portion each include one or more locating features. At least one or more elements of the upper portion or the lower portion do not move relative to the rigid member. One or more elements of the upper portion and one or more elements of the lower portion move relative to each other. The elements of the upper part move while the lower part is stationary. One or more elements of the upper portion are movable relative to each other. The movement is a first movement type, a second movement type, or both. One or more elements of the lower portion move relative to each other.

Unless defined otherwise, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. Although methods and materials similar or equivalent to those described herein can be used in the practice or testing of the present invention, suitable methods and materials are described below. All publications, patent applications, patents, and other references mentioned herein are incorporated by reference in their entirety. In case of conflict, the present specification, including definitions, will control. In addition, the materials, methods, and examples are illustrative only and not intended to be limiting.

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

Drawings

While the specification concludes with claims particularly pointing out and distinctly claiming the subject matter which is regarded as forming the present invention, it is believed that the invention will be better understood from the following description which is taken in conjunction with the accompanying drawings in which like designations are used to designate substantially identical elements, and in which:

FIG. 1A is a perspective bottom view of a razor according to one embodiment of the invention;

FIG. 1B is a perspective top view of a front portion of the razor of FIG. 1A;

FIG. 1C is a front view of the blade cartridge unit shown in FIGS. 1A and 1B;

FIGS. 1D-1E are diagrammatic, schematic views of a handle and blade cartridge unit of the present invention;

FIGS. 1F-1H are schematic layouts of the axes of motion in perspective views of a razor of the present invention;

FIG. 2 is a perspective top view of one embodiment of a handle of the present invention;

FIG. 3 is a perspective bottom view of the handle of FIG. 2;

fig. 4 is a perspective top view of an alternative embodiment of a razor of the present invention;

FIG. 5 is a perspective bottom view of the razor of FIG. 4;

FIG. 6 is a close-up view of the proximal end of the handle of the present invention;

FIG. 7A is a perspective top view of one embodiment of a handle of the present invention;

FIG. 7B is an exploded view of the razor of FIG. 7A;

FIG. 8A is a perspective top view of one embodiment of a handle of the present invention;

FIG. 8B is an exploded view of the razor of FIG. 8A;

fig. 9A is a perspective top view of a portion of a frame of a handle according to an embodiment of the present invention;

FIG. 9B is a perspective bottom view of FIG. 9A;

FIG. 9C is an exploded view of FIG. 9A;

fig. 9D is a close-up side view of a portion of the proximal end of the handle of the present invention;

fig. 9E is a close-up side view of a portion of the proximal end of the handle of the present invention;

FIG. 9F is an exploded view of one embodiment of the movable member assembly of the present invention;

FIG. 10 depicts a lower element of the movable member assembly of FIG. 9F;

11A-11B depict the upper element of the movable member assembly of FIG. 9F;

FIG. 12 depicts a portion of the movable member assembly of the present invention;

13A-13B depict schematic diagrams of embodiments of the framework of the present invention;

14A-14F depict schematic views of embodiments of the rigid member platform of FIGS. 7A and 7B;

15A-15G depict schematic views of embodiments of the rigid member platform of FIGS. 8A and 8B;

16A-16D depict schematic views of embodiments of locating features and their use in accordance with the present invention;

17A-24B depict a method of assembling a portion of a handle according to an embodiment of the present invention;

FIGS. 25A-25D show schematic views of trapezoidal prismatic elements of the present invention.

Detailed Description

The articles "a", "an" and "the" mean "one or more" unless stated otherwise.

The invention described herein relates to novel razor structures and methods of making such structures. The razor structure involves layering of functional components, as well as layering of one or more movable members and components above and below a member of the handle made of a more rigid material than the rest of the handle. Preferably, such a rigid member forms a relatively thin and wide section of the handle, at least one or more of the functional components above the rigid member being directly connected to the underlying member by an aperture, opening or thin and relatively wide section of the razor handle. By selecting materials and designs, such thin and relatively wide sections of razor handles are generally more rigid than the other large components in the handle. Functional components of the components, such as the cartridge ejection mechanism and the pivoting mechanism, may be attached above and below the rigid member.

Existing razor designs place the functional components within the internal cavity of the rigid component of the razor handle. Advantages of the layering of the functional components and assemblies of the present invention above and below a relatively wide and relatively thin rigid member over prior razors include the ability to: large and more complex features are incorporated within those features and razors with a greater variety of improved consumer benefits are manufactured in a simple, reliable and cost effective manner.

The razor structure also facilitates providing the consumer with a safe product with good product integrity in the event of accidental falls. Most existing handles weigh less than 56 grams, and most weigh less than 40 grams. As handles become more complex and premium at the market level, they tend to weigh more. The razor structure of the present invention is well suited for handles that weigh two to three times more than most razors commonly found on the market, specifically about 57 grams to about 150 grams, and preferably about 80 grams. In the present invention, such handles are considered "heavy" handles.

The razor structure and method of making the razor structure of the present invention is also advantageous for the non-limiting embodiments of the razors described herein, which may provide benefits to the skin of a consumer using a razor handle having a skin interconnecting member by which benefits may be provided and which is in a pivoting relationship with the body of the handle. The skin interconnect member may be engaged or secured to a razor cartridge.

Other embodiments of razor structures and methods of manufacture are contemplated in the present invention, such as those without a skin interconnect member or pivoting mechanism.

The movable member or portion of the present invention is desirably provided on a razor structure or component of a razor, preferably on a handle.

As used herein, the "body" of the handle represents a razor handle of the present invention without the skin interconnect member 22. As shown in fig. 2, the body 16 includes a shank main section 21 and a shank transition section 23. The shank transition section and the shank main section are coupled together to form a majority of the body of the shank. The handle transition section 23 may comprise a skin interconnection member 22, which may not be part of the body. The handle main section may comprise a longitudinal section of the handle.

As used herein, "movable member" or "movable member assembly" means a member made up of one or more portions on the razor that are capable of moving the razor or providing a motion function to the razor. For example, the movable member of the present invention may preferably include a portion that provides a pivoting mechanism or a release or ejection mechanism.

As used herein, the term "spring", "spring mechanism" or "spring member" means any type of mechanical spring, such as a compression spring, a leaf spring or any feasible spring or combination thereof. The spring member of the present invention generally has a ring shape. As used herein, the term "ring" means a generally curved circular shape that may form a ring. Non-limiting rings of the present invention include oval, circular, elliptical, annular, substantially V-shaped, teardrop shaped, or any modification or combination thereof. The loop may be split and the loop itself, the end portion or distal end of the loop may be unconnected or free, unsupported, connected or mounted or overlapping one another. The distal ends may face each other or may face away from each other. When straightened, the annular spring member of the present invention desirably has an overall length of from about 30mm to about 90 mm.

The spring mechanism of the present invention is based on the interaction between portions of the movable member assembly (whether disposed on a cartridge or a handle of the razor) and the spring member. During the pivoting or ejecting function, the spring member provides a resistance which is a function of its preload compression, its geometry and material, and the geometry of the carrier structure, and depending on the strength of this resistance, the effect will be greater or lesser.

As used herein, the term "rigid member" refers to a member constructed of hard metal that may include a rigid member platform. The terms frame and rigid member of the present invention are used interchangeably herein. However, the subframe is typically not part of the rigid member of the present invention. The rigid member may be a longitudinal portion in the main section of the handle. The rigid member platform may house a movable member assembly having one or more movable members disposed thereon or therethrough. The frame 18 is desirably constructed of a hard metal. The hard metal may be composed of a die cast material. A non-limiting example of the diecasting material of the present invention is zinc. Die cast zinc materials include ZAMACK3, ZAMACK5, and ZA 8. Other suitable materials include fiberglass reinforced plastics such as IXEF, stainless steel, aluminum die cast, and magnesium die cast. The rigid member or frame may be constructed of one material (preferably a strong metal), but may be formed as two bodies that are subsequently joined. In this case, it is preferred that the rigid member platform is made of a hard metal that must be harder than the rest of the frame.

The rigid member platform of the present invention may be a section of a rigid member having a wide and thin profile relative to the entire rigid member. The movable member assembly may be mounted above and below the rigid member platform. In the present invention, the ratio of the maximum width to the median thickness of the platform itself is about 7 to 60, and preferably about 20. The median thickness of the lands is in the range of about 0.5mm to about 2.5mm, and preferably about 1 mm. The area of the rigid member platform, including the area from features such as openings and pockets, is about 50mm²To about 700mm²And preferably about 300mm². The rigid member platform has a hydraulic diameter of about 8mm to about 50mm, and preferably about 20mm (e.g., in standard engineering, the diameter may be defined as about four times the area divided by the perimeter). The width of the rigid member platform is in the range of about 10mm to about 50 mm. The rigid member platform itself has a length to thickness ratio of 7 to 60, and preferably about 20.

The rigid member and rigid member platform of the present invention are shown and described with respect to fig. 13-15.

As used herein, the term "locating feature" means a feature such as a hole or opening, a slot, one or more protrusions, or any combination thereof. These features provide the structure: the structure enables the movable assembly to travel to attach the movable assembly or sub-frame to a rigid member or rigid member platform, and they provide attachment points to the rigid frame for other rigid features, enhancing integrity.

In one embodiment of the invention, the locating feature is a hole. The feature may be provided in a portion of the frame (or rigid member), such as in a rigid member platform, or in one or more or all portions of the movable member assembly of the razor structure of the invention. In another embodiment of the invention, the locating features are protrusions and holes. The frame may be part of the handle or may be part of a razor cartridge. The locating features are used to align and couple together portions of the razor structure by utilizing the locating features in the frame and the portions.

As used herein, the term "benefit" or "benefit delivery component" or "benefit delivery system" refers to something delivered to a user that is considered advantageous. In the context of a razor or hair removal device, the term benefit refers to a skin benefit. Such a skin benefit may be heating or cooling of the skin. Another benefit to the user is a fluid (e.g., liquid) or wax to the skin. Further, benefits may be provided in combination, such as the benefits of heat and fluid. These may be advantageous to the user by enhancing the shaving experience of the user.

Referring to fig. 1A-1C, a shaving razor 10 of the present invention includes a handle 12 and a cartridge unit 15 removably connected or releasably attached to the handle 12 and containing one or more blades 17 having a cutting edge 33. The handle 12 may include a handle main section 21 for holding the handle. The handle 12 may include a handle transition section 23 that connects the handle main section 21 to the cartridge unit 15. The blade cartridge unit 15 may be configured to rotate about an axis of rotation a1 that is substantially parallel to the blade 17 and substantially perpendicular to the handle 12. As shown in the illustrated embodiment, the shaving razor may be configured to deliver benefits to the skin of a user by extending the handle 12 through an opening 100 in the cartridge unit 15 to enable the handle benefit delivery component to be brought into proximity with the skin.

In fig. 1D-1E, the graphical layout of the handle 12 and blade cartridge unit 15 of the present invention is shown in a rest, undeflected, unloaded, rest position. Generally, the skin contacting surface of the blade cartridge unit 15 is typically a few millimeters above or within the cartridge plane P1 when the blade cartridge unit 15 is in its rest position. Generally, the plane P2 may be oriented at an angle to the blade holder plane P1, which plane P2 lies along the general mid-plane of the handle main section 21. The included angle between the planes P1 to P2 between the planes P1 and P2 may be in the range of-60 degrees to +90 degrees. The narrower preferred range of angles from P1 to P2 is from-25 degrees to +25 degrees. The drawings of the present invention show an included angle P1 to P2 of approximately +16 degrees. Generally, the plane P3 may be oriented at an angle to the main handle section midplane P2, which plane P3 lies along the generally midplane of the handle transition section 21. The included angle between the planes P2 to P3 between the planes P2 and P3 may range from-90 degrees to +90 degrees. The narrower preferred range of the included angle P2-P3 is from-90 degrees to +45 degrees. The drawings of the present invention show an included angle P2 to P3 of +21 degrees. Generally, the plane P4 may be defined as being perpendicular to planes P1, P2, and P3, the plane P4 lying longitudinally along the handle 12 at the general mid-plane of the handle 12 and cartridge unit 15.

Referring to fig. 1F, 1G, and 1H, planes P2, P3, and P4 may be generally used to define additional axes of rotation or directions of linear movement of the various components of the handle, as shown in fig. 1D and 1E. The axis a2 along the shank main section 21 may be defined as the intersection of planes P2 and P4; and an axis a3 along the shank transition section 23 may be defined as the intersection of planes P3 and P4. Another axis a4 within the shank transition section 23 may be defined as being perpendicular to the plane P3 and lying on the plane P4. Another axis a5 within the handle main section 21 may be defined as being perpendicular to the plane P1 and lying on the plane P4.

Disclosed herein are two types of non-limiting embodiments of razors that provide skin benefits. The first razor embodiment provides benefits to the user by heating or cooling the skin. The second razor embodiment provides benefits to the user through a fluid (e.g., liquid) or wax to the skin. It should be noted that many of the components described with respect to razors that provide benefits by heating and cooling the skin may also be incorporated into razors that provide benefits by delivering fluids and waxes to the skin. Both embodiments share a common problem and have similar solutions, including structural elements of the handle 12, the handle main section 21, the handle transition section 23, and the skin interconnecting member 22, mechanisms that enable the skin interconnecting member 22 to rotate about different combinations of axes a1-a5, and the manufacture of these components.

As shown in fig. 1A, 1B and 1C, this first razor embodiment may have a handle 12, a cartridge unit 15 that may be releasably attached to the handle 12 and may contain one or more blades 17, and a heat delivery element that may deliver a thermal skin benefit. A portion of the handle 12 may extend through the cartridge unit 15 and be exposed as a heating surface 82, discussed more fully below. As shown in fig. 1A and in more detail in fig. 2 and 3, with the cartridge unit 15 removed, the thermal surface 82 is a surface of the skin interconnect member 22 and may be used to deliver cooling or heating benefits to the user during shaving. Heating or cooling of the skin interconnecting member 22 can be achieved by pressing the skin benefit actuator 14, which can be a push button, a touch sensitive button or a slide button, and which closes the power supply circuit within the handle 12 to the circuit within the skin interconnecting member 22. The handle 12 may hold a power source, such as one or more batteries (not shown), that supplies power to the handle skin interconnect member 22. Heating or cooling of the skin interconnecting member 22 may also be achieved passively, such as by immersing the skin interconnecting member 22 in water at a temperature different than ambient temperature. In certain embodiments, the heat delivery element may comprise a metal, such as aluminum or stainless steel. In certain implementations, the heat delivery element may include a high capacity material such as a metal or a phase change material. In certain embodiments, the heat delivery element may comprise a high thermal conductivity material such as copper, aluminum, or a thermally conductive plastic such as(trade mark symbol). The razor handle disclosed herein may include a heat delivery element disclosed in a commonly owned, co-pending U.S. application having attorney docket number 14532FQ, which is hereby incorporated by reference.

In the illustrated embodiment, the skin interconnect member 22 is configured to pivot about axes a1 and a 4. Other embodiments may be configured to move the skin interconnection member 22 about the axis a1, a2, A3, a4, a5, or any combination thereof. The bearings capable of these rotational movements may be located directly along an axis, such as a pin bearing or a shaft, or they may be offset from the axis of rotation, resulting from a virtual pivot. The virtual pivot bearing includes a shell bearing and a link.

In a similar manner, fig. 4 shows another embodiment of a razor that can deliver a benefit by delivering a fluid or wax to the skin of a user. As shown in fig. 5, which shows the underside of the razor depicted in fig. 4, a portion of the handle 12 may extend through the cartridge unit 15 and be exposed as a face 80, discussed more fully below. As shown in fig. 4 and 5 and in more detail in fig. 6, where the cartridge unit 15 has been removed, face 80 is a surface of the skin interconnect member 22 and may have an opening 78 through which fluid may be dispensed for skin comfort during shaving. Fluid flow from the reservoir in the handle 12 may be achieved by pressing the skin benefit actuator 14, which may be a push button, touch sensitive button, or sliding button, which activates the pumping mechanism 72 (shown in fig. 7B) to push fluid toward and through the skin interconnect member 22. The pumping mechanism may include compression of a flexible fluid reservoir, actuation of a manual pump, or activation of a powered pump.

As shown in the illustrated embodiment of fig. 4-6, the skin interconnecting member 22 is configured to pivot about axis a1, as described in fig. 1F-1H. Alternative embodiments may be configured to pivot about both axes a1 and a2 in a manner similar to the thermal benefit razors described previously. Alternative embodiments may be configured to rotate about any combination of axes a1, a2, A3, a4, and a5 using virtual pivots or bearings located directly along the axes.

The embodiment in fig. 1-6 shows that the handle 12 may be configured to be comprised of a body 16 and a skin interconnect member 22. As shown in fig. 6, body 16 and skin interconnect member 22 may be connected by a number of components including arm 24, bearing 30, springs (not shown), circuitry, wires and tubing 27. These connecting components may be configured to be flexible when the skin interconnecting member 22 pivots relative to the body 16.

Referring now to fig. 7A-7B and 8A-8B, respectively, embodiments of razor handles that provide benefits to the user by delivering a fluid or wax proximate to the skin and embodiments of razor handles that provide thermal or cooling benefits are described in more detail. It should be noted that many of the components described with respect to razor 10 providing benefits by delivering a fluid or wax to the skin may also be incorporated into razor 10 providing heating and cooling of the skin as they relate to handle 12, handle main section 21, handle transition section 23, and skin interconnect member 22 pivoting about axis a1 described herein, including their structural features, their connection features, their product safety and integrity features, their manufacture, their pivotal movement, spring mechanisms forcing pivoting to a rest position and limiting the range of movement, and the shape of the pivoting handle head.

In fig. 7A-7B and 8A-8B, the handle 12 may include a body 16, which may include a main frame 18 and a subframe 20. The body 16, including its component main frame 18, upper subframe 19 and lower subframe 20 members, may comprise durable materials such as metal, cast metal, plastic, impact resistant plastic and composite materials.

The main frame 18 may be made of metal and may provide a significant portion of the structural integrity of the handle. Preferably, the component main frame is made of a lightweight, stiff (high modulus of elasticity) and impact resistant material to minimize its bulk and maximize the bulk of the other components, while still providing product integrity and safety. In one embodiment, the frame 18 is made of zinc. In one embodiment, the main frame 18 is made of die cast zinc. Die cast zinc materials include ZAMACK3, ZAMACK5, and ZA 8. Other suitable materials include fiberglass reinforced plastics such as IXEF, stainless steel, aluminum die cast, and magnesium die cast. The subframe 20 may be made of a plastic material and may overlie a majority of the main frame 18 and provide a significant portion of the size and comfort of the handle 12.

As shown in fig. 7A-7B and 8A-8B, handle 12 may also include one or more movable elements of a movable member assembly 44a mounted on frame 18 that serves as a cartridge ejection mechanism. To enhance product integrity and safety of both the handle and the cartridge during an accidental drop, the cartridge ejection mechanism is designed to move in more than one direction from an initial rest position. Preferably, the type of movement is linear movement along axis a2 or A3 toward the razor cartridge to eject the cartridge and linear movement along the same axis away from the cartridge to mitigate damage and absorb energy during an accidental drop.

With continued reference to fig. 7A-7B and 8A-8B, the skin interconnecting member 22 may be connected to the body 16 by one or more arms 24. The skin interconnecting member 22 is pivotable about a rotational axis a4 defined by the connection of the skin interconnecting member 22 to the pin 30 provided at the distal portion of the arm 24. The cartridge unit 15 is attached to the skin interconnect member 22 such that the cartridge unit 15 may pivot on the handle 12 to provide a greater skin contact area on the user's skin during shaving.

The benefit delivery system may be disposed above, below, or through the frame. As shown, for example, in fig. 7B and 8B, the benefit delivery systems 72, 201 and 14, 301 are each disposed in a section below the rigid member or frame 18. Advantageously, the benefit delivery system is disposed between the rigid member and the sub-frame. The subframe may be mounted to the frame.

The skin interconnect member 22 may have a shape that both beneficially facilitates attachment to the cartridge unit 15 and helps deliver skin comfort benefits from the handle 12 to and through the cartridge unit 15 attached to the handle 12.

The shape of the skin interconnecting member 22 may alternatively be described as a "funnel" or "cone" or "trapezoidal prism". As understood from the description herein, the description "trapezoidal prism" is a general description with respect to the overall visual impression of the skin interconnecting member. For example, a schematic diagram of a trapezoidal prismatic element is shown and described in more detail below with respect to fig. 25.

The description of "trapezoidal prism" is used herein as the best description for the overall visual appearance of the skin interconnect member 22, but the description does not imply any particular geometric shape or dimensional requirements other than those described herein. That is, the skin interconnecting member 22 need not have a complete edge or surface. Furthermore, the edges need not be continuous and straight, and the sides need not be continuous and flat.

The skin interconnect member 22 may have a shape that both beneficially facilitates attachment to the cartridge unit 15 and helps deliver skin comfort benefits from the handle 12 to and through the cartridge unit 15 attached to the handle 12.

As shown in fig. 9A-9B, the frame 18 and the fully assembled movable member assembly 44 operably coupled thereto are shown.

Various elements, such as gripping members 39 and other features, are removed from the frame and/or handle, thereby illustrating the frame 18 as a skeletal structure upon which the movable member assembly 44 is disposed.

The frame desirably provides a base on which other elements of the razor may be disposed. The frame may be located substantially in the center of the handle 12. As shown in the figures herein, ergonomic elements such as gripping portions 39, protrusions or buttons, and benefit dispensing structures such as electronics, fluids, thermal elements, etc., may all be disposed on any side of the frame or within the frame 18 or within the handle transition section 23.

The movable member assembly 44 is configured to have rotational movement about an axis of rotation a4 that is substantially perpendicular to the axis of rotation a1 and substantially perpendicular to the longitudinal axis a2 or A3 of the shaving razor 10. The movable member assembly 44, or a portion thereof, may be configured to have linear motion substantially parallel to a longitudinal or linear movement axis a2 or A3 that is substantially parallel to the frame 18. The linear movement axis A3 is substantially parallel to the handle transition section 23 and the linear movement axis a2 is substantially parallel to the handle main section 21.

When the blade cartridge unit 15 is attached to the handle 12, the blade cartridge unit 15 is configured to rotate about a plurality of axes of rotation, such as a first axis of rotation a1 and a second axis of rotation a 4.

The movable member assembly 44 is configured to move in a first type of movement and/or a second type of movement. The first movement type of the present invention includes rotational movement and the second movement type includes non-rotational or linear movement. Preferably, the rotational movement is about an axis of rotation a4 or an axis of rotation a1 or both (as shown in fig. 1F-1H) that is substantially perpendicular to the frame 18, and the linear movement is along an axis of movement a2 or A3 (as shown in fig. 1F-1H) that is along a substantially straight or linear path that is substantially parallel to the frame 18.

The frame 18 may have any suitable size, shape or configuration. While shown as part of a razor handle, the frame of the present invention may or may not be part of a razor handle. If the frame 18 is part of a razor handle, as shown for example in FIG. 1B, the frame 18 may desirably include longitudinal members. If the frame 18 is part of the shank transition section 23, the frame 18 may comprise any shape member. If the frame 18 is part of a razor cartridge or other component (not shown), the frame may or may not be longitudinal. The frame preferably comprises a rigid member and is preferably made of a hard metal. The movable member assembly is substantially constructed of plastic, but some elements (e.g., spring members) may be constructed of metal, such as steel or stainless steel.

In fig. 9A-9C, it should be noted that the frame has upper and lower sides 92a, 92b, proximal and distal ends 96, 98. The frame 18 is arranged in a novel manner such that it extends between the movable member assemblies 44, as will be described in greater detail below. In a preferred embodiment, the upper and lower portions of the movable member assembly are coupled to each other and within the frame.

Fig. 9A depicts a front perspective view showing the frame 18, the frame upper side 92a, and the upper portion 44a of the movable member assembly 44 along with the arm portion 52 of the second lower element 49 b.

Fig. 9B depicts a rear perspective view showing the frame 18, the frame underside 92B, and the lower portion 44B of the movable member assembly 44, along with the respective second and third lower elements 49a, 49B, along with the arm portion 52 of the second lower element 49B.

The frame 18 also includes a frame locating feature 43. The stiffening member or frame locating feature 43 of the present invention preferably comprises an aperture, but slots or other feasible structures or configurations or combinations thereof are contemplated.

The aperture 43 shown in fig. 9C is provided at the proximal end 96 of the frame 18 and serves as a locating feature whose function will be described in further detail below. The aperture 43 advantageously comprises a circular shape, but any shape is contemplated in the present invention. Thus, in addition to its utility, the aperture shape provides an aesthetic or design element. Further, while other holes 45 are present in the frame 18, the present invention describes the frame locating feature holes 43 towards the proximal end 96.

In fig. 9C, the frame 18 and movable member assembly 44 are expanded or disassembled for the purpose of illustrating the various components and their arrangement together. The movable member assembly 44 includes an upper portion (44a) and a lower portion (44 b). The upper and lower portions may be an integral unit, or they may be two or more units coupled together. The upper portion 44a of the movable member assembly 44 is disposed substantially on the upper side 92a of the frame and the lower portion 44b of the movable member assembly 44 is disposed substantially on the lower side 92 b.

The upper portion 44a of the movable member assembly 44 can move in both the first and second movement types. In a second type of movement (e.g., non-rotational, linear), the upper portion may be comprised of a button, such as an eject button, that is used to remove the blade cartridge unit 15 from the handle 12 when pushed.

In one embodiment, the upper portion 44a includes a first upper element 47a, a second upper element 47b, a third upper element 47c, and a fourth upper element 47d, all of which are operatively coupled to one another. The upper portion 44a may be constructed of more or fewer elements and may have any suitable size, shape or configuration in accordance with the present invention.

Additionally or alternatively, the upper portion 44a includes an upper portion locating feature 46 in one or more of each upper element, and preferably in each upper element, wherein the features are all holes, and more preferably the holes are substantially similar to the rigid member locating feature 43, and most preferably substantially circular, although any possible configuration of locating features and shapes is contemplated.

The first upper element 47a serves as a base structure for the upper part 44 a. Which preferably comprises rails, tracks and/or protrusions. Ideally, it is coupled to one or more of the upper elements, such as the second and third upper elements, but also to one or more of the lower elements, as will be described below. In one embodiment, the first upper element 47a is constructed of a less expensive and more flexible designed material that enables more complex features (e.g., snap fit, bearing surfaces, etc.) to be achieved in a smaller volume than would be possible if the rigid member itself were used without such an interface. Plastic or other flexible materials are contemplated in the present invention for any element that is closest to or in contact with the metal rigid member. For example, the first upper element 47a may be made of plastic, while the rigid member is made of die-cast zinc material.

The second upper element 47b is preferably a spring member arranged between the first and the third upper element 47 c. The spring member is desirably disposed within one or both of the first and third upper elements. As shown, the spring member may be annular or substantially circular in shape. The spring helps to provide either the first type of movement or the second type of movement. Preferably, the element 47b provides a second type of movement (e.g. linear).

The spring member of the present invention may be attached to a frame or rigid member to provide movement of the upper portion, the lower portion, or a combination thereof.

The spring member may have an attachment point between any element within the movable assembly 44 (i.e., any element of the upper portion, any element of the lower portion, and any combination thereof). At least one connection of the spring means is desirably connected to any one of the frame 18, the first upper element 47a or the first lower element 49 a. The connection to the rigid frame may provide a simpler design with less bulk, while the connection to the first upper or lower element may provide design flexibility by allowing the construction of complex mechanisms with less space and lower cost than mounting them directly to the frame 18.

The direct connection of the spring members to the frame 18 may provide smoother movement and less complex design when the upper portion 44a and the lower portion 44b are connected and move together relative to the frame 18. The preloading of the spring member may be used to provide a better consumer experience by preventing the upper and lower portions 44a, 44b from rattling within the handle 12, and by pushing any of the upper portion, the lower portion, or a combination thereof against a bearing surface on the rigid member, or by maintaining a gap between the rigid member and the upper and lower portions.

The third upper element 47c is preferably an eject button desirably coupled with one or both of the second upper element 47b (e.g., a spring member) and the first upper element 47a (e.g., a base structure), desirably providing a second or linear movement in a forward path along axis a2 or A3 (as shown in fig. 1F-1H) to eject or separate a cartridge unit (e.g., unit 15 in fig. 1F-1H) from the razor handle. The fourth upper element 47d comprises the outermost upper element and may be a dome-shaped feature. The fourth upper element 47d generally provides a finger pad area for comfortably placing a user's finger for use with the third upper element (e.g., the eject button) 47c, along with aesthetic external decorative enhancements. The fourth upper element may be dome shaped.

The lower portion 44b includes a first lower element 49a, a second lower element 49b and a third lower element 49 c. The lower portion 44b may be constructed from more or fewer elements and may have any suitable size, shape, or configuration.

Additionally or alternatively, the lower portion 44b includes a lower portion locating feature 48 in one or more of each lower element, and preferably in each lower element, wherein the features are all holes, and more preferably the holes are substantially similar to the rigid member locating feature 43 and/or the upper portion locating feature 46, and most preferably substantially circular, although any possible configuration of locating features and shapes is also contemplated.

The first lower element 49a of the lower part 44b is preferably constituted by a spring member which is arranged between the lower side of the frame or the lower side of the first upper part 47a and the second lower element 49 b. The spring member is desirably provided on the underside 92b of the upper frame 18a and/or within any of the elements provided on the underside of the frame, such as the second lower element 49b, but may also be provided on the underside of the first upper element 47a (not shown). As depicted, the spring member is comprised of an annular, V-shaped, or generally circular shape.

The second lower element 49b of the lower portion 44b is preferably constituted by a bottom base structure with rails, rails and/or projections and a pair of arms 52. The pair of arms are preferably connected to an interconnect member for connection to the cartridge unit or directly to the cartridge unit. This arrangement helps to provide a first or second type of movement, preferably a first type of movement (e.g. rotation), when coupled with the spring member of the first lower element 49 a. This first type of movement allows the blade cartridge unit 15 to move or pivot in a rotational or side-to-side manner along the axis of rotation a4 when connected to the handle 12.

The third lower element 49c comprises the outermost lower element and may be a dome-shaped feature similar to the fourth upper element 47 d. The third lower element 49c generally provides a bottom finger pad area for comfortable placement of the user's fingers, along with aesthetic external cosmetic enhancements.

Fig. 9D is a close-up side view showing the frame 18 disposed between the upper and lower portions of the movable member. The upper portion 44a is shown with a dome 47d and an eject button 47c provided on a first upper element or top pod 47 a. The first lower element 49a and the second upper element 47b (e.g. spring members) are not shown, but are provided within the lower portion and the upper portion, respectively. The second lower element 49b is arranged below the frame 18.

FIG. 9E is a close-up perspective view of the movable member assembly 44 just prior to being coupled together. All elements of the upper and lower portions 44a, 44b of the movable member assembly 44 are depicted without the frame 18. Clearly showing the elements to be attached within the frame.

It should be noted that the bottom portion 92 of the first upper element 47a and the top portion 94 of the second lower element 49b are generally surrounded or covered by the frame 18 toward a proximal end 96 of the frame 18, as shown in fig. 7.

Fig. 9F is a close-up exploded side view of the movable member assembly 44 without the frame 18. The upper portion 44a is shown as being coupled to the lower portion 44 b. The lower portion 44b is shown with a first lower element 49a, a second lower element 49b and an arm 52, and the upper portion 44a is shown with a first upper element 47a and a third upper element 47 b. The second upper element 47b (e.g., a spring member) and a fourth upper element (e.g., an outer dome) are not shown in this view, but are disposed within the upper portion 44 a.

Fig. 10 shows a top view 100 of the upper surface 101 of the second lower element 49 b.

As shown, the upper surface 101 of the second lower element 49b includes one or more rails 102, a protrusion 104, a recess 106, and an edge 108. The first lower element 49a comprising an annular spring member is shown partially disposed within a pair of curved tracks 102 of the second lower element 49 b. The third lower element 49c is partially shown at the outer surface of the hole 48.

Fig. 11A and 11B depict the upper surface 111 and the lower surface 112, respectively, of the first upper element 47a constituted by the base structure. These surfaces are comprised of one or more rails 113, protrusions 114, depressions 116, notches 117, and edges 118.

Desirably, the upper portion 44a and the lower portion 44b are coupled to each other, respectively. The joining of the upper and lower portions may be accomplished by mechanical joining such as snap-fit joining, chemical joining such as adhesives or glues, frictional joining such as welding (including ultrasonic welding, such as energy director or pinch welding, or twist, spin, laser, or hot plate (e.g., mirror image) type welding), or by any other feasible means or any combination of the foregoing.

In one embodiment of the invention, the coupling is preferably achieved by engaging one or more features of the lower surface of the first upper element 47a with one or more features of the upper surface of the second lower element 49 b. For example, the protrusion 104 on the upper surface 101 of the second lower element 49b desirably engages a depression or recess in the lower surface 112 of the first upper element 47a, as shown in the top view of the coupling arrangement 120 of the second lower element 49b engaging the first upper element 47a in fig. 12. Additionally or alternatively, preferred embodiments of the present invention include welding, more preferably ultrasonic welding, and most preferably pinch-off ultrasonic welding.

The joining regions (e.g., weld regions or mechanical joining regions) may be located on the outer surfaces of the upper and lower elements, may be located on the interior of the elements (as shown in fig. 18 below), or may be a combination. In one embodiment, the engagement region is not in contact with the frame 18. By not being in contact with the frame, portions of the movable member assembly may move independently of the frame.

Once the upper and lower portions are engaged and secured to one another, the movable member assembly 44 may essentially function as an integral unit.

In the present invention, a single component such as the upper portion 44a or the lower portion 44b serves multiple functions. For example, when the razor is assembled and substantially perpendicular to the frame of the handle, the lower portion 44b facilitates an axis of rotation in the razor handle, i.e., substantially perpendicular to the axis of rotation of the one or more blades. When rotated from the rest position, the lower portion 44b and, for example, the second lower element 49b may generate a return torque by a spring member 49a (such as shown as a ring spring, but may include a cantilever spring or a leaf spring) to return to the rest position. The return torque is generated by the spring member of the second lower element 49 b. In addition, the upper portion 44a also serves as a carrier for the ejector button assembly, and may also serve as a carrier for other components of the razor such as a docking structure (not shown) and/or a cartridge unit (e.g., via the docking structure). In this embodiment, a first lower element 49a (spring member) may be attached to the frame 18, providing optimal movement and clearance for the assembly.

In an alternative embodiment, the movable member assembly 44 is unitary and is optionally formed of a single material.

In fig. 13A and 13B, the positioning features of two embodiments 130a and 130B of the frame 18 of the present invention are shown. In embodiment 130a, frame 18 includes a rigid member platform 132a corresponding to the views shown in fig. 7A, 7B. In embodiment 130a, the bottom side 92b of the frame 18 comprises a rigid member platform 132a in the handle transition section 23. The locating feature of the rigid member or frame 18 is an opening 43 in the rigid member platform 132. The protrusion 134 is disposed in the rigid member platform 132. The protrusions may engage other features such as arms 24, which may be made of metal. The protrusions 134 of the frame 130a may be used to attach the subframe 20 to the frame 18.

As described above, the frame 18 of the present invention may be constructed of die cast zinc such as ZAMACK3, ZAMACK5, and ZA 8. Other suitable materials include fiberglass reinforced plastics such as IXEF 1032, stainless steel, aluminum die casting, and magnesium die casting.

The arm 24 of the present invention is shown in fig. 6, 7A, 7B, 8A, 8B and 16. With a rigid member or frame 18 made of a hard metal such as die-cast zinc having features that couple with hard metal arms (e.g., stainless steel), a robust product can be prepared, particularly for heavy handles, and damage can be mitigated in the event of an accidental drop.

In embodiment 130B, the frame 18 includes a rigid member platform 132B corresponding to the views shown in fig. 8A, 8B. In the embodiment 130b, the bottom side 92b of the frame 18 includes a rigid member platform 132b in the handle transition section 23. The locating feature of the rigid member or frame 18 is an opening 43 in the rigid member platform 132. The protrusion 134 is disposed in the rigid member platform 132. The protrusions 134 of the frame 130A may be attached to the sub-frame 20 or a component such as a circuit or benefit delivery system. Fig. 15A-15G show close-up views of the stiffener platforms 132a and 132 b.

In fig. 14-15, perspective and cross-sectional views of the stiffener platforms 132a and 132b of the frames 130a and 130b of fig. 13 are depicted, respectively, illustrating the thickness and width of the stiffener platforms of the present invention.

As shown in fig. 14A, the rigid member platform 132b has a top surface 142, a bottom surface 143, a wall 146, and a locating feature that includes an opening 43 and one or more slots 144. The rigid member platform may be enclosed or partially enclosed by walls 146 (e.g., sidewalls).

As shown in fig. 15, the rigid member platform 132a has a top surface 142, a bottom surface 143, a wall 146, and a locating feature that includes an opening 43, one or more pockets 152, and one or more protrusions 134. The rigid member platform may be enclosed or partially enclosed by walls 146 (e.g., sidewalls).

Detail a of fig. 14 shows the median thickness T1 of the top surface 142 and the bottom surface 143 of the rigid member platforms 132a and 132 b. T1 is depicted in cross-sectional view B-B taken along the midline of the rigid member platform, as shown in detail A of FIG. 14.

Fig. 15 shows cross-sectional views a-A, C-C and D-D corresponding to the embodiment of fig. 8A and 8B. In views A-A and C-C, the median thicknesses T1 and T2 can be seen along with the widths W1 and W2. In this embodiment, W1 represents the maximum width of the stiffener platform and W2 is less than W1. In both cases, the ratio of the maximum width to the median thickness exceeds 20.

The maximum length L1 across the platform of the rigid member is shown as being parallel to the longitudinal axis of the razor handle in the entire cross-sectional view E-E. The maximum width W1 across the platform of the rigid member is shown to be transverse to the longitudinal axis of the razor handle. Rigid member platform 132 may be partially surrounded by wall 146 having a height T2. These walls provide additional product integrity to the rigid member and allow flexibility in design aesthetics. The embodiment of fig. 7A and 7B has a pivot of rotation in the handle that passes through or extends through the rigid member platform. Bearing surface 149 is also depicted in detail a of fig. 14. A clearance C of about 0.1mm to about 1mm is the distance between the bearing surface 149 and the top surface 142 or bottom surface 143 of the rigid platform member. The bearing surface 149 is located within about 1mm of a positioning feature, such as a slot, hole, opening about which the movable member assembly travels.

The upper and lower portions of the moveable member assembly are coupled together by a hole 43 through the rigid member platform and are held in place and in the gap by a spring member mounted to the rigid member. The spring member of the present invention, while flexible in the desired direction of motion, is stiff enough in other directions of motion to maintain adequate clearance between portions of the movable member assembly and the rigid member and rigid member platform. The spring member may be preloaded as described herein.

In the present invention, the median thickness T1 of the lands 132a or 132b is in the range of about 0.5mm to about 2.5mm, preferably about 1 mm. The ratio of the maximum width W1 to the median thickness T1 of the platform itself is about 7 to 60, and preferably about 20. The area of the rigid member platform, including the area from features such as openings and pockets, is about 50mm²To about 700mm²And preferably about 300mm². The perimeter of the rigid member platform may be about 40mm to about 90mm, and preferably 63 mm. The rigid member platform has a hydraulic diameter of about 8mm to about 50mm, and preferably about 20mm (e.g., in standard engineering, the diameter may be defined as about four times the area divided by the perimeter). The maximum width W1 of the rigid member platform is in the range of about 10mm to about 50 mm. The ratio of the maximum length L1 to the median thickness T1 of the rigid member platform itself is 7 to 60, and preferably about 20. The height T2 of the wall is in the range of about 1.5mm to about 18mm, and preferably about 4 mm.

Thus, the present invention includes a relatively thin rigid member platform, which is beneficial because it provides robust support for complex functional members above or below it, and is easy to manufacture or assemble, including flexibility to use other manufacturing techniques such as additive manufacturing, while also providing space for benefit delivery system components.

Fig. 16A-16B show views 169a and 169B depicting the use of locating features to attach other components to the frame 18. The protrusions 161 in views 169a and 169b are attached to the locking structures 162 in the rigid arms 24, thereby providing rigidity to the frame 18 extending beyond the body 16. In view 169b, the protrusions 163 of the rigid member platform facilitate positioning and locking the subframe 20 to the rigid member platform 132a or 132b using the subframe structure 164.

In a preferred embodiment of the invention, these upper and lower elements are coupled together by securing each other with a rigid member positioning feature 43. This may be desirably accomplished by utilizing the stiffening member positioning feature apertures 43 of the frame 18 to align with the upper apertures 46 and the lower apertures 48, as described in more detail below.

Referring to fig. 17A-17D, a method of the present invention for assembling the various razor portions described above with respect to fig. 1-16 is shown and described herein. Any of the mounting steps may be accomplished by any feasible method including, but not limited to, mechanical bonding, frictional bonding (e.g., welding), and chemical bonding (e.g., adhesive). The mechanical engagement may include one or more structures or protrusions that provide a stationary surface for a portion or snap fit. Chemical bonding includes gluing or adhesives.

In a preferred embodiment, at step 1 of fig. 17B, the first lower element 49a of the lower portion 44B is first mounted to the main frame 18 of the handle 12. In a non-limiting embodiment, the lower element 49a is a spring member, and may be an annular spring member, as shown in fig. 17. The annular spring member may have a shape that is substantially oval, circular, elliptical, annular, modified V-shape, teardrop shape, or any combination thereof. In the illustrated embodiment, the annular spring member can be considered to be tear drop shaped. The spring member has an end portion. The end portion may have a distal end that may be spaced apart. Mounting the spring member to the frame 18 may be accomplished by attaching one end of the spring member in a stationary surface on a protrusion on the frame. In one embodiment, the annular spring member is not permanently attached to the frame. Mounting the spring member to the frame may also be accomplished by any feasible means, including but not limited to mechanical engagement. The spring member may be preloaded in the second lower element and the frame. In one embodiment, the spring member 49a includes a handle or curved structure 171 that is placed around the central protrusion 172 such that the inner surface of the handle (e.g., into the loop) rests along the outer surface of the central protrusion 172, while the outer surface of the spring member 49a rests on either side of the central protrusion 172 along the surface of the two elongated protrusions 173a and 173b, as shown in the close-up views in step 1 and step 2. The close-up view of step 1 depicts the central protrusion and elongated protrusion of the frame. The close up view of step 2 depicts the underside of the second lower element 49b and together with fig. 10 provides two possible embodiments for coupling the second lower element and the spring member. As also shown in fig. 17, at step 1, the skin interconnecting member 22 is mounted to the main frame 18.

At step 2 shown in fig. 17, the second lower member 49b is mounted to the resulting structure forming a part of the lower portion from step 1. In one embodiment, the second lower element 49b may provide a preload force on the spring member 49a after it is installed. The second lower element 49b may comprise an arm connected to a razor cartridge as will be described herein. As noted above, the second lower element 49b may provide a type of rotational movement of the razor cartridge relative to the handle. In one embodiment, the spring member 49a is completely enclosed or covered within the lower portion 44 b.

Turning to fig. 18, step 3 of the inventive method of assembling the movable member 44 is shown. Step 3 depicts the first upper element 47a of the upper portion 44a disposed on top of the main frame 18 of the handle 12. In one embodiment as shown, a thermal element 182 in the form of a flexible circuit may be disposed therebetween. As shown, the flexible circuit has a circular shape with a centrally located hole to align with locating features of other elements of the movable member assembly. The flexible circuit may provide thermal or cooling benefits to the skin interconnect member 22, which may be appreciated by a user when attached to a razor cartridge. Fig. 18 shows a close-up sectional view (a) of the structure obtained in step 3. There, the first upper element 47a is shown disposed on top of the second lower element 49b and extending through the main frame 18. The main frame is disposed therebetween. The thermal element 182 is disposed between the first upper element and the main frame.

At step 4, the first upper element 47a is fixed to the second lower element 49 b. This fixing step preferably consists of welding between the two elements, more preferably of ultrasonic welding, and most preferably of ultrasonic welding of the pinch-off type. The solder material 184 is shown in close-up cross-sectional view (B) of step 4. It can be seen that the welding material 184 is arranged in the region between the first upper element 47a and the second lower element 49 b. Other methods for securing these elements are also contemplated (e.g., gluing).

These elements are coupled together through a main frame, which, as noted herein, is preferably a rigid member, and more preferably constructed of a die cast material such as zinc. In this way, the upper portion 44a may be secured to the lower portion 44b through the main frame, as the first upper element is part of the upper portion and the second lower element is part of the lower portion. In this embodiment, the main frame extends between an upper portion and a lower portion. In this embodiment, the upper and lower portions engage within, pass through or surround the locating feature 43 of the rigid member or main frame. The upper and lower elements of the upper and lower portions have locating features 46, 48, respectively, which are holes, i.e., generally circular holes, having a size and shape similar to that of the rigid members.

The upper and lower elements may also be operably coupled via a mechanical engagement, such as a snap fit. Features on the upper surface of the second lower element 49b and features on the lower surface 47a may engage within, pass through, or surround rigid member locating features, such as the holes 43 provided in the rigid member. The one or more surface features may be recesses, protrusions, recesses, or other attachment structures that may mate or engage, or any combination thereof.

Turning to fig. 19, step 5 of the method of assembling the movable member 44 is shown. At step 5, the distal end of the bracket arm 192 is installed into the skin interconnect member 22.

At step 6 shown in fig. 19, the proximal arm of the bracket arm 192 is mounted to the second lower element 49 b. After step 6, the skin interconnection member 22 is mounted to the second lower element 49 b. A pivot spring member (not shown) may be partially disposed within skin interconnect member 22 to pivot relative to arm 192. The pivot spring member may be preloaded.

The pivot spring member may be any spring member that facilitates the biasing of the pivot and pivots the pivot. The pivot spring member may be, for example, any of a torsion coil spring, a leaf spring, a helical compression spring, and a coil spring. In one embodiment, the spring member comprises one or more coil springs. In one embodiment, two coil springs may be coupled together in spaced relation by a main rod portion. The pivot spring members are described in commonly owned co-pending U.S. docket numbers 15136P, 15137P, 15138P, which are hereby incorporated by reference.

In fig. 20A, at step 7, the bracket arm 192 is fixed in position within the second lower element. In a non-limiting embodiment, also as shown by the direction of the arrows in the partially cut away perspective view of fig. 20, a method of cold stamping, cold press fitting, or cold heading may drive a staking pin into the second lower element to secure the bracket arms 192 in place.

The portion of the main frame 18 corresponding to the opening 194 of the arm 192 may be permanently deformed by pressing into the opening 194. An operation known as cold stamping or cold staking allows the arms 192, and thus the skin interconnect member 22, to be securely coupled to the main frame 18 (and thus the handle 12). The cold stamped pocket 202 may be formed after the cold stamping is complete, as shown in fig. 20.

In fig. 21, step 8 is shown as including attaching a third lower element 49c to the second lower element 49b and passing through the locating feature or hole 48. The third lower element 49c is a dome-shaped element having a rim 214 and a dome-shaped hole 48. The dome hole may or may not be the same size and shape as other locating features in the razor. The dome element 49c is disposed within and through the locating feature 48 of the second lower element 49b and the rim extends to the upper surface of the first upper element 47a as shown in the cut-away close-up view (a) in fig. 21. At step 9, the upper edge 214 of the dome element 49c is crimped onto the first upper element 47 a. The crimped region 212 is shown by the arrow in the cross-sectional cut close-up view (B) of fig. 21. Alternatively, the edge may be crimped onto any element of the upper portion 44a, or it may be otherwise attached to the frame 18.

Fig. 22 shows a third upper element 47c in the form of an eject button for the razor. The top side 222 of the eject button is cleaned at step 10. In one non-limiting embodiment, plasma is used to clean the top side of the third upper member button. At step 11, the underside 224 of the fourth upper element 47d is also cleaned. In a non-limiting embodiment, the underside of the dome-shaped member is cleaned with alcohol. At step 12, the topside surface of the ejection button element is prepared so that the underside of the dome-shaped element may be mounted thereon. In a non-limiting embodiment, step 12 includes an adhesive or glue applied to a glue area 226 on the top side 222 of the third upper component eject button 47c, as shown in FIG. 22. At step 13, the underside of the dome-shaped element is mounted on glue area 226, and the glue secures elements 47c and 47d together once the dome element is placed on the top side of the eject button. The lower edge portion of element 47d may extend through the aperture 46 of the eject button.

Fig. 23 depicts the mounting of the second upper element 47b to the underside of the third upper element 47 c. The second upper element 47b is a spring member and the third upper element 47c is an ejection button element. In a non-limiting embodiment, the spring member can be an annular spring member, as shown in fig. 23. The annular spring member may have a shape that is substantially oval, circular, elliptical, annular, modified V-shape, teardrop shape, or any combination thereof. In the illustrated embodiment, the annular spring member may be considered to be circular in shape. The spring member has an end portion. The end portions may overlap as shown. Mounting the spring member to the eject button 47b at step 14 may be accomplished by attaching a portion of the spring member in a stationary surface on a protrusion on the button. In one embodiment, the annular spring member is not permanently attached to the eject button. Mounting the spring member to the button may also be accomplished by any feasible means, including but not limited to other types of mechanical engagement. The spring member may be preloaded in the button. In one embodiment, the spring member 47B includes a handle or curved structure 232 that is placed around the central protrusion 234 such that the inner surface of the handle (e.g., into the loop) rests along the outer surface of the central protrusion 234, while the outer surface of the spring member 47B rests on either side of the central protrusion 234 along the surfaces 235 of the two elongated protrusions 236a and 236B, as shown in the close-up views (a) and (B) of fig. 23. The close-up view (B) depicts the central protrusion and the elongated protrusion of the underside of the button. The close-up view (a) depicts other resting surfaces 237 on protrusions 238 on the underside of button 47 c. Fig. 23 and 23 together provide two possible embodiments for coupling the third upper element (e.g. the eject button) and the spring member.

Fig. 24 depicts step 15, the final step of assembling the movable member assembly. In step 15, the resulting coupled eject button assembly, including elements 47b, 47c and 47d of fig. 23, is mounted to the upper surface of the first upper element 47a, which was previously mounted to the frame in steps 3 and 4 of fig. 18. In one embodiment, the mounting step 15 is accomplished via a snap-fit mechanism between features on the lower surface of the eject button 47c and features on the upper surface of the first upper element 47 a. These features may provide a suitable button assembly in the razor. For example, the protrusion 242 may include a chamfered surface 244. These chamfers 244 may apply a pre-load force to release the spring member from the ejection button assembly rest position. As shown in the close-up view of fig. 24, other surface features 246 on the underside of the eject button assembly may limit vertical or lateral movement to guide the eject button. Once the last step 15 occurs, the spring member 47b may be completely enclosed within the upper portion 44 a.

It should be noted that at least one or more elements of the upper or lower portion do not move relative to the rigid member. For example, the lower portion may include an element that does not move relative to the rigid member.

The frame, the movable member assembly having the upper portion and the lower portion including the ejector button assembly, and the rotational moving unit (second lower element 49b) are configured to simplify assembly, for example, in high-speed manufacturing. Each component is configured to self-align and securely seat. In one embodiment, each component is joined to the other component in only a single orientation so that the components are not inaccurately or inaccurately assembled. Furthermore, each component does not require the additional step of dimensional adjustment or any additional adjustment during manufacture to ensure proper engagement with the other components. The design of the handle also provides control and precision. For example, when the razor is assembled, the movable member and/or the cartridge unit is substantially centered, the preload of the springs can be precisely controlled over time (even after repeated use), and the performance of each spring is consistently and robustly controlled.

Fig. 25 shows a schematic view of the trapezoidal prism shape of the skin interconnect member of the present invention. The shape of the at least one skin interconnecting member 22 may alternatively be described as a "funnel" or "cone" or "trapezoidal prism shape. As understood from the description herein, the description "trapezoidal prism" is a general description of the overall visual impression with respect to the pivot head. For example, fig. 25 shows schematics 123A and 123B of trapezoidal prismatic elements, and illustrates a shape having a relatively wide top surface (or opening) 325, a relatively narrow bottom surface 324, two long major surfaces 326, and two end surfaces 328 that are generally trapezoidal. Fig. 25 also shows a close-up side view 123C of an embodiment of the skin interconnection member 22 of the handle of the present invention, illustrating a generally trapezoidal prismatic or prism-like shape 345 of the skin interconnection member 22; and an isolated view 124D of the components of one embodiment of the skin interconnect member 320 that produce a generally "trapezoidal prism" shape.

The various elements of the movable member assembly are desirably formed of plastic, including thermoplastic elastomers. The spring member may be made of plastic, impact resistant plastic, metal, and composite materials. In one embodiment, the spring member may be made of a material that resists stress relaxation, such as metal, polyetheretherketone, and some grades of silicone rubber. Such an embodiment of the spring member constructed of a stress relaxation resistant material may prevent the pivot head from undesirably "permanently deforming," which is a permanent deformation of the spring member that prevents the pivot head from returning to its rest position when unloaded. In one embodiment, the spring member may be made from 200 series or 300 series stainless steel in a spring temper according to ASTM a 313. In one embodiment, the spring member may be constructed of stainless steel wire (e.g., 302 stainless steel wire) having an ultimate tensile strength metal of greater than 1800MPa or an engineering yield stress between about 800MPa and about 2000 MPa.

The arm 24 or frame 18 may be made of plastic, impact resistant plastic, metal, and composite materials. In one embodiment, the arm 24 and the frame 18 may be constructed of metal. The arm 24 and frame 18 may be made of a 200 or 300 series stainless steel having an engineering yield stress greater than about 200MPa, and preferably greater than 500MPa, as measured by ASTM standard E8, and a tensile strength greater than 1000MPa, again as measured by ASTM standard E8.

The arms 24 and the frame 18 may be made from a zinc die cast having an engineering yield stress of about 200MPa, measured by ASTM standard E8, and a tensile strength of about 300MPa, again measured by ASTM standard E8.

Preferably, the component is formed from a thermoplastic polymer. For example, non-limiting examples of materials for the movable member having desirable properties such as flexibility, durability (failure due to drop impact), fatigue resistance (failure due to bending upon repeated use), and creep resistance (relaxation of the material) may include

757 (available from Chi Mei corporation (Tainan, Taiwan)),5526 and 8283 (from e.i. dupont de Nemours)&Co.(Wilmington,Delaware))、122L (from E.I. DuPont de Nemours&Co.(Wilmington,Delaware))、M90 (available from TiCona LLC (Florence, Kentucky)),

7233 (available from Arkema Inc. (Philadelphia, Pennsylvania)), (available from Arkema Inc.),S500, S600F20, S600F40, and S600LF (available from e.i. dupont de Nemours)&Co.(Wilmington,Delaware))、1400A (M90 (available from TiCona LLC (Florence, Kentucky)),100ST and 500T (from E.I. DuPont de Nemours)&Co.(Wilmington,Delaware))、XT20 (available from TiCona LLC (Florence, Kentucky)) and

8150 (from e.i. dupont de nemours)&(Wilmington, Delaware)). Furthermore, the choice of material may affect the stiffness and yield stress of the movable member or spring. For example, each material may have a different stiffness depending on the temperature and the rate of rotation of the upper or lower portion of the movable member relative to the frame. The dimensions of the spring element may be varied to achieve a desired torque and/or a desired stiffness.

The handle, blade unit, and other components of the rigid plastic components of the shaving system may be made of any suitable material, including, for example, polyethylene terephthalate (PET or PETE), High Density (HD) PETE, Acrylonitrile Butadiene Styrene (ABS), thermoplastic polymers, polypropylene, oriented polypropylene, polyurethane, polyvinyl chloride (PVC), polyethylene terephthalate (PET), polyethylene terephthalate (pe), polyethylene terephthalate (pp), polyethylene terephthalate,

Polytetrafluoroethylene (PTFE), polyester, high gloss polyester, or combinations thereof.

It should be understood that every maximum numerical limitation given throughout this specification includes every lower numerical limitation, as if such lower numerical limitations were expressly written herein. Every minimum numerical limitation given throughout this specification will include every higher numerical limitation, as if such higher numerical limitations were expressly written herein. Every numerical range given throughout this specification will include every narrower numerical range that falls within such broader numerical range, as if such narrower numerical ranges were all expressly written herein.

The dimensions and values disclosed herein are not to be understood as being strictly limited to the exact numerical values recited. Rather, unless otherwise specified, each such dimension is intended to mean both the recited value and a functionally equivalent range surrounding that value. For example, a dimension disclosed as "40 mm" is intended to mean "about 40 mm".

Each document cited herein, including any cross-referenced or related patent or application, is hereby incorporated by reference in its entirety unless expressly excluded or otherwise limited. The citation of any document is not an admission that it is prior art with any disclosure of the invention or the claims herein or that it alone, or in combination with any one or more of the references, teaches, suggests or discloses any such invention. Further, to the extent that any meaning or definition of a term in this document conflicts with any meaning or definition of the same term in a document incorporated by reference, the meaning or definition assigned to that term in this document shall govern.

While particular embodiments of the present invention have been illustrated and described, it would be obvious to those skilled in the art that various other changes and modifications can be made without departing from the spirit and scope of the invention. It is therefore intended to cover in the appended claims all such changes and modifications that are within the scope of this invention.